r22 MM Full Book PDF

R22 MAINTENANCE MANUAL
AND INSTRUCTIONS FOR CONTINUED AIRWORTHINESS

RTR 060 VOLUME I
Production Certificate Number 424WE

Type Certificate Number H10WE
Robinson Helicopter Company Phone: (310) 539-0508

2901 Airport Drive Fax: (310) 539-5198
Torrance, California 90505-6115 Web: www.robinsonheli.com
United States of America
OFFICE HOURS
Monday through Friday, 7:30 a.m. to 4:30 p.m., Pacific Time.
Lunch hour is 11:30 a.m. to 12:30 p.m.
HOLIDAYS
Please visit www.robinsonheli.com for a complete list of holidays and company shutdowns.
CUSTOMER SUPPORT AND SPARES ORDERS

Please visit www.robinsonheli.com for a complete support directory.
Procure parts from any R22 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.
OCT 2018 Introduction Page i

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 OCT 2018

CHAPTER LIST
Introduction
Chapter 1 General
Chapter 2 Inspection
Chapter 3 Life-Limited Components
Chapter 4 Airframe
Chapter 5 Landing Gear
Chapter 6 Powerplant
Chapter 7 Drive Train
Chapter 8 Flight Controls
Chapter 9 Rotor Systems
Chapter 10 Rigging, Track and Balance
Chapter 11 Environment Control
Chapter 12 Fuel System
Chapter 13 Instruments
Chapter 14 Electrical and Avionics Systems
Chapter 15 Furnishings
Chapter 16 Dimensions and Descriptions
Chapter 17 Jacking and Hoisting
Chapter 18 Weight and Balance
Chapter 19 Ground Handling
Chapter 20 Parking and Storage
Chapter 21 Placards and Markings
Chapter 22 Servicing
Chapter 23 Standard Practices
Chapter 24 Lights
Chapter 25 Doors and Windows
Chapter 26 Main Rotor
Chapter 27 Main Rotor Drive System
Chapter 28 Tail Rotor
Chapter 29 Tail Rotor Drive System
Chapter 30 Engine Controls
Chapter 31 Engine Oil System
Chapter 32 Police Version
Chapter 33 Electrical System
Chapter 34 Avionics
Chapter 35 Wiring Diagrams
Chapter 36 Special Tools
Chapter 37 Revision Log
OCT 2018 Introduction Page iii

Intentionally Blank
Page iv Introduction OCT 2018

TECHNICAL PUBLICATIONS
RECOMMENDED CHANGE REPORT
Please direct recommended changes to RHC Technical Publications via the email address
listed below, by phone, or by submitting a duplicate of this completed form by fax or mail.
Please include or have available the information detailed 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: [email protected] Robinson Helicopter Company
Phone: (310) 539-0508 Attention: Technical Publications
Fax: (310) 539-5198 2901 Airport Drive
Torrance, CA 90505-6115
United States of America
Date: Publication:
Name: Chapter:
Company: Section:
Helicopter Model: Page:
Serial Number: Revision:
Phone:
Email:
COMMENTS:
OCT 2018 Introduction Page v

Intentionally Blank
Page vi Introduction OCT 2018

CHAPTER 1
GENERAL
Section Title Page
1.000 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1

1.001 R22 Maintenance Manual Revisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1
1.002 R22 Maintenance Authorization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
1.003 R22 Component Maintenance Authorization . . . . . . . . . . . . . . . . . . . . . . 1.2
1.004 Maintenance Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
1.005 Notations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
1.006 Maintenance Manual and Illustrated Parts Catalog References . . . . . . . . . 1.3
1.007 Definitions and Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
1.008 Service Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
1.009 Assembly Instructions for R22-series Helicopter Crated for Export . . . . . . 1.7
1.100 Helicopter Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11
1.101 Scheduled Maintenance and Inspections . . . . . . . . . . . . . . . . . . . . . . . . 1.11
1.102 Additional Component Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12
OCT 2018 Chapter 1 General Page 1.i

Intentionally Blank
Page 1.ii Chapter 1 General OCT 2018

CHAPTER 1
GENERAL
1.000 Introduction
The R22 Maintenance Manual contains instructions necessary for proper maintenance,
servicing, and handling of R22-series helicopters. The R22 Instructions for Continued
Airworthiness (ICA) includes the R22 Maintenance Manual (MM), R22 Illustrated Parts
Catalog (IPC), R22 Service Bulletins (SBs), R22 Service Letters (SLs), Lycoming O-320-
series and O-360-series Operator’s Manuals, applicable Lycoming technical publications,
and applicable component manufacturer technical publications.
Service Bulletins are issued by Robinson Helicopter Company (RHC), Lycoming, and
component manufacturers. RHC Service Bulletin compliance is mandatory; comply with
other applicable Service Bulletins as directed. RHC technical publications are available online
at www.robinsonheli.com. Recent technical publications are available from Lycoming at
www.lycoming.com, and from Continental Motors, Inc. (CMI) at www.continentalmotors.
aero.
Kit instructions are issued for field installation of either optional or mandatory (due to
Service Bulletin or parts obsolescence) equipment upgrades, or provisions for upgrades.
Kit instruction issued by RHC either implement approved type design data, or are approved
as type design data.
CAUTION
Always read instructions completely before performing a task.
1.001 R22 Maintenance Manual Revisions

Before using the R22 Maintenance Manual, verify it consists of current effective pages.
The list of effective pages is located in the Revision Log in Chapter 37. When a new
manual is purchased, complete and submit the Subscription Order Form available online at
www.robinsonheli.com. Subscribers receive publication revisions for a two-year period.
Renew subscriptions annually. The revision status for all RHC technical publications is
available online at www.robinsonheli.com.
OCT 2018 Chapter 1 General Page 1.1

1.002 R22 Maintenance Authorization
Only appropriately certificated mechanics who have successfully completed an R22
factory-sponsored maintenance course, or are under direct supervision of the above-stated
mechanic, may perform maintenance, repairs, or inspections on R22-series helicopters.
Annual inspections of U.S.-registered light helicopters must be performed by holders of
an Inspection Authorization (IA) or by repair stations certificated by the Federal Aviation
Administration (FAA). The daily preflight and some preventive maintenance may be
performed by the above-stated mechanics, or by the pilot/owner after receiving appropriate
instruction in accordance with the R22 Pilot’s Operating Handbook and applicable aviation
regulations.
1.003 R22 Component Maintenance Authorization

Only appropriately certificated mechanics who have successfully completed both a factory-
sponsored maintenance course and component maintenance course, and who possess
technical data supplied by RHC, are authorized to perform maintenance specified in the
Component Maintenance Manual (CMM). Component maintenance may only be performed
at an RHC-authorized Service Center that has required special tools.
1.004 Maintenance Record

The Airframe Maintenance Record is available online at www.robinsonheli.com.
Airframe Maintenance Record blank PDF forms may be used for R22-series, R44-series, and
R66-series 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]).
A Component Record is a maintenance record of the removals, installations, or maintenance
performed on a life-limited or TBO component. When a life-limited or TBO component is
installed in the helicopter, the Component Record card is inserted in the Airframe Maintenance
Record. When a life-limited or TBO component is removed from the helicopter, remove the
Component Record card and keep the card with the Component. Major assemblies may
contain one or more life-limited or TBO component.
RHC encourages operators to utilize Component Record cards to assist in tracking time on
interchangeable parts since service lives may be different between models.
RHC does not create Component Record cards for spares, however, operators may create
their own.
RHCs Repair Station does not require a Component Record card in order to perform work
on a component, unlike a Component/Return Authorization form.
RHC recommends using a toner-based laser, or a pigment-based inkjet, color printer and 65
lb white (96 bright) premium card stock for Maintenance Record or Component Record card
production. Maintenance Record binders and tab sets are available separately (P/N R8656
Maintenance Record Binder and P/N R8650 Maintenance Record Tabs).
Page 1.2 Chapter 1 General OCT 2018

1.005 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.
1.006 Maintenance Manual and Illustrated Parts Catalog References

Maintenance Manual and Illustrated Parts Catalog Section and Figure references are subject
to relocation and renumeration. Effort will be made at the time of RHC technical document
revisions to correct superseded references, however, certain documents may not otherwise
require revision and superseded references may remain. A keyword or part number search
in online documents (Ctrl+F [PC] or Command+F [Mac]) may help to locate applicable data.

1.007 Definitions and Abbreviations
Refer to R22 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. RHC
Technical Support must be notified whenever the part fails to meet
the special inspection requirements.
12 years: With respect to a 12 year inspection or life-limit, 12 years means 12
years from the date of the factory-issued airworthiness certificate
or factory-issued authorized release certificate (FAA Form 8130-3,
Airworthiness Approval Tag).
Annually: With respect to an annual inspection, annually means within the
preceding 12 calendar months.
Datum: An imaginary vertical plane from which all horizontal measurements
are taken for balance purposes with the aircraft in level flight
attitude. Refer to § 16-20 for R22 datum location.
Empty Weight: Empty Weight includes the weight of the airframe, powerplant,
required and installed equipment, fixed ballast, unusable fuel,
and gearbox oil. Refer to R22-series Type Certificate Data Sheet
(TCDS) in Chapter 3. Refer to Equipment List/Weight and Balance
Data Sheet (RF 134) and Weight and Balance Record in R22 POH
Section 6 for installed equipment.
Life-Limited Part: Refer to Chapter 3. Any part for which a mandatory replacement
limit is specified in the type design, the Instructions for Continued
Airworthiness, or the maintenance manual.
Time in Service: With respect to maintenance time records, time in service means
the time from the moment an aircraft leaves the surface of the
earth until it touches it at the next point of landing.

1.007 Definitions and Abbreviations (continued)
B. Abbreviations
14 CFR: Title 14 of the Code of Federal Regulations. The Federal Aviation

Regulations (FARs) are part of the CFR.
AOG: Aircraft on Ground
ATA-100: Air Transport Association of America Specification No. 100
BL: Butt Line Station locations
CO: Carbon Monoxide
CRA: Component Return/Authorization
ELT: Emergency Locator Transmitter
FS: Fuselage Station locations
HID: High Intensity Discharge
HS: Horizontal Stabilizer Station locations
LBL: Left Butt Line Station locations
LED: Light Emitting Diode
LH: Left-hand
LRU: Line-Replaceable Unit
MRDS: Main Rotor Drive Shaft
MRGB: Main Rotor Gearbox
OEM: Original Equipment Manufacturer
R22 IPC: R22 Illustrated Parts Catalog
R22 MM: R22 Maintenance Manual
R22 POH: R22 Pilot’s Operating Handbook
RHC: Robinson Helicopter Company
RH: Right-hand
RS: Rotor Station locations
SB: Service Bulletin
SL: Service Letter
TBO: Time Between Overhaul
TCDS: Type Certificate Data Sheet
TRDS: Tail Rotor Drive Shaft
TRGB: Tail Rotor Gearbox
TS: Tailcone Station locations
TSN: Time Since New
TSO: Time Since Overhaul
WL: Water Line Station locations

1.008 Service Information
A. Part Designation
RHC parts are designated with an alphanumeric part number beginning with letter “A”,
“B”, “C”, etc., followed by three digits and a dash number.
A revision letter or letters follow(s) the stamped or ink-marked part number. Revision
progression is A thru Z, followed by AA thru AZ, followed by BA thru BZ, etc. Unless
otherwise specified, any revision of the same part number is interchangeable, such as
“A101-1 A” and “A101-1 D”.
A change in dash number indicates a change in form, fit, and/or function (e.g. part
number C339-1 is not interchangeable with part number C339-10 even though both
are jackshaft weldments for [hydraulic] R44s).
B. Returning Parts
All parts shipped to RHC must include a signed Component Return/Authorization (CRA)
Form available online at www.robinsonheli.com.
C. Ordering and Shipping
Procure parts from any R22 Dealer or Service Center, or order directly from assigned
RHC Customer Service Representative via email, fax, or phone.
D. Warranty Claims
Complete CRA Form (refer to Part B) and, in the Warranty Claim section, indicate if
rotorcraft or component is under warranty. If claim is for parts or for labor allowance
due to a Service Bulletin issued against rotorcraft or component, write in “per SB-XX”
adjacent to requested warranty action.
E. Customer Support Directory
Please visit www.robinsonheli.com for a complete support directory.

1.009 Assembly Instructions for R22-series Helicopter Crated for Export
NOTE
Aircraft assembly to be performed by a certificated mechanic.
1. Remove all components from tailcone crate and all accessible components from cabin
crate. Assemble landing gear per §§ 5.220 (float gear only) and 5.320.
CAUTION
Do not lift helicopter and attached crate using main rotor hub;
damage to main rotor gearbox and frames could result.
2. Attach a hoist to main rotor hub per § 17-20. Lift aft end of crate while taking up slack
in hoist. When main rotor shaft is vertical, remove bolts at landing gear attach points
and remove crate. Install landing gear per § 5.120. Lower helicopter on ground.
3. Install front cross tube cover panel. For float landing gear, set float pressure per Mariner
supplement of Pilot’s Operating Handbook and verify float stabilizer is being used in
place of tail skid.
4. Install tailcone per § 4.312. Install tail rotor visual warning guard.
5. Install empennage assembly per § 4.322.
6. Install exhaust system per § 6.520. Install lower half of cooling fan scroll.
7. Remove preservative plugs from engine cylinder upper spark plug holes. Install upper
spark plugs and special torque per § 23-33. Connect ignition leads.
8. Fill engine oil to six quart mark on dipstick, as required.
9. Install main rotor blades per § 26-10. Match color coded markings on blades, hub bolts,
hub, and pitch links. Attach upper end of pitch links to pitch horns.
10. Install tail rotor per §§ 9.212 or 9.213, as applicable.
11. If required, fill battery with electrolyte and charge.
12. Fill main and tail rotor gearboxes with A257-2 oil. For helicopters shipped “on-side”,
inject 6 ounces A257-2 oil into aft vent hole atop main rotor gearbox static mast tube.
13. Fuel helicopter and drain a small amount of fuel through gascolator.

1.009 Assembly Instructions for R22-series Helicopter Crated for Export (continued)
14. If ship is equipped with artificial horizon, directional gyro, or vertical card magnetic
compass, install as follows:
Artificial Horizon and/or Directional Gyro:
a. Remove amber ALT light and red OIL light from B050 console. Pull out A777‑1,
A981-1, or B197-1 instrument face by removing perimeter mounting screws.
Place a pad under face to prevent scratches.
b. Install required instrument(s) using screws provided.
CAUTION
Directional gyro mounting screws must not exceed 1 inch in
length or unit will be damaged.
c. Connect straight multi-pin connector to directional gyro and/or angled connector

to artificial horizon ensuring that angled strain relief points down. Ensure that
connectors lock in place. Ty-rap excess wiring.
d. Install instrument face, ALT light, and OIL light.
Vertical Card Magnetic Compass:
Locate two wires extending from windshield bow. Slide one piece of heat-shrink
tubing (provided) over each wire. Connect compass pins to wire sockets (polarity
not critical). Position heat-shrink tubing over connections and apply heat. Install
compass using two screws provided.
15. Install battery (Negative Ground System).
NOTE
This must be performed by a qualified pilot and a certificated
mechanic.
16. Perform preflight inspection per Pilot’s Operating Handbook and inspection per §§ 2.205
and 2.210.
17. Check tail rotor balance per § 10.240.
18. Perform hover checks in § 2.220.1. DO NOT proceed into forward flight at this time.
19. Track and balance main rotor per § 10.230.
20. While climbing at takeoff power per placard and 50 KIAS:
a. Evaluate roughness at maximum and minimum power-on RPM.
b. At minimum power-on RPM perform 30° left yaw to check for adequate directional
control.

1.009 Assembly Instructions for R22-series Helicopter Crated for Export (continued)
21. During level flight at 3000 feet pressure altitude (if able), MCP, with right trim and
governor on:
a. Verify longitudinal and lateral cyclic control forces are neutralized (no tendency of
cyclic to creep longitudinally or laterally).
b. Verify collective control forces are neutralized (no tendency of collective to creep
up or down).
c. Verify throttle correlation. Set MAP to 22 inches and turn governor off. Without
twisting throttle, lower collective to 12 inches MAP then raise it to 22.5 inches
MAP. RPM must stay in green arc.
22. Evaluate roughness at minimum power-on RPM, takeoff power per placard, and Vne per
placard.
23. Check all instruments, gauges, and avionics for proper operation.
24. During autorotation at 50 KIAS and 90% rotor RPM, perform 30° right yaw to check
for adequate directional control.

Every 2200 hours
Every 12 months
Every 24 months
Every 100 hours
Every 300 hours
Every 500 hours
Every 800 hours
Every 4 months
First 100 hours
Every 50 hours
Every 12 years
TABLE 1 SCHEDULED INSPECTIONS
First 25 hours
Every 4 years
Consult latest revision of listed
publications for specific applicability.
Perform inspection per Lycoming Operator’s Manual.* • • • •

Perform Lycoming SI 1129
• •
Methods of Checking DC Alternator and Generator Belt Tension.
•
Cylinder Compression.
• •
Maintenance Items for Special Attention.
Perform Lycoming SB 301*
•
Maintenance Procedures and Service Limitations for Valves.
Perform Lycoming SB 366, as applicable
•
Carburetor Throttle Body Screw Inspection.
Perform Lycoming SB 388 (also applies to replacement cylinders)
• •
Procedure to Determine Exhaust Valve and Guide Condition.
Perform Lycoming SB 480
• • •
I. Oil & Filter Change & Screen Cleaning / II. Oil Filter/Screen Content Inspection.
Perform CMI SB 643, as applicable
• • • •
Maintenance Intervals for All CMI/TCM/Bendix Magnetos & Related Equipment.
Perform CMI SB 658
• •
Distributor Gear Maintenance.
Perform CMI SB 663
• •
Two-Wire Magneto Tach. Breaker Contact (Points) Assy. P/N 10-400507.
Perform CMI SB 670
• •
Replacement and maintenance of Magneto Distributor Block.
Perform 100-hour/annual inspection per § 2.400. • •
Lubricate A181-4 Revision K, L, and M bearings per § 22-42. • •
Lubricate A181-4 Revision N bearing per § 22-42. • •
Lubricate A184 bearing per § 22-41. • •
Perform clutch assembly lubricant inspection & servicing per § 22-30. •
Drain and flush gearboxes per §§ 22-13 & 22-23. •
Clean gearbox chip detectors per §§ 22-11 & 22-21. • •
Perform FAA AD 88-26-01 R2 (A158-1 spindles only). •
Perform 2200-hour inspection per § 2.600. •
Inspect emergency locator transmitter (ELT) per U.S. 14 CFR § 91.207. •
Test and inspect transponder per U.S. 14 CFR § 91.413. •
Perform 12-year inspection per § 2.600.** •
* Shorter interval than published on referenced document.

** 12-year inspection is only required for helicopters that have accumulated 12 years in service and less than 2200 hours
time in service since new, since last 2200-hour inspection, or since last 12-year inspection.

1.100 Helicopter Servicing
1.101 Scheduled Maintenance and Inspections

Required maintenance and inspection intervals are given in Table 1. Publications listed
are subject to revision.
Consult the following for specific applicability, as some aircraft may require maintenance
and inspections in addition to the requirements in Table 1:
● Aircraft maintenance records
● Service Bulletins (SBs)
● Aviation regulations
● Airworthiness Limitations
● Airworthiness Directives (ADs)
Preventive maintenance is required between scheduled inspections. Fluid leaks,
discoloration, fretting, galling, chafing, nicks, scratches, dents, cracks, and corrosion all
warrant further investigation. Unairworthy items must be replaced or repaired as allowed
by RHC.

1.102 Additional Component Maintenance
A. Remove the following components when they have accumulated 12 years time in
service and less than 2200 hours time in service since new, since last overhaul, or
since last 12-year maintenance:
Part Number Description Action

A005-4 A154-1 Main Rotor Hub & Perform inspection and repair per MM § 2.610, return
Bearing Assembly to RHC for inspection and repair, or replace with new.
A005-12 B370-1 Main Rotor Hub &
Bearing Assembly
A005-6 A016-4 Main Rotor Blade & Submit to RHC-authorized component maintenance
A158-1 Spindle Assembly facility for 12-year maintenance, or replace with
A005-7 A016-6 Main Rotor Blade & new or overhaul exchange. 12-year maintenance
A158-1 Spindle Assembly includes blade replacement (as required), spindle
bearing replacement (as required), pitch horn screw
A005-14 A016-6 Main Rotor Blade &
replacement, boot and o-ring replacement, and
A158-3 Spindle Assembly
inspection.
A006-1 & -6 Main Rotor Gearbox Submit to RHC-authorized component maintenance
Assembly facility for 12-year maintenance, or replace with new
or overhaul exchange. 12-year maintenance includes
pinion seal replacement, o-ring replacement, sealed
bearing replacement, rubber mount replacement,
additional bearings replacement (as required), and
inspection.
A007-3 or -5 Fanshaft Assembly Replace with new A007-5 fanshaft assembly.
A008-2 or -4 Tail Rotor Assembly Replace with new A008-4 tail rotor assembly.
A014-8 Landing Gear Assembly Replace with new.
originally installed on R22
S/N 0002 thru 0487.
A017-2 Swashplate Assembly Submit to RHC-authorized component maintenance
facility for 12-year maintenance, or replace with new
or overhaul exchange. 12-year maintenance includes
inspection and repair as necessary.
A018-1 Clutch Assembly (anodized) Submit to RHC-authorized component maintenance
A018-2 Clutch Assembly facility for 12-year maintenance, or replace with new
(metalized) or overhaul exchange. 12-year maintenance includes
seal and o-ring replacement, bearing replacement, and
inspection.
A020-2 Upper Frame Assembly S/N Replace with new. Note: Frame replacement may
0399 and prior (originally require tailcone forward bay replacement.
installed on R22 S/N 0002
thru 0311).
A021-1 Tail Rotor Gearbox Replace with new or overhaul exchange B021-1 tail
Assembly rotor gearbox assembly.
A031-1 Tail Rotor Pitch Control Replace with new.
A041-11 or Tail Rotor Drive Shaft Replace with new A041-11 or -12 damper bearing as-
-12 Damper Bearing Assembly sembly or replace with new B224-1 or -3 drive shaft.

1.102 Additional Component Maintenance (continued)
since last 12-year maintenance (continued):

A044-1 Horizontal Stabilizer Rev M and prior (originally Replace with new.
installed on R22 S/N 0002 thru 0631).
A051-1 or Clutch Actuator Assembly (A051-1 includes Replace with new or overhaul
A051-3 gearmotor assembly) exchange.
A120-1 Tail Rotor Bellcrank Replace with new.
A169-1, -2, Muffler with Risers Rev J and prior (baffled Replace with new.
or -4 muffler with straight tailpipe, originally
installed on R22 S/N 0002 thru 0500) with
subsequent revision.
A169-6 or Muffler with Risers (O-320 engine) Visually inspect muffler interior;
-35 verify no obvious loss of material.
A169-24 or Muffler with Risers (O-360 engine) Visually inspect muffler interior;
-37 verify no obvious loss of material.
A190-1 or -2 V-Belt Set Replace with new A190-2 v-belt
set.
A193-2 Flex Plate Replace with new A947-2 flex
plate assembly.
A193-3 Flex Plate Replace with new A947-3 flex
plate assembly.
A197-1 thru Tail Rotor Drive Shaft Assembly originally Replace with B224-1 drive shaft &
-7 installed on R22 S/N 0002 thru 0747. appropriate B223 yoke.
A258-1 Main Rotor Pitch Link Assemblies Replace with new A258-1 or
A258-5 link assembly.
A258-5 Main Rotor Pitch Link Assemblies Disassemble. 10X visually inspect
barrel; verify no corrosion.
A480-1 Swashplate Boot Replace with new.
A493-1 Lower Sheave Rev H and prior (anodized, Replace with new.
originally installed on R22 S/N 0002 thru
0294) with subsequent (steel-sprayed)
revision.
A649-1, -2, Oil Cooler Replace with new or overhaul
or C649-1 exchange C649-1 oil cooler.
A785-1 Hose – Air (intake) Replace with new.
A785-2 Hose – Air (hot air inlet) Replace with new.
A785-6 Hose – Air (engine cooling) Replace with new.
A785-7 Hose – Air (alternator cooling) Replace with new.
A785-32 Hose Replace with new.

since last 12-year maintenance (continued):

A792-2 or -4 Dual Tachometer Replace with new or overhaul exchange A792-4
dual tachometer.
B021-1 Tail Rotor Gearbox Assembly Perform 12-year maintenance per MM § 2.620,
or replace with new or overhaul exchange.
B173-1 V-belt – Alternator Replace with new.
B174-1 Fanwheel (Rev “J” or Perform 12-year maintenance per MM § 2.630,
subsequent) or replace with new or overhaul exchange.
B283-1 Hose Assembly (fuel system) Replace with new.
Revision A thru P
Revision A thru P
Revision A thru P
B286-2 Governor Controller Replace with new or overhaul exchange.
D756-2 (or Bellcrank Assembly – Throttle Replace with new.
A011-2)

B. Remove the following components when they have accumulated 2200 hours time in
service since new or since last overhaul:

A005-4 A154-1 Main Rotor Hub & Bearing Perform inspection and repair per MM §
Assembly 2.610, return to RHC for inspection and
A005-12 B370-1 Main Rotor Hub & Bearing repair, or replace with new.
Assembly
A005-6 A016-4 Main Rotor Blade & A158-1 Replace with new or overhaul exchange
Spindle Assembly A005-7 or A005-14 main rotor blade and
A005-7 A016-6 Main Rotor Blade & A158-1 spindle assembly.
Spindle Assembly
A005-14 A016-6 Main Rotor Blade & A158-3
Spindle Assembly
A006-1 & -6 Main Rotor Gearbox Assembly Replace with new or overhaul exchange
A006-6 main rotor gearbox assembly.
A007-3 or -5 Fanshaft Assembly Replace with new A007-5 fanshaft assembly.
A008-2 or -4 Tail Rotor Assembly Replace with new A008-4 tail rotor assembly.
A014-8 Landing Gear Assembly originally Replace with new.
installed on R22 S/N 0002 thru
0487.
A017-2 Swashplate Assembly Submit to RHC-authorized component
maintenance facility for overhaul, or replace
with new or overhaul exchange.
A018-1 Clutch Assembly (anodized sheave) Replace with new or overhaul exchange.
A018-2 Clutch Assembly (metalized sheave)
A020-2 Upper Frame Assembly S/N 0399 Replace with new. Note: Frame replacement
and prior (originally installed on R22 may require tailcone forward bay replacement.
S/N 0002 thru 0311).
A021-1 Tail Rotor Gearbox Assembly Replace with new or overhaul exchange
B021-1 tail rotor gearbox assembly.
A031-1 Tail Rotor Pitch Control Replace with new.
A041-11 or Tail Rotor Drive Shaft Damper Replace with new A041-11 or -12 damper
-12 Bearing Assembly bearing assembly or replace with new B224‑1
or -3 drive shaft.
A044-1 Horizontal Stabilizer Rev M and Replace with new.
prior (originally installed on R22 S/N
0002 thru 0631).
A051-1 or Clutch Actuator Assembly (A051-1 Replace with new or overhaul exchange.
A051-3 includes gearmotor assembly)
A120-1 Tail Rotor Bellcrank Replace with new.
A121-17 Push-Pull Tube Assembly Replace with new.

service since new or since last overhaul (continued):

A169-1, -2, Muffler with Risers Rev J and Replace with new.
or -4 prior (baffled muffler with straight
tailpipe, originally installed on R22
S/N 0002 thru 0500).
A169-6 or Muffler with Risers (O-320 engine) Replace with new A169-35 muffler.
-35
A169-24 or Muffler with Risers (O-360 engine) Replace with new A169-37 muffler.
-37
A189-10 Nut – Double Lock Replace with new.
A190-1 or -2 V-Belt Set Replace with new A190-2 v-belt set.
A193-2 Flex Plate Replace with new A947-2 flex plate assembly.
A193-3 Flex Plate Replace with new A947-3 flex plate assembly.
A197-1 thru Tail Rotor Drive Shaft Assembly Replace with new B224-1 drive shaft &
-7 originally installed on R22 S/N appropriate B223 yoke.
0002 thru 0747.
A258-1 Main Rotor Pitch Link Assembly Replace with new A258-5 link assembly.
A258-5 Main Rotor Pitch Link Assembly Disassemble; fluorescent penetrant inspect
barrel.
A426-6 Cap – Collective Spring Replace with new.
A480-1 Swashplate Boot Replace with new.
A493-1 Lower Sheave Rev H and prior Replace with new.
(anodized, originally installed on
R22 S/N 0002 thru 0294).
A615-1 Gasket – Carburetor-to-Air Box Replace with new.
A628-6 Connector Assembly – Harness Replace with new.
A636-2 Support (O-320 engine) Replace with new.
A649-1 or -2 Oil Cooler Replace with new or overhaul exchange
C649‑1 oil cooler.
A723-1 Oil Line Assembly Replace with new A723-5 oil line assembly.
A723-2 Oil Line Assembly Replace with new A723-6 oil line assembly.
A780-33 Cable Assembly Replace with new.
A785-1 Hose – Air (intake) Replace with new.
A785-6 Hose – Air (engine cooling) Replace with new.
A785-7 Hose – Air (alternator cooling) Replace with new.
A785-32 Hose Replace with new.
A792-2 or -4 Dual Tachometer Replace with new or overhaul exchange
A792‑4 dual tachometer.

service since new or since last overhaul (continued):

A947-1 Flex Plate Assembly – Forward Replace with new.
A947-2 Flex Plate Assembly – Replace with new.
Intermediate
A947-3 Flex Plate Assembly – Aft Replace with new.
B021-1 Tail Rotor Gearbox Assembly Replace with new or overhaul exchange.
B173-1 V-belt – Alternator Replace with new.
B174-1 Fanwheel (Rev “J” or subsequent) Replace with new or overhaul exchange.
B224-1 Tail Rotor Drive Shaft Replace with new.
B224-3 Tail Rotor Drive Shaft Replace with new.
B286-2 Governor Controller Replace with new or overhaul exchange.
B350-2 Pin – Spring (fanshaft nut) Replace with new.
C636-2 Support (O-360 engine) Replace with new.
C649-1 Oil Cooler Replace with new or overhaul exchange.
D756-2 (or A011-2) Bellcrank Assembly – Throttle Replace with new.
F628-8 Buckle Assembly Replace with new.
KI-217-1 R22 Bladder Fuel Tank Installation Required for helicopter S/N 0002 thru
Kit 4620 per R22 SB-109, if not previously
accomplished.
KI-2207 A017-1 Swashplate Installation Replace existing parts with kit parts.
Kit
KI-2208 R22 A057-2 Airbox Assembly Required for helicopter S/N 2571M thru
Installation Kit 2664 if not previously accomplished.
AN320-18 Nut – Fanshaft Replace with new.
MS16562-15 Pin – Spring Replace with new.
MS20002-18 Washer Replace with new.
MS24665-355 Cotter Pin Replace with new.
NAS1149F1832P Washer Replace with new.
NAS630-80 Bolt Replace with new.
NAS6604-38 Bolt Replace with new.

C. Engine Limits
Refer to latest revisions of Textron Lycoming Service Instruction No. 1009 and
Lycoming Service Bulletin No. 240.
D. Airframe and Engine Accessory Limits
Refer to accessory manufacturer’s instructions for continued airworthiness for
accessory limits. Remove accessories per R22 Maintenance Manual or accessory
manufacturer’s instructions as required.

CHAPTER 2
INSPECTION
Section Title Page
2.000 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1

2.100 General Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
2.110 Ball and Roller Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
2.120 Push-Pull Tubes, Rod Ends, and Spherical Bearings . . . . . . . . . . . . . . . . . 2.1
2.121 Push-Pull Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
2.122 Rod Ends and Spherical Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
2.125 Elastomeric Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
2.130 Telatemp Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
2.140 Torque Stripes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
2.200 Ground and Flight Check For 100-Hour/Annual Inspection . . . . . . . . . . . . . . . 2.7
2.205 Ground Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7
2.210 Run Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
2.220 Flight Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
2.300 Airframe Preparation For 100-Hour/Annual Inspection . . . . . . . . . . . . . . . . . . 2.10
2.400 100-Hour/Annual Airframe Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
2.410 Inspection Procedures and Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
2.500 Special Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.41
2.501 Clutch Actuator Upper and Lower Bearings . . . . . . . . . . . . . . . . . . . . . . . 2.41
2.502 A181-4 Actuator Lower Bearing Inspection and Lubrication . . . . . . . . . . . . 2.41
2.503 A184 Actuator Upper Bearing Inspection and Lubrication . . . . . . . . . . . . . 2.42
2.507 V-Belt Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.43
2.508 Lower Sheave V-Belt Wear Pattern Inspection . . . . . . . . . . . . . . . . . . . . . 2.45
2.510 Tail Skid Strike . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.46
2.520 Tail Rotor Strike . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.47
2.530 Main Rotor Strike . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.48
2.540 Rotor/Engine Overspeed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.49
2.550 Hard Landing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.51
2.560 Steel Tube Frame Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.53
2.570 Main Rotor Blade Detail Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.54
2.571 Spar Cover Adhesive Damage (A016-2 main rotor blade only) . . . . . . . . 2.54
2.572 Main Rotor Blade Sealant and Filler Cracking . . . . . . . . . . . . . . . . . . . . 2.56
2.573 Visual Inspection of Main Rotor Blade Root Area . . . . . . . . . . . . . . . . . 2.57
2.580 Float Inspection and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.58
2.590 Windshield Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.59
2.600 2200-Hour/12-Year Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.60
OCT 2018 Chapter 2 Inspection Page 2.i

CHAPTER 2
INSPECTION (Continued)
Section Title Page
2.610 Main Rotor Hub Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . 2.62

2.620 Tail Rotor Gearbox 12-Year Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 2.64
2.630 Fanwheel 12-Year Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.65
2.640 Main Rotor Blade Static Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.66
2.700 Additional Special Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.69
2.710 Volcanic Ash Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.69
2.720 Lightning Strike . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.70
Page 2.ii Chapter 2 Inspection OCT 2018

CHAPTER 2
INSPECTION
2.000 Introduction
The R22 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. Fluid leaks, discoloration,
dents, scratches, nicks, cracks, galling, chafing, fretting, and corrosion all warrant further
investigation. Unairworthy items must be replaced or repaired as allowed by Robinson
Helicopter Company. This section contains procedures for performing the required periodic
airframe inspections.
2.100 General Procedures

Unless otherwise specified, the following general procedures apply to R22 inspection. When
required, magnetic particle inspection may be performed in accordance with ASTM E 1444
and MIL-STD-1907. Fluorescent penetrant inspection may be performed in accordance
with ASTM E 1417 and MIL-STD-1907.
2.110 Ball and Roller Bearings

The first indication of bearing failure is usually an increase in bearing noise. Noise
will almost always start several hours before bearing failure or any increase in bearing
temperature. Listen to drive system during start-up and shutdown. A failing bearing will
produce a loud whine, rumble, growl, or siren sound. Upon hearing an unusual noise,
thoroughly inspect all bearings before further flight. A failing bearing may have a distorted
seal or be exuding a large amount of grease. Do not rely on Telatemps to detect failing
bearings as temperature increase may occur only seconds before bearing disintegrates.
Refer to § 22-40.
The failure of either actuator bearing in flight could cause loss of power to the rotor
system and could result in a serious accident. The actuator upper ball bearing is on the
clutch shaft aft of the upper sheave; the actuator lower roller bearing is on the fanshaft aft
of the lower sheave. Just before complete failure of an actuator bearing, the clutch light
may flicker constantly (on and off in less than one second). This should not be confused
with its normal on-off re-tensioning in flight (on for 1-8 seconds then off). Flight should
not be resumed until cause of the flickering clutch light has been determined.
OCT 2018 Chapter 2 Inspection Page 2.1

FIGURE 2-1 ROD END AND SPHERICAL BEARING PLAY LIMITS AND TORQUE STRIPE APPLICATION
FIGURE 2-1A ROD END CENTERING

(Position rod ends for maximum rotation)
Page 2.2 Chapter 2 Inspection OCT 2018

2.120 Push-Pull Tubes, Rod Ends, and Spherical Bearings
2.121 Push-Pull Tubes

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 and 1-inch minimum blend radius. If depth exceeds these
limits, tube must be replaced.
If tube is dented or flattened more than 5 percent of its diameter, it must be replaced.
2.122 Rod Ends and Spherical Bearings

Refer to Figure 2-1.
1. Maximum axial play: 0.020 inch
Maximum radial play: 0.010 inch
2. Looseness between bearing outer race and rod end housing is not permitted.
3. Rod ends not riveted in place must block passage of 0.020 inch diameter wire
through witness hole, if provided.
4. Rod end jam nuts and palnuts must be torqued per § 23-32 and torque striped, per
Figure 2-1, at the most visible position for pre-flight inspection. Torque stripe must
extend across nuts to both rod end shank and push-pull tube (or pitch link barrel,
yoke, support, strut, etc.). Torque stripes are subject to deterioration and must be
periodically renewed.
5. Rod ends must be centered, i.e., rod ends should be positioned to allow as much
movement as possible without binding.
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.
CAUTION
Teflon-lined bearings must not be lubricated or solvent cleaned.

FIGURE 2-2A FIGURE 2-2B
ELASTOMER FATIGUE ELASTOMER OIL CONTAMINATION
FIGURE 2-2C
ELASTOMER OVERLOAD

2.125 Elastomeric Bearings
Elastomeric bearings are used in the A062-1 tail rotor hub. Fatigue, oil contamination, or
overload can degrade the elastomer.
Small surface cracks (fatigue cracks) and elastomer dust or “eraser crumbs” (see Figure
2-2A) are normal and are not causes for replacement. As cracks grow, enough elastomer
will be lost to cause reduced stiffness and increased vibration. If deep (greater than 0.10
inch) cracks are present over more than 25% of elastomer face, replace bearing.
Avoid exposure to oil, grease, hydraulic fluid, cleaning solvent, and rust-preventative fluids.
Immediately wash off any such contaminants with detergent and water. Contaminated
bearings exhibit swelling, wavy edges, or debonding (see Figure 2-2B) and must be
replaced.
Overload occurs when elastomer’s tensile strength or rubber-to-metal bond strength is
exceeded. This can occur when normal loads are applied to a bearing weakened by
fatigue or oil contamination. Overload is indicated by large extrusions from and large
clean cracks in elastomer as shown in Figure 2-2C.
Elastomer may also separate (debond) from metal bushings. If separation occurs over
more than 25% of bonded area, replace bearing.

2.130 Telatemp Indicators
Self-adhesive Telatemp indicators record changes in operating temperatures of bearings
and gearboxes. To use a Telatemp, draw a reference line between the highest temperature
square which has darkened during normal operation and the next undarkened square.
During every check thereafter, determine if an additional square has blackened. If
an indicated temperature increase cannot be accounted for by a change in operating
conditions, carefully examine the component before further flight.
NOTE
Telatemps can indicate erroneously if contaminated by a
petroleum product, typically appearing as white, unactivated
square(s) between darkened squares at each end; replace any
Telatemp indicating as such and clean area with acetone prior
to installing.
Part Number Temperature Range

F110-2 60°C / 140°F — 88°C / 190°F
F110-4 104°C / 220°F — 132°C / 270°F
Usage
F110-4 on A006-1 Main Rotor Gearbox
F110-2 on A184-3 Upper Actuator Bearing (just aft of upper sheave)
F110-2 on A181-4 Lower Actuator Bearing (just aft of lower sheave)
F110-2 on A021-1 or B021-1 Tail Rotor Gearbox
2.140 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 torqe
to fastener. If fastener moves, disassemble joint and inspect parts for damage such as
fretting, thread deformation, hole elongation, etc.; replace damaged parts. If fastener
does not move, install new palnut as required & standard torque per § 23-32. Torque
stripe fastener per Figure 2-1.

2.200 Ground and Flight Check for 100-Hour/Annual Inspection
Complete the following checklists in conjunction with a 100-hour or annual inspection.
Note and correct any discrepancies.
2.205 Ground Check
1. Throttle Control: Check for freedom of rotation with collective full down
and full up.
2. Throttle Overtravel Spring: Check by twisting throttle past idle position
to override stop. Release throttle and ensure it returns immediately to
normal idle position.
3. Mixture Control: Check for smoothness of operation with no binding.
Check press-to-unlock button for proper function. Verify 0.03 to 0.10
inch spring-back at full rich position.
4. Carburetor Heat Control: Check for smoothness of operation with no
binding. Verify 0.03 to 0.10 inch spring-back at full off position.
5. Cyclic Control: Check freedom through full travel with friction and
right trim off. Verify friction knob rotates 1/8 to 1 turn clockwise
before adding friction. Check full travel with friction and right trim
on. Verify 10 pounds maximum friction measured laterally at grip
with right trim off, friction on, and MR blade pitch links fore and aft.
6. Collective Control: Check freedom through full travel with friction off.
Check freedom through full travel with friction on; friction should be 12
to 20 pounds measured at grip.
7. Carb Heat Assist (if installed): With collective down and full carb heat,
raise collective full up and verify carb heat off. Lower collective full
down and verify carb heat full on. With collective friction off, push carb
heat off and verify collective stays down.
8. Tail Rotor Pedals: Check for smooth operation with no binding.
9. Removable Controls: Verify security of attached fasteners.
10. Lighting and Instruments: Turn MASTER switch on and verify —
a. Carbon Monoxide caution light blinks twice
b. Carb Air Temp approximately same as Outside Air Temp
c. ALT caution light on
d. OIL pressure warning light on
e. Fuel quantity gages – indication of fuel level
f. Navigation and panel lights – check function
g. Strobe light – check function

2.205 Ground Check (continued)
10. Lighting and Instruments: Turn MASTER switch on and verify — (continued)
h. Landing lights – check function
(clutch switch must be Engaged to check landing lights)
i. Map light – check function
j. Ammeter – shows discharge
k. Oil temperature gage – slight needle deflection with engine cold
l. Cylinder head temp gage – slight needle deflection with engine cold
m. MR CHIP light – on when sender shorted or test switch depressed
n. MR TEMP light – on when sender shorted or test switch depressed
o. TR CHIP light – on when sender shorted or test switch depressed
p. LOW FUEL light – on after approximately 1 second delay when low
fuel sender in tank is depressed or when test switch depressed

ROBINSON MAINTENANCE MANUAL MODEL R22
2.210 Run Up
1 . Perform preflight inspection per POH.
2. Turn MASTER switch on. Apply rotor brake and verify BRAKE light on.
With brake applied, verify starter does not activate when key is turned
to START position.
3. Start engine and run up using POH checklist, except leave cyclic and
collective frictions on and governor off before proceeding. After engaging
clutch switch, verify blades turn within 5 seconds and CLUTCH light
extinguishes within 100 seconds.
4. Ammeter indicates charge, AL T light off.
5. Both magnetos ground (momentarily off) at 60% RPM.

6. Select alternator and battery switches off and verify-
a. Engine and rotor tachometers operate.
b. All warning/caution lights extinguished, indicating proper function of
tachometer bus isolation diode.
7. No unusual bearing noise when varying RPM through operating range.
Mechanic to listen near V-belt drive for symptoms of failing bearing as
described in Section 2.11 0.
8. Set RPM at 75%, governor on, Increase to 85%, release throttle and
verify governor increases RPM to 104% ± 1.5%. Increase RPM to
106%, release throttle, and verify governor decreases RPM to 104% ±
1.5%.
9. Engine and rotor tachometer needles within 1% of each other at 104%
RPM.
1 0. Verify alternator voltage as follows:
13.4 to 13.9 vdc for A942-3 alternator control unit
13.0 to 13.7 vdc for A942-1 or -2 alternator control unit
11. Heater operates properly (if installed).
12. Tachometer needles do not jump more than 2% when transmitting on
118.00, 125.00, and 136.975 MHz with governor on.
13. Raise collective control 0.5 inch at grip and slowly decrease RPM. Verify
low rotor RPM warning horn and light activate at 97 to 96% RPM and
remain on as RPM is decreased to idle.
14. Idle RPM with engine warm, clutch engaged, throttle closed: 53 to
57%.
15. Idle mixture with engine warm, clutch disengaged, throttle closed: 2
to 4% RPM rise as mixture is pulled slowly to idle cut-off. Adjust idle
mixture screw as required. If unable to obtain rise, set idle mixture
screw to nominal position of 1 Yz turns out from full-in then adjust as
required for smooth idle.
Change 26: APR 2007 2.9

2.220 Flight Check
1. Hover:
a. All gages green
b. Controllability in left and right pedal turns
c. Vibration levels
2. Level flight: Approximately 3000 feet density altitude (if possible),

maximum continuous power, governor on, right trim on, frictions off.
a. Vibration levels
b. Longitudinal cyclic trim - cyclic does not creep forward or aft
c. Lateral cyclic trim - cyclic does not creep left or right
d. Collective spring - collective does not creep up or down
e. Tail rotor pedal position - 0.0 to 0.5 inch left
2.300 AIRFRAME PREPARATION FOR 1 00-HOUR/ANNUAL INSPECTION
The airframe must be thoroughly cleaned prior to inspection in accordance with U.S. FAR
43, Appendix D, paragraph (a). Cleaning should include a wipe down of main and tail rotor
blades, hubs, and airframe exterior with a mild soap and water solution. Refer to R22 POH
Section 8 for cleaning instruction. Note any fluid leakage before cleaning.
CAUTION
Do not spray magnetos, main rotor hub, tail rotor gearbox vent,
or swashplate area with high pressure water as water may
enter and cause corrosion and breakdown of lubricants.
2.10 Change 25: JUN 2006

2.400 100-HOUR/ANNUAL AIRFRAME INSPECTION
Perform 100 hour or annual airframe inspections per Section 2.41 0. RHC recommends
keeping a copy of the most recently performed checklist with the aircraft's maintenance
records.
2.410 Inspection Procedures and Checklist
R22 Serial No.: Technician name:

Registration No.: Technician
Hourmeter Indication: Certificate number:
Aircraft Total Time:
Numbers in parentheses indicate access location per Figures 2-3A and 2-38.
1. Remove Landing Light Retainer ( 1 A)
NOTE
Do not remove pedal bearing block cover plates ( 1 B) unless

function check of pedals indicates a problem with bearing
blocks.
Landing Light Retainer and Support: Inspect condition. Verify support

security.
Tail Rotor Pedal Bearing Blocks: Use an inspection light and mirror to
inspect bearing blocks. Maximum allowable play is 0.050 inch axially
and 0.020 inch radially. Verify security.
Tail Rotor Pedal Bearing Blocks Sheet Metal Supports: Use an inspection
light and mirror to verify no cracks or fretting in bearing block vertical
sheet metal supports.
Tail Rotor Pedals: Inspect condition. Verify no cracks. Verify security

and operating clearance.
Push-Pull Tubes: Inspect condition. Verify no cracks at ends. Inspect

rod ends per Section 2.120. Verify security and operating clearance.
Sheet Metal Structure: Inspect condition. Verify no corrosion. No
cracks.
Battery Box (if installed in nose): Inspect drain attachment to battery
box. Verify no electrolyte leakage.
Chin Area: Verify no loose equipment or debris.
Wiring: Inspect condition. Verify no loose, broken, or chafed wires.

Verify neatness and security.
Fasteners & Torque Stripes: Inspect condition and verify security of all
fasteners. Renew deteriorated torque stripes per Figure 2-1.
Change 25: JUN 2006 2.11

2.410 Inspection Procedures and Checklist (cont' d)
FIGURE 2-3A ACCESS COVERS AND INSPECTION PANELS
2.12 Change 25: JUN 2006

2.410 Inspection Procedures and Checklist (continued)
FIGURE 2-3B ACCESS COVERS AND INSPECTION PANELS
2. Open Upper Console Assembly (2) or Lower Faceplate per Section 14.1020
(10-hole instrument console only)
Upper Console Assembly: Inspect condition. Verify hinge security.

Instruments and Instrument connections: Inspect condition. Verify
security.
Strobe Power Supply and Wiring (alternate locations – atop horizontal
firewall or behind right seat back): Inspect condition. Verify no cracks in
mounting area. Verify security.
B255-1 Bracket (10-hole instrument console only): Inspect condition of
grommet and bracket contacting brace assembly between windshields.
Tail Rotor Push-Pull Tubes: Inspect condition of visible portions. Verify
operating clearance.
Battery and Box (if installed in nose): Inspect condition. Check battery
cell fluid level and specific gravity (non-sealed battery only). Verify
security of connections. Verify no corrosion in surrounding structure.
Radio Tray(s): Inspect condition. Verify security. Verify no loose or poor
wire connections.
Wiring: Inspect condition. Verify neatness, security, and no chafing.

3. Open Circuit Breaker Panel (3)
WARNING
Ensure electrical system remains off while circuit breaker panel

is open.
Wiring: Inspect condition. Verify neatness, security, and no chafing.

Connections: Inspect condition. Verify security and no corrosion.
Circuit Breakers: Inspect condition. Verify security. Check airworthiness
directive applicability. Verify red button (collar) on CLUTCH circuit
breaker button.
Copper Bus Bars: Inspect condition. Verify no corrosion. Verify bus bars
are not bent and will not contact surrounding structure.
Circuit Breaker Box Interior: Inspect condition. Verify cleanliness.
Close and Secure: Circuit breaker panel.
4. Remove Horizontal Cover (4A), Cyclic Box Cover (4B), Belly Panel (4C) and Vertical
Panel (4D)
To remove cyclic box cover, unscrew trim adjustment knob, remove spring pin in
cyclic friction knob, and, on ships equipped with carburetor heat assist, unscrew
carburetor heat knob.
Covers: Inspect condition. Verify placard legibility.

Cyclic Box Assembly: Inspect condition. Verify no cracks, loose rivets,
or corrosion. Verify security.
Cyclic Stick Assembly: Inspect condition. Verify no cracks in weld areas.
Verify security and operating clearance. Verify no more than 0.015 inch
wear in plates at bottom of stick from A121-1 push-pull tube’s forward
rod end housing.
Cyclic Pivot (forward end of torque tube): Inspect condition. Inspect
bearings per § 2.120. Verify security and operating clearance.
Cyclic Right Trim: Rotate main rotor blades until pitch links are located
fore and aft. Grip cyclic and activate right trim. Trim should produce a
right cyclic stick force. Move cyclic stick fully left and verify right trim
spring coils do not bind. Verify security and operating clearance.

2.410 Inspection Procedures and Checklist (cont'd)
Panel (40) (cont'd)
Cyclic Friction: Inspect condition. Inspect rod ends per Section 2.120.
Cyclic Horizontal Push-Pull Tube: Inspect condition. Verify no cracks

around reinforcement blocks at tube ends. Verify security and operating
clearance.
Tail Rotor Horizontal Push-Pull Tubes: Inspect condition. Verify no
cracks at ends. Inspect rod ends per Section 2.120. Verify security
and operating clearance.
Tail Rotor Push-Pull tube Lower Bellcrank: Inspect condition. Verify

security and operating clearance.
Mixture Cable: Verify security.
Carburetor Heat Cable: Verify security.
Carburetor Heat Assist Bellcrank (if installed): Inspect condition. Verify

Carburetor Heat Assist Push-Pull Tube (if installed): Inspect condition.
Verify no cracks at ends. Inspect rod ends per Section 2. 120. Verify
Pitot and Static Lines and Drains: Inspect condition. Verify no cracking,
chafing, or kinking. Remove drain plugs from tee fittings in each line and
drain any water. Install drain plugs.
Elastic Trim Cord: Remove trim cord assembly and stretch it. While
stretched, check cord for voids which may indicate broken strands. Slide
both hooks back and verify security of locking rings. Install cord. Verify
NOTE
Elastic trim cord is not required if cyclic does not need forward
trim in cruise flight.
Change 25: JUN 2006 2.15

2.410 Inspection Procedures and Checklist (cont'd)

Panel (40) (cont'd)
Electrical Wiring: Inspect condition. Verify no loose, broken, or chafed

wires. Verify neatness and security.
Tail Rotor Vertical Push-Pull Tube: Inspect condition. Verify no cracks at

ends. Inspect rod ends per Section 2.120. Verify security and operating
clearance.
Cyclic Push-Pull Tubes: Inspect condition. Verify no cracks at ends.

Inspect rod ends per Section 2.120. Verify security and operating
clearance. Contact between A 121-3 & -7 push-pull tube lower ends is
permitted when cyclic stick is in aft corners of cyclic box.
Cyclic Bellcrank: Inspect condition. Verify security and operating

clearance.
Cyclic Yoke (aft end of torque tube): Inspect condition. Inspect bearings
per Section 2.120. Verify security and operating clearance.
Cyclic Fork (attaching bellcrank to collective stick): Inspect condition.

Inspect rod end per Section 2.120. Verify security. Verify operating
clearance.
Throttle Overtravel Spring: Inspect condition. Inspect rod ends per

Section 2. 120. Verify security and operating clearance. Contact
between overtravel spring and A 1 21-1 push-pull tube is permitted when
cyclic stick is in forward right corner of cyclic box.
Collective Friction and Stop Assembly: Inspect condition. Verify no

nicks, cuts, or scratches. Move collective up and down and verify no
bending or binding. Verify security and operating clearance.
Collective Boot: Inspect condition. Verify no tears. Ensure tie string

ends are tucked into boot (if installed - current production aircraft use
Ty-raps to secure boot around collective stick).
2.16 Change 25: JUN 2006

5. Remove Seat Backs (5A & 5B) & Collective Spring Guard (5C under left seat)
Seat Backs and Collective Spring Guard: Inspect condition. Verify

upholstery security.
Upper Frame Assembly: Inspect condition of visible portions. Verify
security.
Electrical and Antenna Wiring: Inspect condition. Verify security. Verify
no chafing. Check grommets for proper installation.
Pitot and Static Lines: Inspect condition. Verify no chafing or kinks.
Collective Stick Assembly: Inspect condition. Inspect bearings per
§ 2.120. Verify security and operating clearance. Verify no cracks in
welds. Verify security of removable stick (if installed). If applicable, verify
A783‑1 retainer is secured to collective stick with ty-raps per Figure 2-4.
FIGURE 2-4 A783-1 RETAINER SECURITY
Throttle Connecting Rod: Inspect condition. Verify no cracks. Verify

Governor: Inspect condition. Inspect rod ends per § 2.120. Verify
security and operating clearance. Verify sufficient wiring slack with full
up collective.
Collective Spring: Inspect condition. Inspect rod ends per § 2.120. Verify
no binding or roughness during operation. Verify lubrication of guide rods.
Verify spring coils do not touch each other when collective is full down.
Verify no elongation of lower cap guide rod holes. Verify security and

5. Remove Seat Backs (5A & 5B) & Collective Spring Guard (5C under left seat) (continued)
Firewall Drains: Inspect condition. Verify drains are unobstructed. Verify

tubing clamps are not cutting tubing. Verify security.
Governor Controller and Wiring: Inspect condition. Verify security.
Main Fuel Tank Outlet & Fuel Line: Inspect condition. Verify no leakage.
Verify security. Verify smooth operation of fuel valve.
Fuel Shut-Off Valve: Inspect condition. Verify no leakage. Verify security.
Verify smooth operation of fuel valve.
Aux Fuel Tank Fuel Line: Inspect condition. Verify clearance to structure.
Verify no leakage. Verify security.
6. Open Cowling Door(s) (6A & 6B) & Remove aft Cowling (6C)
Cowling Doors: Inspect condition. Verify proper operation of fasteners.

Electrical Wiring: Inspect condition. Verify no loose, broken, or chafed
wires. Verify neatness and security.
Actuator Fuse(s) and Holder(s): Inspect condition. Verify no corrosion.
Verify correct AGC-1½ fuse(s), twist-to-lock function, and security.
Antennas and Connections: Inspect condition. Verify security of antenna(s)
and antenna connection(s).
Emergency Locator Transmitter (if installed): Inspect condition. Verify
security. If applicable, comply with U.S. 14 CFR 91.207 (d).
Pitot Line and Static Vent: Inspect condition. Verify no chafing, kinks, or
tight bends. Verify static vent is clean and unobstructed.
Fuel Tanks: Inspect condition of visible portion. Verify no leaks. Verify
security. Check interior for foreign objects and cracks in baffle.
Aux Fuel Tank Fuel Line: Inspect condition. Verify clearance to structure.
Verify no leakage. Verify security.
Fuel Gage Sender(s) and Wiring: Inspect condition. Verify no fuel leaks.

6. Open Cowling Door(s) (6A & 6B) & Remove Aft Cowling (6C) (continued)
Fuel Tank Sump Drain(s): Inspect condition. Verify drain valve(s) open
easily, drain fuel freely, spring closed, and seal completely.
Low Fuel Warning: Turn battery on. With a clean wooden dowel, gently
depress low fuel sender float in main fuel tank and verify LOW FUEL warning
light illuminates after approximately 1 second delay. Turn battery off.
Fuel Cap(s): Refer to Figure 2-4A. Verify A689-6 fuel cap is revision J
or subsequent if bladder tanks are installed (revision J or subsequent caps
may also be used on all-aluminum tanks). Inspect condition. Verify no
deterioration of gasket(s). Verify security when closed. Refer to R22
SB‑107; verify cap decal is legible and properly installed, and alignment
marks on cap and tank align when cap is fully closed.
FIGURE 2-4A A689-6 FUEL CAPS
Collective Jackshaft Supports: Inspect condition. Inspect rod ends per §

2.120. Verify no cracks or corrosion. Verify strut ends are sealed. Verify
security.
Collective Jackshaft: Inspect condition. Verify no cracks or corrosion. If
open type, verify no internal corrosion. Verify security. Verify operating
clearance.
Swashplate Push-Pull Tubes: Inspect condition of visible portions. Verify
no cracks at ends. Inspect rod ends per § 2.120. Verify no tears in,
or wear through, heat-shrink sleeves on forward push-pull tubes. Verify
Push-Pull Tube Guides or Rollers: Inspect condition. Verify cleanliness, no
wear into metal, and free movement of rollers. Verify security.

FIGURE 2-4B A947-1 FLEX PLATE INSPECTION
Tail Rotor Push-Pull Tube and Bellcrank (at forward end of A121-15 push-
pull tube): Inspect condition. Inspect rod ends per § 2.120. Verify no
cracks in tube ends. Verify no cracks at bellcrank sheet metal mounting.
Verify security and operating clearance.
Main Rotor Gearbox Cooling Air Duct and Nozzle: Inspect condition. Verify
security. Verify no rips, holes, chafing, or obstructions. Inspect condition
and verify security of horizontal firewall grommet around duct.

Main Rotor Gearbox: Inspect condition, especially gearbox mounts,

static mast tube-to-gearbox attachment, and mast tube lower casting (if
applicable). Inspect Telatemp per § 2.130. Verify proper oil level with no
leakage. Verify security. Verify security of Hall Effect senders.
NOTE
At 500 hours time in service or annually, whichever occurs

first, remove chip detector and clean any varnish accumulation
from detector’s magnetic probe and adjacent metal body using
a toothbrush and approved solvent per § 22-11. Drain and flush
gearbox at intervals not to exceed 500 hours time in service
(refer to § 22-13).
Rotor Brake: Inspect condition, including activating cable & pulley and
microswitch. Verify integrity of brake pads and 0.030 inch minimum pad
thickness. Verify brake pad clearance to input yoke when brake is off.
Verify security and operating clearance.
MRGB Input Yoke: Inspect condition. Verify security and operating
clearance. Verify security of magnets.
Forward Flex Plate: Refer to Figure 2-4B. 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. Verify proper installation,
security, and operating clearance.
WARNING
A193 flex plates, which do not have bonded washers, are

obsolete and must be replaced with A947 flex plates having
bonded washers. If a bonded washer separates from an A947
flex plate, flex plate is unairworthy and cannot be repaired.
Ensure A947-1 forward flex plate is Rev E or subsequent
(identified by letter, “E” or subsequent letter, on two adjacent
arms of flex plate).
Clutch Shaft Forward Yoke: Inspect condition. Verify no cracks, corrosion,

or fretting. Verify security and operating clearance.
Clutch Assembly: Inspect condition. Verify no oil leakage. Verify no clutch
shaft corrosion, especially at shaft-to A966-1 seal junctures. Remove any
light surface corrosion at shaft-to-seal junctures and apply wax or suitable
corrosion preventative compound. Verify no cracks in seal retainer plates.
NOTE
Clutch assembly lubricant inspection and servicing (§ 7.214) is

recommended every 500 hours time in service.

Upper Sheave: Inspect condition. Verify smoothness of drive belt contact

surfaces. Replace any sheave having corrosion, pitting, flaking, roughness,
sharp ridges, wear through anodized coating, or blistering of optional
metalized coating.
Upper Steel Tube Frame: Inspect condition. Verify no cracks or corrosion.
If corrosion is found, inspect and repair per § 2.560. Use an inspection
light and mirror to inspect all parts of each weld.
CAUTION
Upper steel tube frame is fatigue loaded and therefore susceptible

to fatigue cracks. Inspect all joints very thoroughly.
Horizontal Firewall: Inspect condition, especially where bolted to steel

structure. Verify no cracks, buckling, or wrinkles.
Cabin Aft Bulkhead: Inspect condition. Verify no corrosion, loose rivets,
deformation, or cracks.
7. Remove Side Skirts (7A, 7B, 7D, & 7E), Spark Plug Access Covers (7C & 7F), and
Battery Box Cover (7G, alternate location under upper console or left seat)
Engine: Refer to Lycoming Operator's Manual (Lycoming P/N 60297-12 or

60297-16, as applicable) Sections 4 and 5 and Lycoming Sl 1080 (current
revision) for 100-hour or annual inspection and service procedure.
Muffler: Open heater shroud (if installed). Inspect muffler condition.
Verify no cracks or ruptures. Pay particular attention to tail pipe and riser
attachment areas, welds, clamps, riser flanges and gaskets. Verify no
internal obstructions.
Muffler Leak Check: Pressurize muffler with low pressure air and inspect
for leakage by applying soapy water to exterior and looking for air bubbles.
Verify security.
WARNING
Exhaust system failure can result in carbon monoxide poisoning,

partial loss of power, or fire.
Heater Shroud (if installed): Inspect condition. Close and secure shroud
and connect hoses.
Engine Cooling Panels: Inspect condition. Pay particular attention to panel
attached to oil cooler and panel attached to alternator cooling hose. Verify
no cracks or missing or loose fasteners. Verify security.

Battery Box Cover (7G, alternate location under upper console or left seat) (continued)
Alternator & Pulley: Inspect condition. Verify steel pulley (use magnet);
aluminum pulley is not approved. Verify security.
Alternator Wiring: Inspect condition. Verify no evidence of arcing. Verify
security of output, aux, and field terminal studs. Verify no damage to
insulating spacer at output stud. Verify wiring security.
Alternator Belt: Inspect condition. Replace belt if there are any cracks,
missing teeth or delamination. Check tension per Lycoming Service
Instruction 1129 (current revision). Verify proper belt alignment.
Emergency Spare Alternator Belt: Remove if installed.
Alternator Cooling Hose: Inspect condition. Verify no obstructions or
holes. Verify security.
Vertical Firewall: Inspect condition. Verify no cracks, buckling, or wrinkles,
especially around structural attachment points.
Lower Steel Tube Frames: Inspect condition. Verify no corrosion or cracks,
especially at welds. If corrosion is found, inspect and repair per § 2.560.
Verify proper torque (see § 23-32) and safety wiring of drilled-head bolt at
lower left frame-to-cabin-belly attachment.
Engine Mounts: Inspect condition. Verify security. Replace rubber mounts
exhibiting significant deflection or other than superficial cracks.
Throttle Control: Verify carburetor butterfly bellcrank contacts idle rpm
adjustment screw with collective full down and throttle grip at idle position.
Verify bellcrank contacts full-open stop when throttle is opened with
collective half-up. Inspect rod end per § 2.120. Verify operating clearance,
especially at vertical firewall.
Throttle Correlation Rigging: Check per § 10.150 and adjust as required.
Full Throttle Switch Rigging: Check per § 33-60 and adjust as required.
Carburetor Mixture Control: Verify carburetor mixture control moves
carburetor mixture control arm stop to stop. Inspect condition and verify
security of mixture control cable clamp(s) on air box bracket; push and pull
cable housing to ensure it does not slip in clamp(s). Inspect condition and
verify security of mixture control cable inner wire attachment to carburetor
mixture control arm. Ensure freedom of rotation between mixture control
arm and inner wire retention fitting (bolt) when arm moves. Verify mixture
control safety spring is properly installed (so spring force moves mixture
control arm to full-rich position if inner wire breaks).
Engine Electrical Wiring, Alternator Control Unit: Inspect condition. Verify
no wire chafing. Inspect connections. Verify security and no corrosion.

Battery Box Cover (7G, alternate location under upper console or left seat) (continued)
Oil Lines & Elbows: Inspect condition. Verify clearance and no cracks or
abrasions. Wires, ty-raps, and structure must not contact lines.
Oil Line Clamps: Inspect condition. Verify no broken clamps.
Oil Cooler: Inspect condition. Verify no cracks or leakage. Verify security.
Verify airflow path through cooling fins is unobstructed.
Gascolator: Inspect condition. With fuel valve in OFF position, remove and
clean gascolator bowl and filter screen. Reinstall bowl, turn fuel valve ON.
Safety wire retainer after ensuring no leakage. Verify drain valve opens
easily, drains fuel freely, springs closed, seals completely, and is torque-
striped per § 23-31.
Fuel Hose: Inspect condition, verify security, clearance, no cracks, abrasion
or leakage.
Carburetor Air Box: Open air box. Inspect condition. Verify free movement
of disk in drain valve (not applicable to Mariners). Verify security. If
installed, verify free movement and full closure of spring-loaded alternate
air door.
Carburetor Heat Valve: Verify carburetor heat control fully opens and
closes slider valve. Inspect condition and verify security of carburetor heat
cable clamp on air box. Inspect condition and verify security of carburetor
heat control cable inner wire attachment to slider valve.
Air Filter: Clean B771-1 air filter per § 6.435. Close and secure air box.
Carburetor Air Inlet Hose: Inspect condition. Verify no obstructions,
leakage, or chafing. Verify security.
Carburetor Heat Scoop and Hose: Inspect condition. Verify security.
Verify no obstructions, leakage, chafing, or scoop cracks.
Heater Hoses (if installed): Inspect condition. Verify security and no
obstructions, leakage, or chafing. Verify security.
Battery, Battery Cables, and Battery Box (alternate locations under upper
console or left seat): Inspect condition. Check each battery cell electrolyte
for quantity and specific gravity (non-sealed batteries only). As required,
perform capacity test or replace battery per manufacturer’s instructions.
Verify battery cable security and no cracked or corroded terminals. Verify
security of, and no obstructions in, battery box drain tube (if installed).

8. Remove Tailcone Fairing (8)
Tailcone Fairing: Inspect condition.

Upper Steel Tube Frame: Inspect condition. Verify no cracks or corrosion.
If corrosion is found, inspect and repair per § 2.560. Use an inspection
light & mirror to inspect all parts of each weld.
CAUTION
Upper steel tube frame is fatigue loaded and therefore susceptible

to fatigue cracks. Inspect all joints thoroughly.
Tailcone-to-Upper Frame Attachment: Inspect condition. Verify security.

Upper Frame Protective Clamp: Inspect clamp protecting right side upper
frame tube from drive belt contact; replace if wear has penetrated clamp.
If clamp is not installed, verify no more than 0.0049 inch wear into frame
tube due to drive belt rubbing. Protective clamp may be installed per Figure
2-4C on any R22 if desired.
FIGURE 2-4C UPPER FRAME PROTECTIVE CLAMP INSTALLATION

(View looking forward)

8. Remove Tailcone Fairing (8) (continued)
Actuator Upper Bearing: Inspect condition. Verify no more than 0.060 inch
axial play. Verify no fretting between bearing inner race and clutch shaft.
Verify bearing inner race has not slipped relative to clutch shaft. Inspect
Telatemp per § 2.130. Perform § 22-41 bearing inspection if unexplainable
Telatemp increase has occurred.
CAUTION
A184 bearing requires periodic lubrication per § 1.101.
Actuator Upper Bearing Lubrication: Perform as required.

Clutch Lateral Centering Strut Assembly: Inspect condition. Inspect rod
ends per § 2.120. Verify security.
Intermediate Flex Plate and Yokes: Refer to Figure 2-4B. 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. Verify proper installation,
WARNING

Tail Rotor Push-Pull Tubes and A331-1 Bellcrank: Inspect condition. Verify
no cracks at tube ends. Inspect rod ends per § 2.120. Verify security and
Drive V-Belts: Inspect per § 2.507.
Fanshaft: Inspect condition. Perform 360° visual inspection of exposed
fanshaft for cracks. Verify security and safety wiring of attaching bolts.
Actuator Lower Bearing: Inspect condition, verify bearing inner race has
not slipped relative to fanshaft. Inspect Telatemps per § 2.130. Perform §
22-42 bearing inspection if unexplainable Telatemp increase has occurred.
CAUTION
A181-4 bearing requires periodic lubrication per § 1.101.
Actuator Lower Bearing Lubrication: Perform as required.

Lower Bearing Brackets: Verify no looseness or cracking in A185 brackets
which secure actuator lower bearing to scroll.
Fiberglass Scroll: Inspect condition. Verify no damage to vane assembly in
upper right scroll. Verify security. Verify drain hole is unobstructed.

Scroll Metal Inlet Lips & Gap (if installed): Inspect condition. Verify 0.020
to 0.100 inch gap between lips and fanwheel inlet. (Attach holes in lips
may be elongated to facilitate gap adjustment.)
Fanwheel Assembly: Inspect condition. Verify no cracks or corrosion.
Check leading edge of vanes for damage. Verify alignment of roll pin and
slippage marks on fanwheel. If marks and roll pin do not align, remove
fanwheel and inspect hub and shaft for damage. Verify security.
Actuator (A051-1): Turn master switch on and engage clutch switch. While
actuator is engaging, depress extension limit switch lever and verify gear
motor stops; release lever and verify gear motor resumes running. Use
an inspection mirror to observe column springs at end of belt-tensioning
cycle; springs should snap outward simultaneously. Verify maximum
engaged extension limit per Figure 7-15 is not exceeded. Verify security of
attachment to A181 and A184 bearings. Verify gear motor security and
minimum 0.030 inch clearance to upper frame.
Actuator Spring Switches: Check using either of following two methods,
as appropriate:
Method 1 - (actuator electrical harness must be equipped with “Test” plug)
CAUTION
When using MT558-1 plug assembly (see Figure 2-5), if gear

motor does not shut off when column springs snap outward
then spring switch has failed in closed position; immediately
remove MT558-1 to prevent actuator damage.
a. Disengage actuator. Connect one end of MT558-1 to actuator test

plug. Engage actuator and verify gear motor shuts off when column
springs snap outward.
b. Disengage actuator. Connect opposite end of MT558-1 to actuator
test plug. Engage actuator and verify gear motor shuts off when
column springs snap outward.
c. MT558-1 pins 1-2 jumper tests the wire 98 spring switch; the pins
2-3 jumper tests the wire 91 spring switch (see Figure 14-4A). If
either switch does not function properly, replace switch section per
§ 7.551 before further flight.
FIGURE 2-5

Actuator Spring Switches (continued):
Method 2 - (use if actuator electrical harness is not equipped with “Test”
plug)
a. Refer to Figure 2-5A. Depress column springs on one side of actuator
until springs snap inward (use large screwdriver or similar tool with
several layers to tape over end to protect actuator). Hold springs
inward for at least one second. Actuator motor should not run. If
motor starts, allow motor to run approximately two seconds, then
release pressure on column springs. Depress column springs again. If
motor starts again, opposite spring switch does not function properly.
b. Disengage and re-engage actuator. Repeat step a. on opposite-side
column springs.
c. If either switch does not function properly, replace switch per §
7.551 before further flight.
FIGURE 2-5A ACTUATOR FUNCTION TEST
Lower Sheave: Inspect condition. Verify smoothness of drive belt contact

surfaces. Remove any surface corrosion and refinish with approved
primer. Replace any sheave showing corrosion-pitting or flaking of
metalized coating, roughness, or sharp ridges.

Engine Height: Check per § 6.130 and adjust as required.
Clutch Shaft Angle: Check per § 7.240. Replace drive belts as required.
Sheave Alignment: Check per § 7.230 and adjust as required.
Throttle Correlation Rigging: Check per § 10.150 and adjust as required.
9. Remove 4 Tailcone Inspection Covers (9) : Verify nutplate self-locking
feature when removing.
Inspection Covers: Inspect condition.
Tail Rotor Drive Shaft: Inspect condition. Verify no cracks, bends, or
contact with inside of tailcone. Refer to Figure 7-12C for corrosion
limitations. Check runout per § 7.340.
Tail Rotor Push-Pull Tube: Inspect condition. Inspect rod ends per §
2.120. Verify wear does not exceed § 2.120 limits. Verify no cracks in
ends. Verify operating clearance. Verify tail rotor guard mounting screw
shanks clear push-pull tube.
Damper: Inspect condition. Verify security. Verify bearing housing wear
is within Figure 2-6 limits.
Tailcone Interior: Inspect condition. Verify no loose rivets or corrosion.
Verify no excessive wear in tail rotor push-pull tube bushings. Verify no
cracks, especially at damper-to-tailcone attachment.
Lower, Whip Antenna (if installed): Remove four screws securing antenna
mounting plate to tailcone. Verify no cracks or corrosion on mounting
plate or tailcone mount. Inspect antenna and wiring condition. Install
antenna. Verify security.
Upper Antenna(s) (if installed): Inspect antenna and wiring condition.
Verify security and no cracks at attachment to tailcone.
Tailcone Exterior: Inspect condition. Refer to Figures 2-7A and 2-7B for
dent and scratch limits. Verify no cracks, corrosion, fretting between
skin joints, or loose rivets. Verify drain hole at forward edge of each bay
(except forward) is unobstructed.
Tail Rotor Visual Warning Guard: Inspect condition. Verify no cracks or
corrosion, especially at tailcone attachment. Verify security.
Strobe Light: Inspect condition. Verify cleanliness and security.

FIGURE 2-6 DAMPER BEARING HOUSING WEAR LIMITS

9. Remove 4 Tailcone Inspection Covers (9) (continued)
FIGURE 2-7A TAILCONE DENT LIMITS

BAY 5:
0.00 to 0.10 inch deep — No repair required provided 4 inches minimum between
dented stations.
0.10 to 0.25 inch deep — Repair per § 4.314.
Greater than 0.25 inch deep — Replace bay (requires return to RHC).
ANY OTHER BAY:
Dents with 0.030 inch maximum depth, 1.25 inch maximum diameter, and 0.125 inch
minimum bottom radius are acceptable if there is no more than one dent per station
with 4 inches minimum between dented stations. Otherwise, replace tailcone or
return to RHC for repair.
FIGURE 2-7B TAILCONE SCRATCH LIMITS

Allowable scratch depth varies with scratch angle to tailcone centerline as shown.
For scratches within these limits, polish out scratches using 320-grit or finer abrasive
paper and minimum 0.10 inch blend radius. Polish parallel to tailcone long axis. If
scratches exceed limits, replace tailcone or return to RHC for repair.

10. Remove Plastic Cover (10)
Plastic Cover: Remove and clean. Inspect condition. Replace as required

and install. Verify nutplate self-locking feature when installing.
Empennage: Inspect condition. Verify security. Verify no cracks or
loose fasteners. Verify lower vertical stabilizer and tail skid drain holes
are unobstructed. Refer to special inspection section for tail skid strike
inspection criteria.
Aft Navigation Light: Inspect condition. Verify cleanliness, clear lens,
and security.
Aft Flex Plate: Refer to Figure 2-4B. 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. Verify proper installation,
WARNING

bonded washers. If a bonded washer separates from a A947
Tail Rotor Gearbox: Inspect condition, including seals. Verify proper

oil level and no leakage. Verify security and safety wire integrity. Verify
output shaft cleanliness.
NOTE
At 500 hours time in service or annually, whichever occurs

first, remove chip detector and clean any varnish accumulation
from detector’s magnetic probe and adjacent metal body using
a toothbrush and approved solvent per § 22-21. Drain and flush
gearbox at intervals not to exceed 500 hours time in service
(refer to § 22-23).

10. Remove Plastic Cover (10) (continued)
Tail Rotor Pitch Control Assembly and Aft Bellcrank: Inspect condition.
Inspect spherical bearing in underside of pitch control per § 2.120; it
is permissible to have a single radial crack in this spherical bearing ball.
Verify no excessive looseness on output shaft (0.25 inch maximum
rotational play measured at pitch link attaching bolt head). Verify
operating clearance and assembly slides freely on output shaft. Verify
no leakage at bearing seals. Verify security.
WARNING
A031-1 Rev. J or prior pitch control assemblies require repetitive

inspection per R22 Service Bulletin SB-90A every 300 hours or
annually, whichever occurs first.
Pitch Links: Inspect condition. Inspect rod ends and spherical bearings
per § 2.120. If pitch links are one-piece type, remove and reinstall with
outboard end inboard and inboard end outboard as required to obtain
maximum service life. Verify security and operating clearance.
Tail Rotor Blades: Inspect condition. Refer to § 9.220 for damage
limitations. Inspect bearings per § 2.120. Verify no looseness between
feathering bearing outer races and root fittings. Verify security. Verify
blade tip drain holes (2 per A029-1 blade, 1 per A029-2 blade) are
unobstructed. Verify no corrosion. Tap test bonded areas per § 26-44.
WARNING
Structural damage may occur if compressed air is applied to

blade tip drain holes.
Tail Rotor Hub: Inspect condition. Inspect spherical teeter hinge bearings
per § 2.120; inspect elastomeric teeter hinge bearings per § 2.125.
Verify hub teeters without binding. Verify teeter hinge bearing balls
(P/N A030-1 hubs only), spacers contacting output shaft, nuts, and bolt
remain stationary when teetering hub. Verify no cracks or corrosion.
Verify operating clearance.

11. Open Mast Fairing (11)
Mast Fairing: Inspect condition. Verify no cracks, dents, or corrosion.

Verify no yielding or cracking of A665-1 restraint. Yielding can be caused
by overtightening screws in restraint nutplates.
Upper and Lower Ribs: Inspect condition. Verify security, especially
tightness of lower rib clamp.
Three Vertical Push-Pull Tubes (Two A121-7 and One A121-5): Inspect
condition. Inspect rod ends per § 2.120. Verify no cracks at upper ends.
With collective full up and cyclic full aft, verify no wear of A121-7 tubes
or sleeves, especially where sleeves rub inside guide assembly. Verify
Pitot Tube and Line: Inspect condition. Verify no cracking, chafing, or
kinking. Ensure drain hole on bottom of elbow behind pitot tube is clear.
Verify security.
Fuel Tank Vent Metal Lines and Plastic Tubes: Inspect condition. Verify
no kinking or obstructions. Verify security.
Swashplate Upper Scissors: Inspect condition. Inspect rod ends and
spherical bearings per § 2.120. Measure scissors play per Figure 2-8.
Observe scissor linkage while having someone raise and lower collective.
Verify bolt, journals (or spherical bearing balls and spacers), and arm
rotate together at each scissor linkage pivot. Verify operating clearance.
Swashplate Lower Scissors: Inspect condition. Inspect rod ends per §
2.120. Verify security.
Swashplate Slider Tube: Inspect condition. Verify no cracks at rivet
holes or corrosion on base. Verify no damage to, or wear through,
anodized tube surface. When viewed under 10X magnification, minute
“checkerboarding” of anodized surface is normal.
Remove Swashplate Boot Lower Ty-rap: Lift boot from swashplate. Using
an inspection mirror, inspect area between main rotor drive shaft and
inside of slider tube. Verify no corrosion and no debris. Verify no boot
damage.
Swashplate: Inspect condition. Verify 0.020 inch maximum radial play
between swashplate ball and slider tube. Rotate rotor by hand and verify
operating clearance and no rough or dry bearings.
Swashplate Shimming: Observe swashplate ball from below and have
someone move collective stick slowly up & down. Verify swashplate ball
immediately moves with swashplate when swashplate reverses direction.
Movement of swashplate without attendant ball movement indicates axial
play between ball and swashplate; shim swashplate per § 8.416.
Install Swashplate Boot Lower Ty-rap: Verify correct boot position and
security and no boot damage.
11. Open Mast Faring (11) (continued)
Main Rotor Drive Shaft: Inspect condition of accessible portion. Verify

no corrosion.
FIGURE 2-8 MEASURING UPPER SWASHPLATE SCISSORS PLAY

(Identify scissors bearing type and measure as shown)

12. Rotor Hub and Hinge Bolts
Hub: Inspect condition. Verify no nicks, scratches, gouges, or corrosion.
If main rotor imbalance is suspected, check teeter and coning hinge friction
per § 26-32. Verify no brown or black residue (indicates bearing wear).
Hinge Bolts (three): Inspect condition; corrosion is prohibited. Verify cotter
pins are in place and secure. Verify bolt heads and nuts are torque striped
to thrust washers.
Pitch Links and Rod Ends: Inspect condition. Inspect rod ends per §
2.120, including centering. Verify security, including jam nut tightness and
proper safety wiring.
13. Main Rotor Blades

Boots: Inspect condition. Verify no boot damage or oil leakage. Verify
proper boot position and security. Verify sufficient clearance from hub
assembly through full control travel.
Blade Spindles & Root Fittings: Inspect area for damage per § 26-43.
Comply with FAA Airworthiness Directive 88-26-01 (current revision) as
required (A158-1 spindles only). Verify proper installation and security of
visible fasteners. Renew deteriorated torque stripes per Figure 2-1.
FIGURE 2-9 MAIN ROTOR BLADE TIP AND TIP COVER

13. Main Rotor Blades (continued)
A016-6 Main Rotor Blade Inspection: Remove tip covers. Remove corrosion
and loose paint from tip covers, blade tips, and skin-to-spar bond lines. Epoxy
prime, or prime and paint, any exposed bare metal on tip covers, blade tips,
and skin-to-spar bond lines. Using an AN970-4 washer or 1965-or-later
U.S. quarter-dollar coin, tap-test critical bond areas and verify no dull or
hollow sounds. Visually inspect critical bond areas and verify no separation.
Install tip covers, ensuring cover edges are flush with blade profile.
A016-4 Main Rotor Blade Bond Inspection: Perform R22 SB-103A or
subsequent.
Main Rotor Blade Inspection: Inspect skins and doublers for scratches and
corrosion per § 26-41. Inspect blades for dents and local deformations
per § 26-42 and for voids per § 26-44. As required, wax blades with
soft cleaning cloths using carnauba-type wax (such as SC Johnson® Paste
Wax). Ensure tip cover and blade tip drain holes are unobstructed.
WARNING
Structural damage may occur if compressed air is applied to blade

tip drain holes.
14. Cabin
General: Verify no loose equipment that might interfere with controls.
Seat Belts: Inspect condition. Verify no fraying, broken stitching, holes,
or rotting. Verify no significant discoloration due to UV damage. Check
inertia reels for proper operation. Check buckles for proper operation.
Verify security.
NOTE
TSO tag not required on factory-installed harnesses.
Windows: Minor defects or imperfections that do not impair pilot's visibility

are considered acceptable. Acceptable defects include:
One nick, no more than 0.010 inch deep and no larger than 0.25 by
0.50 inch per square foot.
Scratches no more than 0.010 inch deep and 5 inches long.
Any surface defect such as small spots or stains that can be removed
with light polishing.
For cracks and crazing adjacent to windshield edges refer to § 25-20.
Yaw String: Inspect condition. Minimum 3 inches long each side. Verify
security.

14. Cabin (continued)

Exterior: Inspect condition. Verify no cracks, corrosion, or damage. Verify
no loose rivets. Loose rivets may be indicated by cracked paint and/or
black residue around heads.
Left and Right Navigation Lights: Inspect condition. Verify red left, green
right, lens cleanliness, and security.
Doors: Inspect condition. Verify no structural cracks around hinges or
door latches. Check door vents for operation. Ensure door hinge pins
are secured with cotter pins. Check tightness of hinge mounting screws.
Verify proper operation of door latching and locking mechanisms.
15. Landing Gear

Skid Tubes and Shoes: Inspect condition. Verify no more than 0.5 inch
wide flat area on underside of skid tube due to wear. Verify longitudinal
scratches are not more than 0.030 inch deep, and circumferential scratches
are not more than 0.030 inch deep & are less than 0.50 inch long. Verify
drain holes are open (not applicable to float landing gear). Verify security
of rain caps. Verify minimum 0.05 inch shoe thickness.
Struts and Elbows: Inspect condition. Verify no cracks or corrosion,
especially where joined and in weld areas at bottom of struts. Verify
security. If helicopter routinely performs running landings, torque check
strut-to-skid-tube bolts.
Cross Tubes: Inspect condition. Verify minimum tail skid height per §
5.210. Verify no corrosion. Verify security of rain caps. If a rain cap is
loose, verify no internal corrosion. Verify no fretting at elbows.
Landing Gear Attach Points: Inspect condition. Verify no loose fasteners,
cracks, buckling, or fretting. Inspect mounts and verify no loose swages
or worn bearings.
Floats (if installed): Perform relief valve and bulkhead tests per § 2.580 (2)
and (3). Verify proper inflation pressure per R22 POH. Inspect condition.
Verify security.
Float Skid Tubes (if installed): Remove drain plugs at aft end of skid
extensions. With ground handling wheels installed, pull down on tailcone
to drain any trapped moisture. Install drain plugs.

16. Life-Limited Parts, Additional Limitations, ADs, & SBs

Life-Limited Parts: Refer to helicopter maintenance records and § 3.300.
Replace life-limited parts as required. Verify components installed have
sufficient time remaining for projected operations.
Additional Component Maintenance: Refer to helicopter maintenance
records and § 1.102. Replace components scheduled for 12-year service,
overhaul, or replacement as required. Replace engine and accessories
scheduled for maintenance as required. Verify components installed have
sufficient time remaining for projected operations.
Airworthiness Directives: Verify applicable airframe, engine, and accessory
Airworthiness Directives (ADs) have been performed according to AD
compliance procedures. Some aircraft may be affected by ADs that require
recurring inspections at less than 100-hour or annual intervals. Recent
U.S. Airworthiness Directives are available online at www.faa.gov.
Service Bulletins: Verify applicable airframe, engine, and accessory Service
Bulletins (SBs) have been complied with according to manufacturers’
instructions. Some aircraft may be affected by SBs that require recurring
inspections at less than 100-hour or annual intervals. RHC Service Bulletins
are available online at www.robinsonheli.com, under the Publications tab.
17. Required Documents and Placards

Documents: Check that required documents (Airworthiness Certificate,
Registration, applicable Radio Station License, Pilot’s Operating Handbook,
Equipment List/Weight & Balance Data) are on board, legible, and current.
Placards: Verify required placards are properly installed, legible, and current.
Refer to Pilot’s Operating Handbook Section 2 for placard requirements.
18. Inspection and Access Covers

Foreign Objects Removed: Verify all tools, loose hardware, rags, and other
foreign objects are removed from helicopter.
Covers Closed and Secure: Install/close all inspection and access covers
removed in preceding steps. Verify security of all access covers.
Mariner Airbox Sealed: Ensure air box cover perimeter is sealed with
aluminum tape (Mariner models only).

19. Maintenance Records

Maintenance Records: Verify maintenance records are accurate, legible,
and complete. Enter maintenance performed (such as part replacement,
equipment adjustments, servicing, and lubrication) and inspection data.
Data must include a description of (or reference to data acceptable to the
Administrator) the work performed, date, helicopter total time in service,
signature, certificate type and certificate number of person approving
aircraft for return to service.
SHEAVE ALIGNMENT LEFT: ENGINE HEIGHT:

SHEAVE ALIGNMENT RIGHT: CLUTCH ANGLE:
TRDS RUNOUT:
CHECKLIST COMPLETE:
Mechanic’s signature: Date:

2.500 Special Inspections
2.501 Clutch Actuator Upper and Lower Bearings Inspection and Lubrication
This section has been moved to § 22-40.
2.502 A181-4 Actuator Lower Bearing Inspection and Lubrication

2.503 A184 Actuator Upper Bearing Inspection and Lubrication


Intentionally Blank

2.507 V-Belt Inspection

I
The most common V-belt discrepancies and courses of corrective action are given
below.
1. Belts Cracking:
CAUSE REMEDY
Belt is old. Replace belts per Section
7.280.
Belt slipping causing Replace belts per Section

heat buildup and gradual 7.280. Replace actuator
hardening of undercord. per Section 7.500.
2. Top of Tie Band Frayed or Damaged:
CAUSE REMEDY
Obstruction interfering Remove obstruction, and
with normal belt replace belts per Section
operation. 7.280.
3. Top of Tie Band Blistered or Perforated:
CAUSE REMEDY
Dirt or sand accumulating Replace belts per Section
between belts and 7.280. Periodically wash
sheave. inside of replacement
belts.
Belts worn out Replace belts per Section
7.280.
FIGURE 2-10 V-BELT DISCREPANCIES
Change 25: JUN 2006 2.43

2.507 V-Belt Inspection (cont'd)
4. Belt Cut on Inside:
CAUSE REMEDY
Belt forced over sheave Replace belts per Section
flange during installation 7.280.
without proper slack.
Foreign material fell into Remove foreign material
belt drive. and replace belts per
Section 7.280.
5. Belt Riding Outside Sheave Groove:
CAUSE REMEDY
Belt forced over sheave Replace belts per Section
flange during installation 7.280.
without proper slack.
I FIGURE 2-10A V-BELT DISCREPANCIES
2.44 Change 25: JUN 2006

2.508 Lower Sheave V-Belt Wear Pattern Inspection
Observe wear patterns in paint primer in all four lower sheave grooves. The eight wear
patterns (both sides of all four grooves) should appear very similar and be consistent
around sheave circumference.
If wear pattern is noticeably different from groove to groove, measure width of narrowest
and widest wear patterns. See Figure 2-11. If ratio exceeds 3:1, replace V-belts per
Section 7 .280.
CAUTION
RHC does not recommend using A 170-1 or -2 Revision Nor prior

upper sheaves with A493-1 Revision T or later lower sheaves.
Such combinations may cause excessive drive belt vibration.
l_
0.60 inch groove depth

for "deep-groove" Rev S
WEAR PATTERN RATIO and prior lower sheaves;
IN GROOVES NOT MORE 0.43 inch groove depth
THAN 3:1 for "shallow-groove"
Rev T and subsequent
0.925 inch for "deep-groove"
Rev S and prior sheaves;
I lower sheaves
0. 735 inch for "shallow-groove"

Rev T and subsequent lower sheaves
FIGURE 2-11 LOWER SHEAVE V-BELT WEAR PATTERN
Corrected
Change 25: JUN 2006 2.45
2.510 TaiiSkidStrike
A. Scuffing or Slight Bending of Tail Skid
1. Visually inspect tail rotor blades. Verify no evidence of solid object or ground
contact. If tail rotor damage is found, inspect tail rotor per Section 2.520.
2. Visually inspect lower vertical stabilizer. Verify no buckling, cracks, or loose

rivets at tail skid and lower vertical to horizontal stabilizer attach points.
3. Visually inspect horizontal stabilizer to tailcone attach points. Verify no

buckling, loose rivets, or cracking.
4. Visually inspect tailcone. Verify no damage. Also inspect tailcone-to-upper

steel tube frame attach points and verify no buckling or loose attach bolts.
B. Buckling or Breaking of Tail Skid and/or Lower Vertical Stabilizer
1 . Perform inspections per Section 2. 51 O.A.
2. Inspect tail rotor drive shaft run-out per Section 7.340.
3. Remove tailcone and:
a. Visually inspect tailcone attach points. Verify any elongated holes are no
greater than 0.265 inch across at widest point.
b. See Figure 2-12. Using a Section 1 .410 approved paint stripper, remove
paint from and within 2 inches of tailcone attach points on upper frame.
c. Dye penetrant inspect upper steel tube frame at tailcone attach points.
4. Remove stabilizer assembly and:
a. Visually inspect horizontal stabilizer. Verify any elongated holes at attach

points are no greater than 0.265 inch across at widest point. Verify no
loose rivets or buckling.
b. Using a Section 1.410 approved paint stripper, remove paint from tailcone
casting exterior surfaces.
c. Dye penetrant inspect casting.
5. Remove lower vertical stabilizer from horizontal stabilizer and visually

inspect. Verify no buckling, cracks, or loose rivets. Buckling or cracks require
replacement of stabilizer. Loose rivets may be drilled out and replaced. Verify
any elongated holes at attach points on either stabilizer are no greater than
0.200 inch across at widest point.
2.46 Change 26: APR 2007

2.520 Tail Rotor Strike
A. Contact with Small Stone, Tall Grass, or Other Small Object in Free Air
1. Inspect tail rotor per Section 9.220.
2. Check tail rotor drive shaft run-out per Section 7 .340. If run-out exceeds
0.025 inch at any location, shaft must be replaced or repaired.
B. Sudden Stoppage of Tail Rotor due to Ground or Solid Object Contact

(Causing Bending or Shearing of Blade(s))
1. Perform inspections per Section 2.520.A.
2. Using Section 1.41 0-approved paint stripper, strip paint surrounding and at
least 2 inches from tail rotor drive shaft forward holes and aft weld. Dye
penetrant inspect stripped areas. If cracks are found, drive shaft must be
replaced.
3. Visually inspect drive shaft. Verify no deformation, nicks, dents, or scratches.

Nicks and scratches may be polished out per Section 7 .360. Deformation or
dents require replacement of drive shaft.
4. Remove tail rotor and tail rotor gearbox and return to RHC for overhaul.
5. Replace aft and intermediate flex plates.
6. Visually verify tail rotor blades have not struck tailcone and empennage.
7. Visually inspect main rotor system. Verify no nicks, dents, or scratches.
Change 25: JUN 2006 2.47

2.530 Main Rotor Strike
A. Contact with Small Objects in Free Air
1. Inspect main rotor blades per Section 9.130.
2. Verify no buckling or bending of trailing edge.
WARNING
Any main rotor blade buckling or spar bending is considered

sudden stoppage and requires compliance with Part B.
B. Sudden stoppage of Main Rotor Due to Ground or Solid Object Contact
1. Check tail rotor drive shaft run-out per Section 7 .340.
2. Remove following components and return to a RHC authorized overhaul facility

for inspection and/or repair.
a. A005-2 Main Rotor Blade and Spindle Assemblies
b. A005-4 Main Rotor Hub and Bearings
c. A017-2 Swashplate Assembly
d. AO 1 8-1 or -2 Clutch Assembly
e. A 106 Main Rotor Journals
f. A 152-1 Thrust Washers
g. A907-4 or -5 Yoke
h. A908-4 or A006-5 Yoke
3. Replace A947-1 forward flex plate.
4. Return main rotor gearbox to RHC for overhaul.
5. Inspect engine per engine manufacturer's sudden stoppage instructions.
2.48 Change 25: JUN 2006

ROBINSON MAINTENANCE MANUAL MOOEL R22
2.540 Rotor/Engine Overspeed
A. Rotor Overspeed Between 110 and 116%
NOTE
Refer to Part C if a power-on overspeed occurs.
1. 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 B.
2. Remove main rotor blades. Drain pitch bearing housings. Remove outer blade
boot clamps and fold boots away from pitch horns. Rotate spindles to verify
no brinelling of pitch bearings.
NOTE
Bearings have a high preload; slight roughness is normal. If

roughness is evident, return blade and spindle assembly to RHC-
authorized overhaul facility for repair.
3. Visually inspect main and tail rotor blades.
Change 25: JUN 2006 2.49

ROBINSON MAINTENANCE MANUAL MOCEL R22
2.540 Rotor/Engine Overspeed
B. Rotor Overspeed at or Above 116%
NOTE
For power-on overspeeds, Part C must also be performed.
1. Perform inspection per Part A steps 2, 3, and 4.
2. Return blades and hub to an RHC-authorized overhaul facility for NOT inspection
of spindles and hub.
3. Replace any cracked or bent bolts, thrust washers, and journals. Magnetic
particle inspect any parts not replaced.
C. Engine overspeed
Percent engine overspeed is determined from tachometer indication as follows:
Engine Tach Indication (%) x 2550 _

% Engine Overspeed = 100
2700
NOTE
104% Engine Tach Indication 2652 Actual Engine RPM.

Engine is rated at 2700 RPM.
Refer to Lycoming SB 369 (current revision) for eng1ne overspeed inspection

requirements.
2.50 Change 26: APR 2007

2.550 Hard Landing
A. Yielding of Cross Tubes Due to Hard Landings Without Side Loads
NOTE
Side loads are indicated by buckling and bending of steel tube

frame or sheet metal.
1. Visually inspect steel tube frames. Verify no yielding or cracks. Pay particular
attention to lower steel tube frame aft vertical struts.
3. Visually inspect main rotor blades per Section 9.130.
4. Place rotorcraft on level ground and measure from tail skid or bottom of float
stabilizer to ground. Aft cross tube must be replaced if dimension is less
than:
24 inches for Standard or HP.

34 inches for Alpha, Beta, Beta II, Mariner, or Mariner II measured from
tail skid.
37 inches for Mariner or Mariner II, measured from float stabilizer.
Replace forward cross tube if it contacts cross tube cover.
5. Check and adjust upper and lower sheave alignment per Section 7 .230.
B. Hard Landings That May Impose Side Loads on Landing Gear
NOTE
Side loads are indicated by buckling and bending of steel tube

frame or sheet metal.
1. Perform inspection per Part A.
2. Visually inspect fuselage landing gear attach points, vertical firewall, and
horizontal firewall. Verify no buckling or cracks. Pay attention to engine mount
strut-to-vertical firewall attach points.
3. Remove tailcone per Section 4.311.
4. See Figure 2-12. Using a Section 1 .410 approved paint stripper, remove
paint from and within 2 inches of tailcone attach points on upper frame. Dye
penetrant inspect upper steel tube frame at tailcone attach points.
5. Visually inspect tailcone. Verify no buckling or loose rivets.
6. Visually inspect landing gear elbows. Verify no yielding, nicks, or cracks.
Change 25: JUN 2006 2.51

2. 550 Hard Landing
B. Hard Landings That May Impose Side Loads on Landing Gear (cont'd)
INSPECT FIVE AREAS

FOR CRACKS
I FIGURE 2-12 UPPER FRAME CRACK INSPECTION
2.52 Change 25: JUN 2006

2.560 Steel Tube Frame Corrosion
1. For large areas of corrosion, remove frame and strip paint using a Section 1 .41 0
approved paint stripper to determine full extent of corrosion. If corrosion exceeds
Figure 2-13 limits, replace frame.
2. Measure and record diameter of frame member at corroded area(s).
3. Polish out corrosion with 320-grit or finer wet-or-dry sandpaper. Measure frame
member diameter at polished area(s). Compare with measurement(s) from step 2,
and verify polish depth is within Figure 2-13 limits.
4. Clean, prime, and paint frame (see Section 1.400). Install frame if removed in Step 1.
LIGHT SURFACE CORROSION:

0.002 in. MAX. DEPTH AFTER REWORK
~~-.:~·. --------------- --
I_.._ _ 0.10 in. MAX. DIA
_.,-PITTING:
...
·lr
7 0.004 in. MAX. DEPTH
AFTER REWORK
0.50 IN. MIN. SEPARATION

BETWEEN AREAS OF PITTING
FIGURE 2-13 FRAME CORROSION AND REPAIR LIMITS
Change 25: JUN 2006 2.53

2.570 Main Rotor Blade Detail Inspection
2.571 Spar Cover Adhesive Damage (A016-2 main rotor blade only)
Perform this inspection if cracks or chips are noted in adhesive around spar cover.
1. See Figure 2-14. Remove spar cover. Use single-edge razor blade or knife
to lift outboard tip of spar cover from leading edge, then peel cover off with
pliers.
CAUTION
Do not nick or cut main rotor blade.
2. Carefully remove remaining adhesive from leading edge spar cover contact
surfaces by hand block sanding in a spanwise direction with 320-grit or finer
wet-or-dry sandpaper.
3. Remove sanding debris by vacuuming.
4. Using a 1 OX magnifying glass and strong inspection light, inspect doubler and
skin. Verify no corrosion or separation between layers. Additionally verify no
blisters or bulges in skin or doubler. (Blisters or bulges may indicate separation
not visible at leading edge.)
5. Tap test area around the spar cover per Section 9.130 h).
6. Return blade to RHC for inspection and possible repair if any of the following
discrepancies are found:
a. Voids found by tap testing.
b. Blisters or bulges in the skin or doubler.
I c. Separation with a total length greater than 2.5 inches per side. See Figure
2-14.
I d. Any separation between the skin and spar in Area A. See Figure 2-14.
7. If no discrepancies are found, clean spar cover area with Section 1.420-
approved solvent and prime lightly with epoxy primer. Let primer dry for at
least Y2 hour.
8. Bond cover in place with B270-9 adhesive. Follow manufacturer's instructions

for mixing adhesive. Temporarily secure covers in place with masking tape,
and allow adhesive to cure.
9. Clean off excess adhesive. Prime and paint spar cover.
2.54 Change 25: JUN 2006

2.571 Spar Cover Adhesive Damage (A016-2 main rotor blade only) (cont'd)
A 162-1 SPAR COVER
sPAR
-~-;;;Jt~~~~~ ~ ),
~~~r >#§ )§X )q< >PX 2@< I@(@ @ J ->-=-
l.ID
TAP TEST
FOR SEPARATION
BETWEEN
I
LOOK AND
TAP TEST
FOR SEPARATION
\
LOOK AND
TAP TEST
FOR SEPARATION
SPAR AND BETWEEN BETWEEN SKIN
DOUBLER SPAR AND SKIN AND DOUBLER
(UPPER & (UPPER & (UPPER &
LOWER LOWER LOWER
SURFACES) SURFACES) SURFACES)
FIGURE 2-14 MAIN ROTOR BLADE SPAR COVER AREA DETAIL INSPECTION I
(Leading edge view looking aft with spar cover removed)
Change 25: JUN 2006 2.55

2.572 Main Rotor Blade Sealant and Filler Cracking
The painted two-part epoxy filler used as an aerodynamic-smoothing and water-

blocking compound in main rotor blade root fitting and trim tab areas occasionally
cracks. To verify cracks are superficial, perform the following procedure:
1. Remove crack indications by hand sanding with 320-grit or finer wet-or-dry

abrasive paper until cracked paint and filler is removed. Occasionally wiping
with water helps highlight cracks. It is unnecessary to sand through to bare
metal in most cases.
WARNING
Do not use chemical paint strippers or power tools.
2. Sand spanwise with 400-grit or finer wet-or-dry abrasive paper to remove all
chordwise scratches.
3. Tap test suspect area to verify absence of voids.
4. Dye-penetrant inspect suspect area following penetrant manufacturer's

instructions.
5. If no voids and no cracks in metal are found, prime and paint area with approved
materials. Refer to Section 9.130.
6. Replace any blade exhibiting voids or metal cracks prior to further flight and
contact RHC Technical Support for further instructions.
2.56 Change 25: JUN 2006

2.573 Visual Inspection of Main Rotor Blade Root Area
A main rotor blade fatigue failure could occur if the helicopter is repeatedly flown
above its approved gross weight limit or operated above its approved manifold
pressure limits. The first indication of a fatigue crack in progress may be a rotor
that will not stay balanced after being adjusted. Another indication may be a very
fine hairline crack appearing in the areas shown in the figure below.
1. Visually examine both the upper and lower surface of each blade in the areas
shown with a 1 Ox magnifying glass.
2. If any indication of a crack is found, immediately ground the aircraft and return
the suspect blade to the RHC factory for examination.
.. ,
CRACK Will liKElY OCCUR HERE

ON UPPER OR lOWER SURFACE
··'
FIGURE 2-15 MAIN ROTOR BLADE ROOT INSPECTION
Change 25: JUN 2006 2.57

2. 580 Float Inspection and Testing
1 . Inspection Intervals and Float Replacement
Perform Relief Valve Test and Bulkhead Test during each 1 00-hour or annual
inspection. Floats must be repaired or replaced on condition, or upon failure of
Relief Valve or Bulkhead Test.
2. Relief Valve Test
CAUTION
When filling floats, open inflation valve prior to applying air

pressure; do not apply air pressure against a closed valve.
CAUTION
Prior to test, inspect float bag uninflated and with each

compartment individually inflated to 0. 75 to 1.0 psig. Verify
no cuts, tears, punctures, abrasion, delamination (blistering), or
seam separation.
a. Use filtered oil-free dry air to inflate float compartments to 5.0 psig. Inflate by
using a manifold or inflate chambers individually in 0.5 psig increments.
b. Fill relief valve apertures with clean water. Slowly increase pressure and
observe relief valves; bubbles indicate opening. Record opening pressures,
then reduce pressure until bubbles stop, indicating relief valves are closed.
Record closing pressures.
CAUTION
Do not exceed 7 psig in float compartments.
c. Replace any valve not meeting the following criteria:
Opening pressure: 5.5 to 6.5 psig

Closing pressure: 5.5 psig minimum
3. Bulkhead Test
1. Deflate all float chambers, then inflate forward chamber and second chamber
from rear to 3 psig.
2. Repair or replace floats if pressure in inflated chambers after 1 hour, at constant

temperature, is less than 2. 75 psig minimum.
3. Deflate all float chambers, then inflate aft chamber and second chamber from
front to 3 psig. Repeat step 2.
2.58 Change 25: JUN 2006

2.590 Windshield Inspection

2.600 2200-Hour/12-Year Inspection
NOTE
KI-2202 (for R22-series Helicopter S/N 2570 & prior) and
KI-2203 (for R22-series Helicopter S/N 2571 & subsequent)
2200-Hour Inspection Kit contents are available online at www.
robinsonheli.com for review.
NOTE
12-Year Inspection is only required for helicopters that have
accumulated 12 years in service and less than 2200 hours time
in service since new, since last 2200-hour inspection, or since
last 12-year inspection.
1. Refer to helicopter maintenance records and § 3.300; replace life-limited parts, or next
higher assemblies, as required.
2. Refer to helicopter maintenance records and § 1.102; perform additional component
maintenance, as required.
3. Remove engine, engine cooling panels, fanwheel, scroll, air induction system, carburetor
heat system, oil lines, and all hoses. Flush and pressure test oil cooler. Overhaul or
inspect, as required, magnetos, alternator, and carburetor per appropriate manufacturer’s
maintenance publications and service bulletins.
4. Remove horizontal and vertical stabilizers per § 4.320, and replace as required. If
replacement is not required, visually inspect stabilizers and verify no cracks, corrosion,
loose rivets, dents, or deformation. Dye penetrant inspect any suspect areas per
§ 23‑42. Install stabilizers per § 4.320.
5. Remove landing gear assembly per § 5.100, and replace as required. If replacement is
not required, completely disassemble gear and remove paint. Visually inspect parts and
verify no cracks, corrosion, or deformation. Magnetic particle and fluorescent penetrant
inspect per §§ 23-41 and 23-42. Clean, prime, and paint per § 23-60. Assemble gear
if disassembled. Install landing gear assembly per § 5.100.
6. Remove steel tube frames per § 4.200, and replace as required. If replacement is not
required, remove paint. Visually inspect frames and verify no cracks or corrosion.
Magnetic particle inspect per § 23-41. Clean, prime, and paint per § 23-60. Install
frames per § 4.200.
7. Remove cyclic stick per § 8.110. Remove wiring harness. Remove paint via dry media
blasting. Visually inspect and verify no cracks or corrosion. Magnetic particle inspect
per § 23-41. Clean, prime, and paint per § 23-60. Install wiring harness. Install cyclic
stick per § 8.110.

2.600 2200-Hour/12-Year Inspection (continued)
8. Remove A121 push-pull tube assemblies per § 8.160. Remove paint. Visually inspect
and verify no cracks or corrosion. Fluorescent penetrant inspect per § 23-42. Clean,
prime, and paint per § 23-60. Install push-pull tubes per § 8.160.
9. Magnetic particle inspect A650 fittings and A337-1 jackshaft per § 23-41.
10. Inspect airframe wiring condition. Verify no corrosion, insulation deterioration, or other
damage. Verify correct wires attached to correct circuit breakers.
11. Remove main and aux tank fuel bladders per § 12.110 and § 12.120. Visually inspect.
Verify no corrosion, residue, microbial growth, or damage to fabric. Visually inspect
adjacent structure for evidence of bladder leakage. Replace roll-over vent valve o-rings
and packings per § 12.210. Remove any foreign object debris. Install bladders per
§ 12.110 and § 12.120.
12. Perform clutch sheave alignment per § 7.230 and intermediate flex plate shimming per
§ 7.330.
13. Perform main rotor flight control and blade angle rigging per § 10.110 and § 10.120.
14. Perform tail rotor flight control and blade rigging per § 10.130 and § 10.140.
15. Perform 100-hour/annual inspection per § 2.400.
16. Weigh helicopter per § 18-20.
NOTE
Extended low-power operation with new piston rings may
prevent proper piston ring seating.
17. Balance tail rotor per § 10.240. Track and balance main rotor per § 10.230. Perform
ground check, run up, and flight checks per §§ 2.205, 2.210, and 2.220.
18. Drain and flush main and tail rotor gearboxes per § 22-13 and § 22-23.
19. Make appropriate maintenance record entries. Enter maintenance performed (such as
part replacement, equipment adjustments, weighing, servicing, and lubrication) and
inspection data. Data must include a description of (or reference to data acceptable to
the Administrator) the work performed, date, helicopter total time in service, signature,
certificate type and certificate number of person approving aircraft return to service.

FIGURE 2-17 MAIN ROTOR HUB REPAIR LIMITS
2.610 Main Rotor Hub Inspection and Repair

1. Remove main rotor hub bearings per § 26-21 steps 1 and 2.
2. Remove hub paint by dry media blasting.
3. Refer to Figures 2-17 & 2-18. If required, polish surfaces using 320-grit or finer wet-
or-dry sandpaper to 0.25 inch minimum blend radius.
a. Visually inspect hub bearing bores and verify no scoring, scratches, or other obvious
damage. Polish out fretting or corrosion to 0.002 inch maximum depth on inner
and outer surfaces within 1.750 inches of bearing bores (or within 1.875 inches of
B370-1 hub coning hinge bearing bores). Polish out fretting or corrosion to 0.0005
inch maximum depth on inside of bearing bores; maximum bearing bore diameter
is 1.1870 inches (or 1.3120 inches for B370-1 hub coning hinge bearing bores).
b. Visually inspect all other areas of hub for obvious damage. Polish out nicks,
scratches, gouges, or corrosion to 0.010 inch maximum depth within 0.30 inch
of inside and outside edges of hub. Polish out nicks, scratches, gouges, or
corrosion to 0.060 inch maximum depth on all other areas.

2.610 Main Rotor Hub Inspection and Repair (continued)
4. Fluorescent penetrant inspect hub per § 23-42.
5. Prime hub per § 23-60.
6. Install bearings per § 26-21 steps 4 and 5.
7. Mask bearings and topcoat hub assembly per § 23-60.
8. When top coat has sufficiently cured, remove masking.
FIGURE 2-18 MAIN ROTOR HUB REPAIR LIMITS

2.620 Tail Rotor Gearbox 12-Year Maintenance
1. If installed, drain and flush B021-1 tail rotor gearbox assembly per § 22-23 steps 1
thru 8.
2. If installed, remove tail rotor gearbox per § 7.410.
3. Remove hardware securing B546-1 yoke to B545 input gear. Visually inspect yoke
and replace yoke if damaged. Visually inspect input gear splines; return gearbox to
RHC if splines are damaged. Replace input shaft seal per § 7.470 steps 6 thru 17.
4. Remove sight gage and clean glass. Visually inspect gear set; return gearbox to RHC
if corrosion or other damage is detected. Install sight gage and special torque gage
per § 23-33.
5. Replace output shaft seal per § 7.460 steps 4 thru 9.
6. Install tail rotor gearbox per § 7.420 steps 1 thru 3.
7. Remove filler-plug. Fill gearbox to center of sight glass using A257-2 oil. Rotate rotor
system by hand for several revolutions and pull down on tail rotor gearbox several
times. Check gearbox oil level and adjust as required. Install filler-plug in gearbox and
special torque plug per § 23-33.
8. Connect tail light and chip detector wiring to airframe harness at connectors. Turn
battery on. Verify tail light illuminates with position lights turned on. Depress push-
to-test TR CHIP button and verify TR CHIP caution light illuminates. Turn battery off.
9. Install tail rotor per § 9.213.

2.630 Fanwheel 12-Year Maintenance
1. If installed, remove B174-1 fanwheel assembly per § 6.210.
2. Mark fanwheel assembly parts, including balancing hardware, for identical reassembly.
3. Refer to Figure 2-19. Remove hardware securing A187-4 cone assembly, A186-2
hub, and A178-2 spacer(s) to fanwheel and remove parts, noting relative locations for
identical reassembly.
4. Visually inspect all components for obvious damage. Verify no elongation of fastener
holes. Replace parts as required.
5. Assemble fanwheel wet with epoxy primer (refer to § 23-70) between all clamping
surfaces; while primer is wet, special torque NAS6603 bolts to 70 in.-lb and NAS6605
bolts to 300 in.-lb.
FIGURE 2-19 B174-1 FANWHEEL ASSEMBLY

FIGURE 2-20 MT009-10 MAIN ROTOR STATIC BALANCE FIXTURE ASSEMBLY
2.640 Main Rotor Blade Static Balance
CAUTION
Ensure surfaces contacting blade skins and trailing edges are
sufficiently cushioned to prevent blade damage.
1. Refer to Table 26-1. Assemble main rotor blade & spindle assembly to main rotor
hub by selecting a combination of A106 coning hinge journals and A117 coning hinge
shims (if used) to obtain total axial clearance between 0.002–0.006 inch. Install
same length journal (dash number) on leading edge side of both coning hinges.

2.640 Main Rotor Blade Static Balance (continued)
2. Install nuts (dry); tighten nuts on hinge bolts until journals and thrust washers are
firmly seated (snug). Measure gaps between thrust washers and hub bearing faces per
Figure 26-8; verify total axial clearance at each hinge is between 0.002–0.006 inch.
3. Refer to Figure 2-20. Install MT009-10 main rotor static balancing fixture assembly in
hub as shown. Hoist main rotor assembly and position on MT009-9 base assembly.
4. Refer to Figure 2-21. Verify blade pitch angles are approximately equal.
5. Place a spirit level chordwise (parallel with teeter and coning hinges) atop main rotor
hub. Level by adjusting NAS1351-3-10P screws.
FIGURE 2-21 EQUALIZING BLADE PITCH

2.640 Main Rotor Blade Static Balance (continued)
6. Refer to Figure 2-22. Using a depth micrometer or calipers, measure distance between
MT009-2 end plate and MT009-8 shaft thru (either) end plate hole on both sides of
main rotor hub. On side of hub with smaller measured distance, mark top of hub with
letter “N” to indicate nut-side of teeter hinge bolt.
7. Place a spirit level spanwise (perpendicular to teeter and coning hinges) atop main
rotor hub. Place tip cover, tip cover attach screws, and two A722-4 screws as
close to blade tip as possible. Level rotor system by adding A298 balance strips,
NAS1149F0332P washers, and/or NAS1149F0363P washers as required. Final
balance to be within one NAS1149F0332P washer.
8. Apply light coat A257-9 anti-seize to threads and install screws securing tip weights
to blade; special torque screws to 40 in.-lb. Apply light coat A257-9 anti-seize
to threads and install screws securing tip cover to blade; special torque screws to
40 in.‑lb. Recheck spanwise and chordwise balance.
9. Conspicuously mark rotor assembly with colored “X” and “O” on hub, blade roots,
and coning bolts (consistent marking on each side of hub) as reference for correct
assembly on helicopter. Disassemble main rotor assembly.
FIGURE 2-22 MEASURING GAP BETWEEN THRUST WASHER AND HUB BEARING

2.700 Additional Special Inspections
2.710 Volcanic Ash Recommendations
Flight in visible volcanic ash conditions (“ash cloud”) is detrimental to the helicopter and
should be avoided. If helicopter has been operated in visible volcanic ash conditions:
1. Refer to Lycoming SI 1530. Wearing suitable protective equipment, use vacuum
cleaner followed by compressed air to remove as much debris as possible. Do not
use compressed air near main rotor blade drain holes.
2. Refer to R22 Pilot’s Operating Handbook (POH) Section 8. Thoroughly clean, wash,
and rinse helicopter, including inner circumference of drive belts.
3. Remove main rotor blade tip covers and clean blade tips.
4. Using 10X magnification, visually inspect any exposed main rotor blade skin-to-
spar bond line (adhesive) for gaps (empty space between skin and spar). Blade is
unairworthy if any gap, including “pin hole(s)”, is detected in the bond line. Refinish
blade as required.
5. Inspect condition of drive belt sheaves. Replace any sheave having corrosion pitting,
flaking, wear thru metalized or anodized coatings, roughness, or sharp ridges. Replace
drive belts if either sheave has sharp ridge(s) on drive belt contact surface.
6. Disconnect alternator drive belt from alternator. Spin alternator pulley by hand and
verify rotor bearings and brushes operate smoothly; repair alternator as required if
roughness or unusual noise is encountered (volcanic ash can enter via unfiltered
cooling air). Inspect alternator and ring gear support pulleys and verify no wear
steps; replace alternator belt and pulley(s) if wear steps exist. Perform Lycoming
SI 1129 alternator belt tension check and adjust as required.
7. Clean airbox interior and:
a. Inspect air filter and clean or replace as required.
b. Inspect induction system downstream of air filter (a clean, white glove is
beneficial). If volcanic ash is found then:
i. Clean induction system, disassembling as required.
ii. Disassemble carburetor or fuel injection servo, as applicable, inspect for
internal contamination, and overhaul as required.
iii. Perform Lycoming SI 1191 Cylinder Compression check.
iv. Perform Lycoming SB 388 Procedure to Determine Exhaust Valve and
Guide Condition.
v. Inspect spark plug condition; service as required.

2.710 Volcanic Ash Recommendations (continued)
8. Remove each magneto’s distributor gear inspection plug and inspect visible internal
portion for contamination; overhaul magnetos if volcanic ash is found inside (magneto
vent plugs are unfiltered).
9. Inspect engine oil condition. Regardless of oil time-in-service if oil smells bad, is opaque
(or is not obviously brown), or if particulates are detectable on the dipstick, change
engine oil & oil filter, inspect suction screen and old oil filter, and perform Lycoming
SI 1191 Cylinder Compression check if not previously accomplished in step 6.
2.720 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
§ 2.400 and following recommendations for aircraft struck by lightning per Lycoming
Service Bulletin No. 401.
High voltage that is well conducted through the aircraft structure will dissipate and cause
minimal damage. High voltage that is not well conducted through the aircraft structure
can result in excessive heat, which can bake, burn, char, or even melt certain materials.
Heat damage may or may not be detectable by visual inspection. A component may not
exhibit obvious damage, but temperatures above 300º F can alter the strength of some
materials and thus affect a component's service life and airworthiness.
Visually inspect main rotor blades, landing gear, drive train, airframe, and flight controls
thoroughly for obvious damage such as electrical arcing or burns, pitting, or cracking.
Particular attention should be given to rod ends, journals, etc., where the conductive
path is most susceptible. If obvious damage is detected in any of the above-mentioned
systems, additional components may require replacement. Contact RHC Technical
Support with detailed documentation for further guidance prior to approving aircraft for
return to service.

CHAPTER 3
LIFE-LIMITED COMPONENTS
Section Title Page
3.100 Life-Limited Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3.1

3.110 Time-in-Service Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3.1
3.120 Fatigue Life-Limited Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3.1
3.200 Type Certificate Data Sheet (TCDS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3.2
3.300 Airworthiness Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3.9
OCT 2018 Chapter 3 Life-Limited Components Page 3.i

Intentionally Blank
Page 3.ii Chapter 3 Life-Limited Components OCT 2018

CHAPTER 3
LIFE-LIMITED COMPONENTS
3.100 Life-Limited Components
3.110 Time-In-Service Records

It is the operator’s responsibility to maintain a record of time in service for the airframe,
engine, and life-limited components. R22s are equipped with either an oil-pressure-
activated hourmeter which records engine run time or a collective-activated hourmeter
which records flight (collective up) time. Either method may be used to track time in
service, however numerical values for service lives depend on the tracking method used
(refer to § 3.300).
Calendar time in service for the airframe and engine begins on the date of the original RHC-
issued Export (or Standard) Certificate of Airworthiness for the helicopter. For spares
without a storage limit specified in § 23-85, calendar time in service begins on the date
of the RHC-issued Airworthiness Approval Tag (Authorized Release Certificate) issued
with the invoice.
If a component or an inspection is scheduled for hourly and calendar intervals, comply
with whichever requirement comes first, then reset interval unless otherwise specified.
When installing a life-limited part or a part with an overhaul requirement, record in the
helicopter maintenance record the installation date, part number, part name, serial number,
helicopter total time, and time in service accumulated by part since new or since last
overhaul, as applicable.
WARNING
Components with mandatory overhaul times or life limits whose
time in service is not reliably documented cannot be considered
airworthy and must be removed from service.
3.120 Fatigue Life-Limited Parts

The Airworthiness Limitations section lists the mandatory replacement schedule for
fatigue life-limited parts.
Listed items must be removed from the helicopter at the specified intervals and permanently
retired from service by destroying or damaging each part so it cannot inadvertently be
returned to service. Fatigue lives are based upon normal flight service, including 6 rotor
stop-starts and 10 autorotation entries per hour.
OCT 2018 Chapter 3 Life-Limited Components Page 3.1

3.200 Type Certificate Data Sheet (TCDS)
The Robinson R22-series Type Certficate Data Sheet (TCDS) reprinted on the following
pages is subject to revision.
Visit the FAA Aircraft Certification Regulatory and Guidance Library online databases to
determine TCDS revision status at: http://rgl.faa.gov.
Page 3.2 Chapter 3 Life-Limited Components OCT 2018

DEPARTMENT OF TRANSPORTATION
FEDERAL AVIATION ADMINISTRATION
H10WE
REVISION 16
ROBINSON
R22
R22 ALPHA
R22 BETA
R22 MARINER
June 28, 2018
TYPE CERTIFICATE DATA SHEET NO. H10WE
This data sheet, which is a part of Type Certificate No. H10WE, prescribes conditions and limitations under which the product
for which the type certificate was issued meets the airworthiness requirements of Title 14 of the Code of Federal Regulations.
Type Certificate Holder: Robinson Helicopter Company

2901 Airport Drive
Torrance, California 90505
I. Model R22 Helicopter (Normal Category), Approved March 16, 1979
Engine Lycoming O-320-A2B or O-320-A2C or

O-320-B2C (See NOTES 5 & 6)
Fuel See Rotorcraft Flight Manual (RFM)
Engine Limits for all operations 124 hp at 2652 rpm (104%)

See RFM for manifold pressure limit corresponding to 124 hp and ambient
conditions.
Rotor Limits Power Off (Rotor Tach) Power On (Rotor Tach)

Maximum (110%) 561 rpm (104%) 530 rpm
Minimum (90%) 459 rpm (97%) 495 rpm
Airspeed Limits (CAS) 98 KCAS Power On and Off VNE (never exceed) at sea level.
See RFM for reduction of VNE with altitude and temperature.
Altitude Limits Density Altitude Limit - 14,000 feet
CG Range See RFM
Maximum Gross Weight 1300 lbs.
No. Seats 2 (See NOTE 1)
Minimum Weight 920 lbs.
Maximum Baggage 50 pounds of baggage and installed equipment in either baggage compartment,
except combined seat load plus baggage and equipment not to exceed 240 pounds.
Page No. 1 2 3 4 5 6
Rev. No. 16 16 16 16 16 16

H10WE Page 2 of 6
I. Model R22 Helicopter (Normal Category), Approved March 16, 1979, (cont'd)
Fuel Capacity Tanks Without Bladders Tanks With Bladders

Location
Tank Capacity Usable Capacity Usable
(STA)
(gal.) (gal.) (gal.) (gal.)
Main 19.8 19.2 18.3 16.9 108.6
Auxiliary N/A N/A 9.7 9.4 103.8
Oil Capacity Engine Oil, 6 qt. at STA 104.8;

Transmission oil, 1.2 qt. at STA 100.
Rotor Blade and Control Movements For rigging information refer to R22 Maintenance Manual
Serial Nos. Eligible 0002 thru 0300

0302 thru 0349
0352 thru 0356
II. Model R22 ALPHA Helicopter (Normal Category), Approved October 12, 1983
Engine Lycoming O-320-B2C
Fuel See RFM
Engine Limits for all operations 124 hp at 2652 rpm (104%)

See RFM for manifold pressure limit corresponding to 124 hp and ambient
conditions.
Rotor Limits Power Off (Rotor Tach) Power On (Rotor Tach)

Maximum (110%) 561 rpm (104%) 530 rpm
Minimum (90%) 459 rpm (97%) 495 rpm
Airspeed Limits 98 KCAS Power On and Off VNE (never exceed) at sea level.
CG Range See RFM
No. Seats 2 (Pilot Location STA 78.0)

Location
(STA)
Main 19.8 19.2 18.3 16.9 108.6
Auxiliary 10.9 10.5 9.7 9.4 103.8
Oil Capacity Engine oil, 6 qt. at STA 104.8;

Rotor Blade and Control Movements For rigging information refer to R22 Maintenance Manual.
Serial Nos. Eligible 0301, 0350, 0351, 0357 thru 0500, excluding 0364

H10WE Page 3 of 6
III. Model R22 BETA Helicopter (Normal Category), Approved August 12, 1985
The R22 BETA Helicopter includes a 131 hp. takeoff rating. A larger oil cooler and associated installation changes were made to
permit the 131 hp. takeoff rating with the O-320 engine.
Engine Lycoming O-320-B2C or O-360-J2A (See NOTE 11)
Fuel See RFM
Engine Limits for all operations Maximum continuous: 124 hp at 2652 rpm (104%)
Takeoff (5 minutes): 131 hp at 2652 rpm (104%)
See RFM for manifold pressure limit corresponding to hp. rating and ambient
conditions.
Rotor Limits Power Off (Rotor Tach) for Power On (Rotor Power On (Rotor Tach)
O-320-B2C and O-360-J2A Tach) for O-320-B2C for O-360-J2A
Maximum (110%) 561 rpm (104%) 530 rpm (104%) 530 rpm
Minimum (90%) 459 rpm (97%) 495 rpm (101%) 515 rpm
Airspeed Limits (CAS) 98 KCAS Power On and Off VNE (never exceed) at sea level.
CG Range See RFM

Location
(STA)
Main 19.8 19.2 18.3 16.9 108.6
Auxiliary 10.9 10.5 9.7 9.4 103.8

Rotor Blade and Control Movements For rigging information refer to R22 Maintenance Manual.
Serial Nos. Eligible 0501 and subsequent

H10WE Page 4 of 6
IV. Model R22 MARINER Helicopter (Normal Category), Approved September 12, 1985
The R22 MARINER helicopter includes two inflatable floats, additional corrosion protection, 131 hp. takeoff rating, tailcone
with nose-up horizontal stabilizer mounting angle and float stabilizer in place of the tail skid. The helicopter can be used with or
without floats. (See NOTE 9)
Engine Lycoming O-320-B2C or O-360-J2A (See NOTE 11)
Fuel See RFM
Engine Limits for all operations Maximum continuous: 124 hp at 2652 rpm (104%)
Takeoff (5 minutes): 131 hp at 2652 rpm (104%)
See RFM for manifold pressure limit corresponding to hp. rating and ambient
conditions.
Rotor Limits Power Off (Rotor Tach) for Power On (Rotor Power On (Rotor Tach)
O-320-B2C and O-360-J2A Tach) for O-320-B2C for O-360-J2A
Maximum (110%) 561 rpm (104%) 530 rpm (104%) 530 rpm
Minimum (90%) 459 rpm (97%) 495 rpm (101%) 515 rpm
Airspeed Limits (CAS) With Floats Installed

91 KCAS Power On VNE (never exceed) at sea level.
77 KCAS Power Off VNE (never exceed) at sea level.
Without Floats Installed

98 KCAS Power On and Off VNE (never exceed) at sea level.
CG Range See RFM

Maximum Gross Weight 1370 pounds
Minimum Weight 920 pounds
except combined seat load, plus baggage and equipment not to exceed 240 pounds.

Location
(STA)
Main 19.8 19.2 18.3 16.9 108.6
Auxiliary 10.9 10.5 9.7 9.4 103.8

Rotor Blade and For rigging information refer to R22 Maintenance Manual.
Control Movements
Serial No. Eligible 0364, 0501 and subsequent (Suffix "M" added to all MARINERs.)

H10WE Page 5 of 6
DATA PERTINENT TO ALL MODELS
Datum 100 inches forward of main rotor centerline.
Leveling Means Refer to the Weight and Balance Section of the R22 Rotorcraft Flight Manual.
Certification Basis 14 CFR Part 27 dated February 1, 1965, including Amendments 27-1 through 27-10.
§ 27.1559 of Amendment 27-21 is an option for all S/Ns.
National Environmental Act of 1969
Noise Control Act of 1972
Equivalent Safety Finding:

Number TD10352LA-R/S-1
14 CFR Part 27.1401(d), Anticollision Light System
Production Basis Production Certificate No. 424WE, dated March 6, 1981
Equipment The basic required equipment as prescribed in the applicable airworthiness

regulations (See Certification Basis) must be installed in the helicopter for
certification. In addition, the following FAA-approved Rotorcraft Flight
Manual is required:
R22
R22 Rotorcraft Flight Manual dated March 16, 1979, or later revision.
R22 ALPHA
R22 Rotorcraft Flight Manual dated March 16, 1979, with revisions through October
12, 1983 or later (see NOTE 8).
R22 BETA with O-320-B2C

R22 Rotorcraft Flight Manual dated March 16, 1979, with revisions through August
7, 1985 or later (see NOTE 8).
R22 BETA with O-360-J2A

R22 Rotorcraft Flight Manual dated March 16, 1979,with revisions through August
7, 1985 or later. For R22 Rotorcraft Flight Manual with revisions prior to October
13, 2000, Flight Manual Supplement 7 dated January 31, 1996, or later revision, is
required (see NOTE 8).
R22 MARINER with O-320-B2C

7, 1985 or later, and Flight Manual Supplement 4 dated September 9, 1985, or later
revision.
R22 MARINER with O-360-J2A

7, 1985 or later, and Flight Manual Supplement 4 dated September 9, 1985, with
revisions through October 13, 2000 or later. For R22 Rotorcraft Flight Manual with
revisions prior to October 13, 2000, Flight Manual Supplement 8 dated January 31,
1996, or later revision, is required in place of Flight Manual Supplement 4.
ALL MODELS
If fuel tanks with bladders are installed: R22 Rotorcraft Flight Manual dated March
16, 1979, with revisions through February 15, 2013 or later. R22 Mariners also
require Flight Manual Supplement 4 as noted above. Also see Note 8.

H10WE Page 6 of 6
GENERAL NOTES
NOTE 1. Current weight and balance report, including list of equipment included in certificated empty weight , and loading
instructions, when necessary, must be provided for each helicopter at the time of original certification and at all
times thereafter (except in the case of operators having an approved weight control system).
Pilot Location STA 79.0 for helicopter S/Ns 0002 thru 0255 and STA 78.0 for helicopter S/Ns 0256 and
subsequent and helicopters in which Robinson P/N seats A466-1 and A467-1 have been replaced by Robinson
P/N seats A932-1 and A928-1.
NOTE 2. One of the following placards must be installed in clear view of the pilot:
"THE MARKINGS AND PLACARDS INSTALLED ON THIS HELICOPTER CONTAIN
OPERATING LIMITATIONS WHICH MUST BE COMPLIED WITH WHEN OPERATING THIS
ROTORCRAFT. OTHER OPERATING LIMITATIONS WHICH MUST BE COMPLIED WITH WHEN
OPERATING THIS ROTORCRAFT ARE CONTAINED IN THE ROTORCRAFT FLIGHT MANUAL."
Or: "THIS ROTORCRAFT APPROVED FOR DAY AND NIGHT VFR OPERATIONS"
For the R22 MARINER:

"THIS ROTORCRAFT APPROVED FOR DAY AND NIGHT VFR OPERATIONS WITHOUT
FLOATS INSTALLED OR DAY VFR OPERATIONS ONLY WITH FLOATS INSTALLED."
For additional placards, see R22 Rotorcraft Flight Manual.
NOTE 3. Information essential to the proper maintenance of the helicopter, including retirement time of critical
components, is contained in the Robinson R22 Maintenance Manual and Instructions For Continued Airworthiness
(RTR 060). Retirement times are listed in the "AIRWORTHINESS LIMITATIONS" section.
NOTE 4. Deleted as of April 11, 1988.
NOTE 5. Lycoming O-320-A2C, with Retard Magneto Starting System, eligible on S/Ns 0002 thru 0300, 0302 thru 0349,
and 0352 thru 0356 helicopters.
NOTE 6. Lycoming O-320-B2C installed on S/Ns 0175 and 0200 thru 2570 in production. It may be installed in prior
S/N helicopters if the following parts are changed; Robinson P/Ns B193-2 (Window Plate - Instrument Cluster),
A145-3 (Engine), A600-2 (Manifold Pressure Gauge), and A654-40 & -41 (Decals).
NOTE 7. Deleted as of April 25, 2001.
NOTE 8. The R22 "Police Helicopter" configuration requires Flight Manual Supplement 3, dated March 27, 1984 or later.
NOTE 9. The R22 MARINER with floats installed is limited to daylight VFR operation only.
NOTE 10. R22 ALPHA S/N 0364 was converted to an R22 MARINER by the manufacturer. The original R22 ALPHA
dataplate was removed and replaced with an R22 MARINER data plate S/N 0364M.
NOTE 11. Lycoming O-360-J2A installed on S/N 2571 and subsequent in production. Retrofit installation of the O-360-J2A
engines may only be accomplished at the Robinson Helicopter Company.
NOTE 12. Deleted as of May 24, 2018.
.....END.....

3.300 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.
Time in service may be tracked based on engine run time or based on flight (collective up)
time. Either method may be used, however numerical values for service lives depend on
the tracking method used.
R22 Fatigue Life-Limited Parts
Use the following lives if time is tracked based on engine run time as recorded by an
oil-pressure-activated hourmeter:
Part Number Description Maximum Service Life

A016-2 (Retired by AD 2004-19-09) . . Main Rotor Blade . . . . . . . . . . . . . . . . . 2200 Hours or 10 years1
A016-4 and -6 . . . . . . . . . . . . . . . . . . Main Rotor Blade . . . . . . . . . . . . . . . . . 2200 Hours or 12 years1
A029-1 and -2 . . . . . . . . . . . . . . . . . . Tail Rotor Blade . . . . . . . . . . . . . . . . . . 2200 Hours or 12 years1
A146-1 . . . . . . . . . . . . . . . . . . . . . . . . Pinion, Main Gearbox . . . . . . . . . . . . . . 2200 Hours
(O-360 Engine)
A158-3 . . . . . . . . . . . . . . . . . . . . . . . . Main Rotor Spindle . . . . . . . . . . . . . . . . 2200 Hours
B545-1 . . . . . . . . . . . . . . . . . . . . . . . . Gear Set, Tail Gearbox . . . . . . . . . . . . . 2200 Hours
B545-2 . . . . . . . . . . . . . . . . . . . . . . . Pinion, Tail Gearbox . . . . . . . . . . . . . . . 2200 Hours
NAS630-80 (or MS21250-10080) . . . Coning Hinge Bolt . . . . . . . . . . . . . . . . . 2200 Hours
NAS1351-4-20 (or A722-1 or -2) . . . . Pitch Horn Screws . . . . . . . . . . . . . . . . 2200 Hours
NAS6604 (or NAS1304) . . . . . . . . . . Tail Rotor Blade-to-Hub Attach Bolt . . . 2200 Hours
A158-1 . . . . . . . . . . . . . . . . . . . . . . . . Main Rotor Spindle . . . . . . . . . . . . . . . . 2415 Hours2
A020-2 . . . . . . . . . . . . . . . . . . . . . . . . Upper Frame, Rev R & Prior . . . . . . . . . 4200 Hours
A020-2 and -90 . . . . . . . . . . . . . . . . . Upper Frame, Rev S & Subsequent . . . . 4400 Hours
A023-1, -20, -22, and -23 . . . . . . . . . Tailcone Assembly . . . . . . . . . . . . . . . . 4400 Hours
A047-1 and -6 . . . . . . . . . . . . . . . . . . Upper Frame . . . . . . . . . . . . . . . . . . . . 4400 Hours
A154-1 . . . . . . . . . . . . . . . . . . . . . . . . Main Rotor Hub . . . . . . . . . . . . . . . . . . 4400 Hours
B370-1 . . . . . . . . . . . . . . . . . . . . . . . . Main Rotor Hub . . . . . . . . . . . . . . . . . . 4400 Hours
A020-84 . . . . . . . . . . . . . . . . . . . . . . . Lower R.H. Frame . . . . . . . . . . . . . . . . 5110 Hours
A046-2 . . . . . . . . . . . . . . . . . . . . . . . . Lower R.H. Frame . . . . . . . . . . . . . . . . 5110 Hours
A062-2 . . . . . . . . . . . . . . . . . . . . . . . . Tail Rotor Hub . . . . . . . . . . . . . . . . . . . 6000 Hours
A030-1 . . . . . . . . . . . . . . . . . . . . . . . . Tail Rotor Hub Assembly . . . . . . . . . . . 6260 Hours
1
Whichever limit occurs first. Calendar time starts on date of original RHC-issued Airworthiness Approval.
2
Subject to AD 88-26-01 R2 compliance.

3.300 Airworthiness Limitations (continued)
R22 Fatigue Life-Limited Parts (continued)
Use the following lives if time is tracked based on flight (collective up) time as recorded
by a collective-activated hourmeter:
Part Number Description Maximum Service Life
A016-2 (Retired by AD 2004-19-09) . . Main Rotor Blade . . . . . . . . . . . . . . . . . 1964 Hours or 10 years1
A016-4 . . . . . . . . . . . . . . . . . . . . . . . . Main Rotor Blade . . . . . . . . . . . . . . . . . 1964 Hours or 12 years1
NAS630-80 (or MS21250-10080) . . . Coning Hinge Bolt . . . . . . . . . . . . . . . . . 1964 Hours
NAS1351-4-20 (or A722-1 or -2) . . . . Pitch Horn Screws . . . . . . . . . . . . . . . . 1964 Hours
A158-1 . . . . . . . . . . . . . . . . . . . . . . . . Main Rotor Spindle . . . . . . . . . . . . . . . . 2156 Hours2
A016-6 . . . . . . . . . . . . . . . . . . . . . . . . Main Rotor Blade . . . . . . . . . . . . . . . . . 2200 Hours or 12 years1
A029-1 and -2 . . . . . . . . . . . . . . . . . . Tail Rotor Blade . . . . . . . . . . . . . . . . . . 2200 Hours or 12 years1
A146-1 . . . . . . . . . . . . . . . . . . . . . . . . Pinion, Main Gearbox . . . . . . . . . . . . . . 2200 Hours
A158-3 . . . . . . . . . . . . . . . . . . . . . . . . Main Rotor Spindle . . . . . . . . . . . . . . . . 2200 Hours
A188-2 . . . . . . . . . . . . . . . . . . . . . . . . Sprag Clutch Assembly . . . . . . . . . . . . 2200 Hours
A647-1 . . . . . . . . . . . . . . . . . . . . . . . . Bearing, Main Rotor Shaft . . . . . . . . . . 2200 Hours or 12 years1
A647-6 . . . . . . . . . . . . . . . . . . . . . . . . Bearing, Tail Rotor Pitch Control . . . . . . 2200 Hours or 12 years1
A647-8 . . . . . . . . . . . . . . . . . . . . . . . . Bearing, Damper Assembly . . . . . . . . . . 2200 Hours or 12 years1
B545-1 . . . . . . . . . . . . . . . . . . . . . . . . Gear Set, Tail Gearbox . . . . . . . . . . . . . 2200 Hours
B545-2 . . . . . . . . . . . . . . . . . . . . . . . . Pinion, Tail Gearbox . . . . . . . . . . . . . . . 2200 Hours
NAS6604 (or NAS1304) . . . . . . . . . . Tail Rotor Blade-to-Hub Attach Bolt . . . 2200 Hours
A020-2 . . . . . . . . . . . . . . . . . . . . . . . . Upper Frame, Rev R & Prior . . . . . . . . . 3750 Hours
A154-1 . . . . . . . . . . . . . . . . . . . . . . . . Main Rotor Hub . . . . . . . . . . . . . . . . . . 3928 Hours
A020-2 and -90 . . . . . . . . . . . . . . . . . Upper Frame, Rev S & Subsequent . . . . 4400 Hours
A020-84 . . . . . . . . . . . . . . . . . . . . . . . Lower R.H. Frame . . . . . . . . . . . . . . . . 4400 Hours
A023-1, -20, -22, and -23 . . . . . . . . . Tailcone Assembly . . . . . . . . . . . . . . . . 4400 Hours
A046-2 . . . . . . . . . . . . . . . . . . . . . . . . Lower R.H. Frame . . . . . . . . . . . . . . . . 4400 Hours
A047-1 and -6 . . . . . . . . . . . . . . . . . . Upper Frame . . . . . . . . . . . . . . . . . . . . 4400 Hours
A062-2 . . . . . . . . . . . . . . . . . . . . . . . . Tail Rotor Hub . . . . . . . . . . . . . . . . . . . 4400 Hours
B370-1 . . . . . . . . . . . . . . . . . . . . . . . . Main Rotor Hub . . . . . . . . . . . . . . . . . . 4400 Hours
A030-1 . . . . . . . . . . . . . . . . . . . . . . . . Tail Rotor Hub Assembly . . . . . . . . . . . 5589 Hours
1
Whichever limit occurs first. Calendar time starts on date of original RHC-issued Airworthiness Approval.
2
Subject to AD 88-26-01 R2 compliance.
Approved By: Date:

Manager, Federal Aviation Administration
Los Angeles ACO Branch, AIR-790
FAA Approved: This and the previous page constitute the Airworthiness Limitations Section
in its entirety, are considered segregated from the rest of the document, and set forth the
FAA-approved mandatory replacement times for fatigue life-limited parts.

CHAPTER 4
AIRFRAME
Section Title Page
4.000 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1

4.100 Fuselage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1
4.110 Cabin Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1
4.111 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1
4.120 Windshield Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
4.130 Door Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
4.140 Fairing, Cowling, and Inspection Panels . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
4.141 Side Skirts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
4.142 Mast Fairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
4.143 Aft Cowling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
4.144 Cabin Inspection Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
4.200 Welded Steel Tube Frame Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7
4.210 Left-Hand Frame Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8
4.211 Left-Hand Frame Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8
4.212 Left-Hand Frame Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8
4.220 Right-Hand Frame Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9
4.221 Right-Hand Frame Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9
4.222 Right-Hand Frame Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.12
4.230 Upper Frame Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.13
4.231 Upper Frame Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.13
4.232 Upper Frame Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14
4.240 Strut Assembly Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . 4.15
4.300 Tailcone and Empennage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.16
4.310 Tailcone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.16
4.311 Tailcone Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.16
4.312 Tailcone Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.16
4.313 Tailcone Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.17
4.314 Tailcone Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.22
4.320 Empennage Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.22
4.321 Empennage Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.22
4.322 Empennage Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.23
4.323 Upper Stabilizer Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.23
4.324 Lower Stabilizer Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.23
4.325 Horizontal Stabilizer Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.24
OCT 2018 Chapter 4 Airframe Page 4.i

Intentionally Blank
Page 4.ii Chapter 4 Airframe OCT 2018

CHAPTER 4
AIRFRAME
4.000 Description
The R22 is a two-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 primary loads. Fiberglass
and thermoplastics are used in secondary cabin structure, engine cooling shrouds, and
various other ducts and fairings.
A right-side cowl door provides access to the main gearbox and drive system. Additional
access to controls and other components for maintenance is provided by removable panels
and cowlings.
Stainless steel firewalls are located forward of and above the engine.
4.100 Fuselage
4.110 Cabin Assembly

The cabin assembly is a non-field-replaceable assembly.
4.111 Repair
1. Vertical firewall replacement must be performed at the factory in a jig. Firewall repairs
may be accomplished in accordance with U.S. FAA Advisory Circular 43.13-1B
Section 4-59. Firewall material is 0.016 inch, type 301, one-quarter hard corrosion-
resistant (CRES) steel.
2. Keel panel replacement must be performed at the factory in a jig. Keel panel repairs
may be accomplished in accordance with U.S. FAA Advisory Circular 43.13-1B
Sections 4-58 and 4-59. Keel panel material is 0.025 inch, 2024-T3 clad aluminum-
alloy sheet.
3. To preserve crashworthiness, repairs to seat structure are limited to replacement of
damaged components only.
OCT 2018 Chapter 4 Airframe Page 4.1

Intentionally Blank
Page 4.2 Chapter 4 Airframe OCT 2018

Intentionally Blank
OCT 2018 Chapter 4 Airframe Page 4.3

4.120 Windshield Assembly
This section has been moved to Chapter 25 Doors and Windows.
4.130 Door Removal and Installation
This section has been moved to Chapter 25 Doors and Windows.
4.140 Fairing, Cowling, and Inspection Panels
4.141 Side Skirts
CAUTION
This is a structural panel assembly and must be installed for run
up and flight.
Page 4.4 Chapter 4 Airframe OCT 2018

.40 OVERLAP
WINDSHIELD INSTALLATION (S/N 001 thru 591)

POLYVINYL
CHLORIDE TAPE
3/4 WIDE
11
WINDSHIELD
WINDSHIELD INSTALLATION
(S/N 592 & On)
Change 5: 31 JAN 89 Page 4.5

4. 142 Mast Fairing
CAUTION
I Mast Fairing must be installed for flight.
The mast fairing upper rib is mounted to swashplate tube assembly. The lower rib is
clamped to main rotor gearbox mast assembly.
The pitot tube is mounted on lower front of mast fairing.
The fuel tank vent is installed through lower rib of mast fairing. (Vent should have
I approximately 0.30 inch clearance from the aft cowling.)
4.143 Aft Cowling
CAUTION
Aft cowling must be installed for flight.
The aft cowling is a two-piece, sheet-aluminum structure with a removable tailcone

rain guard.
4. 144 Cabin Inspection Panels
CAUTION
I All cabin inspection panels must be installed for flight. With the
exception of side skirts, all panels may be left off for run-up.
1. Seat Backs: Left side seat back has fuel valve attached. Back cushions are
installed using blind rivets.
2. Cyclic Control Inspection Panels - 4 panels:
a. Center belly panel
b. Inside center of cabin (2 each horizontal: 1 each vertical).
c. Instrument console (See Instruments Section 14.000).
d. Forward cross tube inspection panel.
Page 4.6 Change 24: APR 2005

ROBINSON MAINTENANCE MANUAL MODELR22
4.200 ~~LDED STEEL TUBE FRAME ASSE~~LIES
IWARNING I
All welded steel tube structures
used in the rotorcraft are stress_
relieved. No weld repairs are
permissible outside Robinson
Helicopter Co.
1. Frames required on R22 Alpha & Beta Models
A020-2 Upper Frame Serial Number 0400 and subsequent.
A046-l Lower Left Frame
AO 46-2 Lower Right Frame
A046-3 Right-Hand Strut
2. Frames required on R22 Standard & HP Models

A020-2 Upper Frame
A020-l Lower Left Frame
A020-84 Lower Right Frame
A020-3 Right-Hand Strut
3. Optional frame on Mariner
A047-l Upper Frame with Tie Downs
Issued 5/22/87 Page 4.7

4.210 Left-Hand Frame Assembly
4.211 Removal
a) Remove main rotor blades per Section 9.111.
b) Remove clutch assembly per Section 7.210.
c) Remove main rotor gearbox per Section 7.110.
d) Remove tailcone assembly per Section 4.311.
e) Remove power plant per Section 6.110.
f) Remove seat backs and center panels per Section 4.144.
g) Disconnect the three lower fo~1ard firewall and left-

hand upper aft attach ooints on the left-hand frame.
h) Disconnect the aft NAS1306 landing gear attach bolt

from the left-hand landing gear support.
i) Disconnect the two upper left-hand frame attach points

at the vertical firewall.
j) Remove the through bolts connecting the upper frame to

the fuselage and lower left-hand frame assemblv.
k) Remove the left-hand frame.
1) Remove the landing gear support from the left-hand

frame assembly.
4.212 Left-Hand Frame Assembly Installation
a) Install the landing gear support bearing.
b) Position left-hand frame for installation.
c) Install the bolt (internal wrenching) connecting the

upper frame assembly to the left-hand frame assembly
through the horizontal firewall. Torque bolt to 75
f t- 1 b s . (wet) .
Page 4.8 Issued 5/22/87

ROBINSON MAINTENANCE MANUAL MODEL_R22
4.212 Left-Hand Frame Assembly (cont'd)
d) Install the two NAS1304 bolts on upper support of the

left-hand frame to the vertical firewall. Torque to
100 in-lbs. plus nut drag.
e) Install fasteners at firewall forward attachment points.

Torque the attaching screws and bolts per Fastener Tor-
ques, Section 1.300.
NOTE
Lower support at fuselage has a

large-area washer AN 970-4 under
bolthead next to tab of frame.
NOTE
The outboard support of the frame

requires a washer between the
frame and the fuselage skin.
(See Fig. 4-1 View H)
f) Install NAS1306 landing gear attach bolt from frame

support to landing gear. Torque NAS1306 bolts to 300
in.-lb plus nut drag. Install palnuts.
g) Install upper aft support of the left-hand frame arm.

Torque NAS1304 bolt to 100 in-lbs. plus nut drag. In-
stall palnut.
h) Install power plant per Section 6.120.
i) Install tailcone per Section 4.312.
j) Install main rotor gearbox per Section 7.120.
k) Install clutch assembly per Section 7.220.
1) Install main rotor blades per Section 9.112.
m) Install seat backs and panels after verifying all at-

taching nuts and screws are secure.
-4.220 Right-Hand Frame Assembly
4.221 Right-Hand Frame Removal
b) Remove clutch assembly per Section 7.210.
c) Remove main rotor gearbox per Section 7.110.

R 0 BIN soN MAINTENANCE MANUAL MOOELRE2
SHIM HERE IF 0.032 INCH OR LARGER GAP EXISTS
E
F
G
FIGURE 4-1 FRAME-TO-CABIN ATTACHMENTS
Page 4.10 Change 23: JAN 2005

FIGURE 4-1 A A960 CLAMP ASSEMBLY

0
"··~ ~:··,
MS27151-l3 P~UT..:::--:~-
NAS679A4 NUT ""- ,~
s~
~\=--
''
At1960-416L \lASHER~::. ) ' /
~
~
A960-3 CLAMP
~'
' ~ l ( AN960-416L WASHER
FORWARD A020-2 UPPER FRAME~-_./\ I NAS!304-24 BOLT
A960-4 CLAMP ~-~~ ~

~~
A960-2 LUG
I
AN960-416L WASHER /
NAS1304-10H BOLT
.032 STAINLESS STEEL SAFETY WIRE
FORHARD
FIGURE 4-1 B A961 STRAP ASSEMBLY
Issued 5/22/87 4.11

4. 221 Right-Hand Frame Removal (cont' d)
d) Remove tailcone assembly per Section 4.311.
e) Remove powerplant per Section 6.11 0.
f) Disconnect aft landing gear attach bolt from right-hand landing gear support.
g) Disconnect four forward firewall attach points.
h) Remove (2) through bolts connecting right side of upper frame to fuselage.
i) Remove right-hand frame from helicopter.
j) Remove landing gear support from right frame assembly.
4.222 Right-Hand Frame Installation
a). Install landing gear support bearing.
b) Position right-hand frame for installation.
c) Install attaching screw (internal wrenching) connecting upper frame assembly

to right hand frame assembly through horizontal firewall. Torque screw per
Section 1 .330.
d) Tighten lower inboard support attaching screws to the vertical firewall.
e) Install fasteners at the forward firewall attachment points. Torque fasteners

per Section 1. 300.
f) Install landing gear attach bolt from frame support to landing gear.
g) Install powerplant per Section 6.120.
h) Install aft strut assembly between right-hand lower frame and upper frame
assemblies. Torque bolts per Section 1.320. Install palnuts.
NOTE
Seal around inner diameter of bolt holes in strut with 8270-1

sealant. Verify no sealant on bolt threads.
i) Install tailcone per Section 4.312.
j) Install main rotor gearbox per Section 7 .120.
k) Install clutch assembly per Section 7 .220.
I) Install main rotor system per Section 9.112.
4.12 Change 26: APR 2007

ROBINSON MAINTENANCE MANUAL MOCELR22
4. 222 Right-Hand Frame Installation (cant' d)
m) Install seat backs and panels after verifying all

attaching nuts and screws are secure.
4.230 Upper Frame Assembly
4.231 Upper Frame Removal
Before the upper frame is disconnected and removed,

the power plant must be either removed or supported.
I CAUTION I
Extensive damage to the firewall
and lower welded tube structures
will occur if power plant is not
supported or if support is dis-
lodged.
b) Remove clutch assembly per Section 7.210
c) Remove the right and left seat back and center push-
pull tube panel assemblies.
d) Remove main rotor gearbox per Section 7.110.
e) Remove tailcone assembly per Section 4.311.
f) Support power plant or remove per Section 6.110.
g) Disconnect right-hand aft vertical strut assembly at

upper frame and lower right-hand attach points and
remove.
h) Disconnect the forward support at the horizontal and

vertical firewall.
NOTE
If same upper frame is to be re-
installed, any shims found at the
forward support should be rein-
stalled in the same position.
i) Disconnect the two forward through bolts attaching

the upper frame to the· t\vO lower frames.
j) Disconnect the two (internal wrenching) bolts attach-

ing the upper frame to the two lower frames.

4.231 Upper Frame Removal (cont'd)
k) Disconnect the center upper frame mount point at the horizontal

firewall stiffener.
I) Disconnect the aft portion of the upper frame.
m) Remove upper frame.
4.232 Upper Frame Installation
a) Clean upper frame and attach points of all old sealant, grease and
oil.
b) Position upper frame for installation.

I c) Install internal wrenching bolts with anti-seize. Do not tighten at this
time.
I d) Install the two NAS 1306(NAS6606) forward through bolts.
e) Torque the four attach bolts in c & d above to:
NAS 1306(NAS6606) 300 in-lb

I NAS 1351-8H40P 75 ft-lb (wet)
f) Measure gap on the upper frame. Shim as required (see Fig. 4-1 View
A)
g)
I
Install the four attaching bolts in forward support. Do not install
washers under the two 8238-1 bolt heads in the push-pull tube
tunnel. Torque the four bolts to 40 in.-lb plus nut drag (see Fig.
4-1 View A).
h) Install the center support bolts of the upper frame assembly. Torque
I the two NAS1304(NAS6604) bolts.
i) Connect the upper frame to the aft end of the horizontal firewall.
j) Connect the aft end of the upper frame to the lower frame assembly.
k) Torque the NAS1304(NAS6604) attach bolts.
I) Install the power plant, if removed.
m) Seal firewalls at the upper and lower frame attach points to insure
no seepage of fuel in the event of a fuel tank leak. Use Coast Pro-
Seal 89082.
Page 4.14 Change 13: 29 MAR 93

4.232 Upper Frame Installation (cont'd)
n) Install main rotor gearbox per Section 7 .120.
o) Install tailcone per Section 4.312.
NOTE
On A020-2 upper frames S/N 0002 thru 0399 without welded

ta ilcone straps require A960-1 cia mp assembly and A961-1
strap assembly.
p) Install clutch assembly per Section 7.220
q) Install seat backs and panels after verifying all attaching nuts and screws
and secure.
4.240 Strut Assembly Removal and Installation
To remove strut:
a. Remove upper and lower attaching bolts.
b. Remove strut.
To install strut:
a. Line up holes in strut with upper and lower frame tabs. Lower end of
strut goes on aft face of lower frame tab.
b. Install NAS6604-3 attaching bolts wet with 8270-1 sealant on shanks.
CAUTION
Verify threads are clean and dry.
Torque per Section 1.330. Install palnuts, torque per Section 1.320, and
torque stripe.
Change 23: JAN 2005 Page 4.15

ROBINSON MAINTENANCE MANUAL MCCELR22
4.300 TAILCONE AND EMPENNAGE
4.310 Tailcone
4.311 Tailcone Removal
a) Disconnect wiring (antenna, strobe, tail light and chip detector) to

tail cone.
b) Mark tail rotor driveshaft and A947-2 flexplate for reinstallation.
c) Disconnect tail rotor driveshaft flange from flex plate leaving flex plate
connected to clutch shaft. Install attaching hardware back onto flex plate
in the same position from which it was removed.
WARNING
A 193 flex plates, which do not have bonded washers, are

obsolete and must be replaced with A94 7 flex plates having
Ensure A94 7-1 forward flex plate is Rev E or subsequent
(identified by letter "E" or subsequent letter on two adjacent
arms of flex plate).
d) Disconnect aft tail rotor push-pull tube from intermediate bellcrank.
e) Remove five NAS 1304 bolts that hold tailcone to steel tube structure.
f) Carefully remove tailcone.
4.312 Tailcone Installation
a) Install tailcone onto attaching frame structure. Insure wires on tailcone

bulkhead are not pinched between bulkhead and frame.
NOTE
All R 22 helicopters with upper frame A020-2 S/N 0002 thru

0399 are required to install A960-1 clamp and A961-1 strap
assemblies per RHC Service Bulletin 26.
b) Install the five attaching bolts. Torque nuts per Section 1.320. Install
pal nuts.
c) Connect the A 121-17 aft push-pull tube to the intermediate bellcrank.

Torque nut per Section 1 .320. Install palnut.
d) Connect tail rotor driveshaft flange to intermediate flexplate. (see Section

7 .320).

4.312 Tailcone Installation (cont'd)
WARNING
Shim intermediate flex plate per Section 7 .330.
WARNING

bonded washers. If a bonded washer separates from an
A94 7 flex plate, then flex plate is unairworthy and cannot
be repaired.
Torque NAS 1304 attach bolts per Section 1 .320 and install palnuts.
e. Connect electrical connections for strobe, antenna, tail light and chip
detector.
f. Check for clearance between tailcone and upper frame assembly. Refer to
Figure 4-20.
4.313 Tailcone Replacement
The following step-by-step instruction covers set-up, drilling and installation of

doublers to the A023 Tailcone Assembly.
a. Set-up
1. Level helicopter longitudinally and laterally per Section 1 .220(c). Shim

as necessary under landing gear skid tubes to level helicopter.
2. Verify tailcone part number is correct for helicopter model. Slide forward
end of tailcone over upper steel tube frame and support aft end of
tailcone with an adjustable stand.
3. Refer to Figure 4-2A. Insert two bolts into horizontal mounting holes in
tail rotor gearbox mount casting at aft end of tailcone. Place a bubble
level across these bolts and level tailcone horizontally by turning it on the
steel tube frame.
4. Refer to Figure 4-28. Measure from left and right lower frame vertical
strut-to-upper steel tube frame attach points to aft end of tailcone; these
measurements should be equal on both sides. Center tailcone laterally
as required.
Change 21: JUN 2000 Page 4.17

4. 313 Tailcone Replacement (cant' d)
5. Refer to Figure 4-2C. Fill a clear plastic tube with water to level of forward
end of tailcone at lowest point. Extend plastic tube under tail rotor gearbox.
Recheck water level.
6. Refer to Figure 4-2C. From level of forward end of tailcone (at lowest point)
to horizontal centerline of tail rotor gearbox (horizontal mounting bolts), the
distance should be 16.21 ± 0.20 inches. Adjust height of tailcone as
required. Use stand to hold tailcone in place.
7. Refer to Figure 4-2D. Place a straight edge across the forward face of
tailcone and measure gap between straight edge and forward face of the
steel tube mounting structure. Measurements should be taken as close as
possible to the four tailcone mounting points. Adjust tailcone as necessary
to obtain a minimum dimension of 0.10 inch. Recheck and adjust vertical
and lateral centering of tailcone as required.
b) Drilling the Tailcone:
I 1. Refer to Figure 4-2D. Prior to drilling, verify minimum 0.345 inch edge
distance from tailcone edge to hole edge.
2. Clamp tailcone over three of the mounting points to prevent its movement.
To prevent oversize holes, back drill (from inside of tailcone) four mounting
holes, using a center drill with a 0.250 inch diameter shank, then use a
0.250 inch diameter twist drill. After drilling each hole, secure tailcone to
frame with appropriate fasteners to prevent tailcone movement.
I
3. Match drill middle left-hand side tailcone mount from outside using frame tab
as drill guide. Protect steel tube structure inside tailcone from drill bit with
a piece of scrap sheet metal.
4. Deburr drilled holes in tailcone. Refer to Figure 4-2E and accompanying

"CAUTION" statement. Center 8288-1 or -2 doublers over each tailcone
mounting hole and flush with tailcone forward edge. Mark doublers from
inside tailcone for drilling 0.250 inch diameter hole.
5. Refer to Figure 4-2E. Drill 8288-1 or -2 doubler with a 0.250 inch diameter
twist drill at spot marked in step 4. Deburr hole and secure doubler to
tailcone with a NAS 1304-3 bolt. Drill through existing pilot holes in doubler
with a #30 drill bit and secure with clecos.
6. Refer to Figure 4-2E and its accompaying "CAUTION" statement. Remove

NAS 1304-3 bolts. Place 8288-3 doubler on top of 8288-1 or -2 and flush
with tailcone forward edge. Mark 8288-3 doubler from inside tailcone for
drilling 0.250 inch diameter hole. Drill 8288-3 doubler with 0.250 inch
diameter twist drill and deburr. Install 8288-3 doubler atop 8288-1 or -2
doubler and secure with NAS 1304-3 bolt. Drill through existing pilot holes
with a #30 drill bit.
Page 4.18 Change 19: 30 JUN 99

4.313 Tailcone Replacement (cont'd)
7. Remove doublers and deburr. Install doublers with clecos then rivet with
MS20470AD4 rivets trimmed to proper grip length.
8. Prime doubler installation with zinc chromate or epoxy primer then paint to
match tailcone.
9. Install tailcone per Section 4.312.
BOLTS INSERTED TO
SUPPORT LEVEL VIEW
LOOKING
FORWARD
FIGURE 4-2A TAILCONE LATERAL LEVELING
Change 15: 26 JUL 96 Page 4.19

- .--} ~r-------!.t-
r ~
X END OF
TAILCONE
FUSELAGE
FIGURE 4-28 LATERAL TAILCONE CENTERING
BOLT HOLES
TAILCONE ASSY.
{r------~---,---,...~~~<···
16.21 ± 0.20 INCH
-,~~========~-------------------------------------------~~TL.____
CLEAR PLASTIC TUBE
FILLED WITH WATER
-~~ /
FIGURE 4-2C HORIZONTAL LEVELING

TAILCONE
0.010 INCH MINIMUM
CLEARANCE (4 places) ·, I
""< /
~rz-~---L__-
....,:-.,
UPPER FRAME~ '··111"'' ··:
1
• FORWARD ,[ .l :
- ~,- -i --tt-1- - - - - - -
1- I
t! ~ 0. 250 INCH DIAMETER BOLT
0.345 INCH MINIMUM FROM , I~ INSERTED INTO FRAME BOSS
TAILCONE FORWARD EDGE TO j~'"~ _J, 'I FROM INSIDE
BOLT SHANK -~
/L....:--1_ __
FIGURE 4-2D
VERIFYING MINIMUM EDGE DISTANCE /~ 1~- MINIMUM 0.100 INCH

---0.345
INCH
B288-1 DOUBLER MIN.
II
(UPPER-RIGHT, LOWER-RIGHT, .--+-------- - - - --
*)'
AND LOWER-LEFT MOUNTING II
-$-
HOLES) II
* * // /
/
* I
1/
/
B288-2 DOUBLER
I (AT UPPER-AND MIDDLE-LEFT
I
\ MOUNTING HOLES)
FIGURE 4-2E
TAILCONE ATTACH HOLE EDGE DISTANCE
~
-$- *\"I
•* *",,
~ -$-~-(~
~~"'-.\ __* -- _*.~)
AND DOUBLER INSTALLATION
A023 TAILCONE~
A023-2 FRAME I I :: 8288-1 DOUBLER RIVET
(BULKHEAD) - - - - - . . - ' 1 1 ONLY
II CODE:
ICAUTION 1-------- -E7- MS20470AD4-5
POSITION DOUBLERS TO ENSURE MINIMUM 0.345 INCH
DIMENSION SHOWN. RIVET HOLES IN DOUBLERS MUST
NOT PIERCE RADIUS OF A023-2 FRAME UPON DRILLING.
*
-$- MS20470AD4-4. 5
MS20470AD4-4
Change 25: JUN 2006 4.21

4.314 Tailcone Repair - (Permissible in Bay 5 only)
1. Dent Bay 5 only- 0.100 inch to 0.250 inch deep 0.060 inch or greater radius,
not to exceed 5 inches long.
Above described dents may be repaired with 0.032 inch or 0.040 inch thick doubler
of same material using rivets as follows:
DENT AREA
DEPTH: 0.10 TO 0.25 in.
MAX LENGTH 5.0 in.
'")
{
0
0
0 · 25 :L:in. f 1.25 in. min. 0
0
<., 0
t~tooooo ~ 0
-/' 0
0
BAY 4 ° BAY 5 0 BAY 6

0
') 0 0
~, 0
( o EQUAL f
c.,-:>::_';.:-c:o.J-~S-P....,AI:7"CI_N_G __
-.-I 1-:1.47
0_.2_5'f:7i_n~-~-..,---
in. min. 0
- - EQUAL RIVET--- DOUBLER MATERIAL- 0.032 in. or 0.040 in. THICK

SPACING 2024-T3 CLAD ALUMINUM
RIVETS - NAS 1919B04S02, MS20600AD4

(0.125 in. DIA., 0.063/0.125 GRIP
OR EQUIVALENT)
FIGURE 4-2F TAILCONE REPAIR LIMIT

(approved for Bay 5 only)
4.320 Empennage Assembly
4. 321 Empennage Removal
1. Disconnect the navigation light wire at the quick disconnect.
2. Remove two attach bolts at tailcone casting and remove empennage

assembly.
4.22 Change 25: JUN 2006

4.322 Empennage Installation

a) Install empennage assembly onto bulkhead fitting.
b) Install NAS1304 bolts and torque to 100 in-lbs. plus

nut drag. Install palnuts and torque stripe.
4.323 Upper Stabilizer Replacement
a) Drill out the one rivet on the upper stabilizer at-

taching clip. Some ships use a #6 screw.
I
b) Remove (4) upper stabilizer attaching bolts.
c) Remove upper stabilizer.
d) Install new upper stabilizer to the horizontal sta-

bilizer. Slight trimming of the upper stabilizer may
be necessary on installation to avoid contact between
stabilizer skins. I
NOTE
If stabilizer is trimmed, a min-
imum edge distance of .140" to
the 3/32 D. rivets must be main-
tained.
I
e) Mark and drill the aft clip hole in the upper sta-
bilizer using a #30 drill bit for rivet or #27 drill
bit for #6 screw.
f) Attach upper stabilizer to aft clip using 1/8 D. rivet

or #6 screw, washer, and nut.
g) Torque the four (4) attach bolts to 60 in-lbs. plus

nut drag. Torque stripe attach bolts on stabilizer.
4.324 Lower Stabilizer Replacement
Follow procedure called out for the upper stabilizer

replacement in Section 4.323.
UPPER
STABILIZER NAS6603-2
I
NOTE or
No contact permitted HORIZONTAL \,1 NAS1303-2
BOLT
between stabilizer skins. STABILIZER I / AN960-10L
Torque attach bolts to

60 in-lbs. ----""-
NAS660J:5 ro~ CHANNEL--
WASHER
FIGURE 4-3 STABILIZER or Al30-51·

NAS1303-5 SPACERL J
I 1
INSTALLATION
BOLT~ \ -~ I-
P-D-· J I
II
·-IJ-cacl!
Change 11: 7 AUG 92 Page 4.23
4.325 Horizontal Stabilizer Replacement
I a) If prop protractor is used, helicopter will not have

to be leveled. If just a simple level is to be used,
the helicopter will need to be leveled laterally and
I longitudinally per Section 1.210.
b) Install empennage assembly onto bulkhead fitting.
c) Zero prop protractor or an accurate level on M.R. hub.
d) Using MT068 special tool along with a prop protractor

or level, check for correct angle of incidence required
by NOTE below:
NOTE
R22 Standard, HP, & Mariner
Horizontal stabilizer angle of incidence
with ship leveled, to be 1.8° to 2.3° nose
I up and requires A023-1 tailcone.
R22 Alpha & Beta

Horizontal stabilizer angle of incidence,
I with ship leveled, to be 2.8° to 3.3° nose
down and requires A023-20 tailcone.
I e) Verify horizontal stabilizer trailing edge level within

% degree.
f) Insert .250" bolt into the forward attach hole.
NOTE
Top holes of horizontal stabilizer attach
point are are predrilled. Bottom holes are
drilled on installation after setting angle
of incidence and stabilizer trailing edge
is level.
g) Push forward or pull aft slightly on the tail skid to

achieve the angle of incidence per note above.
h) While holding the stabilizer at the correct angle of in-

cidence, drill through the aft attach hole and the lower
horizontal stabilizer skin using .250 (\)inch drill bit.
i) Install the aft bolt and torque to 100 in-lbs. plus nut drag.
I j) Remove the forward bolt. Check the angle of incidence and

trailing edge level again per step d and e. Drill the for-
ward attach hole.
I k) Remove the stabilizer and deburr the holes. Reinstall the

stabilizer, torque the bolts to 100 in-lbs. plus nut drag.
install palnut.
Page 4.24 Change 11: 7 AUG 92

ROBINSON MAINTENANCE MANUAL MDDELR22
1. Level A/C laterally and longitudinally

at the M.R. hub if using simple level
(See Section 1.210). I
2. Horizontal stabilizer to
be level at trailing edge
within ~ degree.
..-
3. Horizontal stabilizer angle of incidence:

1.8 - 2.3 degrees nose up
(R22 Standard, HP, & Mariner)
2.8 - 3.3 degrees nose down MI'068 Tool
(R22 Alpha & Beta) (Angles are built into
Level or prop the MT068 tool, there-
protractor fore check top of tool
level)
·~____._, __ 3. 25"
3.75"
Tool should contact

stabilizer

CHAPTER 5
LANDING GEAR
Section Title Page
5.000 Landing Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1

5.001 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1
5.002 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1
5.100 Landing Gear Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2
5.110 Landing Gear Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2
5.120 Landing Gear Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2
5.200 Cross Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
5.210 Cross Tube Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
5.220 Cross Tube Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4
5.300 Skid Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4
5.310 Skid Tube Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4
5.320 Skid Tube Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4
5.330 Skid Shoe Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4
5.340 Ground Handling Wheel Support Removal and Replacement . . . . . . . . . . . 5.8
5.400 Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8
5.500 Float Ship Landing Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9
5.510 Float Landing Gear Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9
5.520 Float Landing Gear Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10
5.530 Float Tube Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11
5.540 Float Tube Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11
5.550 Float Tube Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.13
OCT 2018 Chapter 5 Landing Gear Page 5.i

Intentionally Blank
Page 5.ii Chapter 5 Landing Gear OCT 2018

CHAPTER 5
LANDING GEAR
5.000 Landing Gear
5.001 Introduction
This section covers removal and reinstallation of the landing gear assembly, cross tubes,
skid tubes, skid shoes, and ground handling wheel supports.
5.002 Description
A 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 crosstube
yields (becomes permanently bent) to absorb the impact. Slight crosstube yielding is
acceptable. Replace forward crosstube when it contacts underlying cover. Yielding
which allows the tail skid to be within 34 inches (24 inches for R22 Standard or HP,
37 inches for Mariner) of the ground when the helicopter is sitting empty on level, hard
surface requires crosstube(s) replacement.
Abrasion-resistant wear shoes are mounted on the bottom of the skids. These shoes
should be inspected periodically, particularly if autorotation landings with ground contact
have been performed.
R22 Mariners have permanently inflated utility floats mounted to skid tubes and incorporate
aft skid extensions to support the floats.
OCT 2018 Chapter 5 Landing Gear Page 5.1

5.100 Landing Gear Assembly
5.110 Landing Gear Removal

1. Remove forward cross tube cover.
2. Jack or hoist helicopter per Chapter 17.
3. Disconnect A936 ground wire at aft-right elbow.
4. Remove four landing gear attach bolts. Slide landing gear clear of helicopter.
NOTE
If jacking helicopter using contour block under vertical firewall,
remove one skid tube to move landing gear clear of helicopter.
5.120 Landing Gear Installation

1. Jack or hoist helicopter per Chapter 17.
2. Lift landing gear one side at a time, install mounting bolts, and standard torque per §
23-32.
NOTE
All mounting bolts are installed from aft side. Ensure large
diameter washers are installed on both sides of strut elbows.
3. Attach ground wire to aft-right elbow lower bolt, standard torque per § 23-32, and
torque stripe per Figure 2-1.
4. Install palnuts, standard torque per § 23-32, and torque stripe per Figure 2-1.
Page 5.2 Chapter 5 Landing Gear OCT 2018

5.200 Cross Tubes
5.210 Cross Tube Removal

Replace cross tube(s) if yielding results in tail skid-to-level ground dimension of less than
24 inches for a Standard or HP, 34 inches for an Alpha/Beta/Beta II, or 37 inches for a
Mariner/Mariner II with float stabilizer installed.
NOTE
See § 2.550 for hard landing inspection criteria.
1. Remove landing gear per § 5.110.

2. Using a soft brass or aluminum drift, carefully tap out spacers securing cross tube in
strut elbow and tap elbows off cross tube.
3. If difficulty is encountered removing strut elbow from cross tube:
a. Install spacer securing opposite strut elbow to cross tube.
b. Disconnect stuck strut assembly from skid tube.
c. Place a rigid support under cross tube.
d. Using strut on stuck elbow as handle, rotate elbow on cross tube to break paint
bond.
e. Remove spacer installed in step a. and remove cross tube.

5.220 Cross Tube Installation
1. Install cross tube in upper strut elbow. Place a wooden block against end of cross
tube and tap as necessary to align mounting hole in cross tube with hole in elbow.
2. Install spacers by tapping them through elbows and cross tubes with a soft face
hammer.
5.300 Skid Tubes
5.310 Skid Tube Removal

Replace skid tubes worn beyond 0.030-inch maximum depth (no length limit) longitudinal
scratch, 0.030-inch maximum depth and 0.50-inch maximum length circumferential
scratch, or 0.50-inch maximum width flat spot.
1. Raise one side of helicopter by jacking under one end of the aft cross tube, one inch
inboard of fitting.
2. Remove 4 bolts at each landing gear strut. Remove skid tube.
5.320 Skid Tube Installation

Place skid tube under fore and aft gear struts and install attach bolts. Standard torque
attach bolts per § 23-32 (self-locking nutplate installed inside skid tube).
5.330 Skid Shoe Removal and Replacement
NOTE
Replace A667-5 and -6 skid shoes less than 0.050 inch thick.
1. Install ground handling wheels.

2. Push down on tail and place a wooden block approximately 4 inches ahead of
intermediate skid shoes. (See Figure 5-3.)
3. Remove bolts attaching forward and intermediate shoes to skids. Discard worn shoes
and screws.
4. Install new skid shoes and screws. Standard torque screws per § 23-32.
NOTE
Some early R22’s had forward skid shoes attached using
aluminum blind rivets (MS20600AD6-4). These can be removed
by drilling off head and punching out shank.

Intentionally Blank

Intentionally Blank

4-6 INCH
WOODEN BLOCK
....__ _ FORWARD AND INTERMEDIATE SKID SHOES
CAUTION:
READ TEXT
FOR INSTRUCTIONS
AFT SKID SHOES
FIGURE 5-3 SKID SHOE REPLACEMENT

5.330 Removal and Replacement of Skid Shoes (cont'd)

e) Tilt the helicopter until the tail skid touches the
ground. Place a 4-6 inch wooden block as far aft' as
possible under each skid tube. (See Figure 5-3).
f) Press down on each skid tip or lift on the tailcone
until the helicopter tips forward. Ballast each skid
at the tip with approximately 25 pounds, or place a
support under the tail skid.
g) Remove and replace the skid shoes per Steps c) and d)
above.
5.340 Removal and Replacement of Ground Handling Wheel Support
a) Remove the two attach bolts and pull the support free of
the skid.
b) Align the mounting holes of the support with the holes
in skid tube. Install the mounting bolts and torque to
50 in.-lb plus nut drag.
5. 400 PREVENTIVE MAINTENANCE
1. Ensure drain holes in bottoms of skid tubes are not plugged
(two per skid), located just aft of forward two skid shoes.
2. Tou~h up skid tubes, cross tubes and struts to prevent cor-
ros~on. Use paints and primers obtained from approved ma-
terials list per Section 1.400.
3. Daily or preflight inspection of skid shoes (Rotorcraft
heavy usage).
4. Install lost or loose raincaps with structural adhesive per
the manufacturer's instructions. (See approved materials
list, Section 1.400).
Page 5.8 Change 6: 28 JUL 89

5.500 FLOAT SHIP LANDING GEAR

The Robinson R22 Mariner Helicopter may be flown with or with-
out the float landing gear installed. If the floats are to be
removed from the helicopter, it is necessary for a complete
standard landing gear to be installed. Do not remove the float
tubes from the landing gear skid tubes.
ICAUTION t
Float landing gear can only be in-
stalled on R22 Mariner helicopters.
Mariner helicopters have a "M" suf-
fix after the helicopter serial num-
ber stamped on the aircraft data
plate.
5.510 Float Landing Gear Removal

a) Remove the complete float landing gear. Refer to
Section 5.110 for landing gear removal.
b) Install a complete standard landing gear. Refer to
5.120 for landing gear installation.
c) Remove the float stabilizer on the lower vertical
fin of the empennage. Install the standard skid
tube and torque the bolts to 30 inch-pounds.
d) Calculate the Weight and Balance using the following
information and enter it into the aircraft records.
Part No. Description Weight CG Arm Moment

(lb) (in) (in-lb)
A034-1 Landing Gear with +62.9 94.6 +59 50
Floats
A014-1 Landing Gear without -32.5 85.5 -2779
Floats
A970 & Float Stabilizer + 0.6 270 + 162

A971 on Lower Tail Fin
A470-1 Standard Tail Skid - 0.2 272.5 - 54

5.510 Float Landing Gear Removal (cont'd)
e) Review the flight limitations of the R22 Mariner

without floats installed in the Mariner Supplement
9-4 of the Pilot's Operating Handbook.
f) Complete a Pre-flight Inspection and Run-up per the

Pilot's Operating Handbook.
g) Complete a Flight Check per Section 2.220.
h) Check and adjust the autorotation RPM per Section

10.250 (It will usually require lengthening the
pitch links approximately% to 1 full turn).
5.520 Float Gear Installation
a) Remove the standard landing gear. Refer to Section

5.110 for landing gear removal.
b) Install the complete float landing gear with float

tubes attached to the skid tubes. Refer to Section
5.120 for landing gear installation. Use existing
landing gear hardware to install the float landing
gear except for the palnuts which must be replaced.
c) Remove the lower vertical fin skid tube on the

ernmpenage.

5.520 Float Gear Installation (cont'd)
d) Install the float stabilizer in place of the skid tube

and torque the bolts to 30 in-lbs.
e) Calculate the new helicopter Weight and Balance using

the information given above and enter the change into
the aircraft records.
f) Check and adjust the autorotation RPM per Section

10.250 (It will usually require shortening the
pitch links approximately ~ to 1 full turn).
g) For float pressure information See Pilot's Operating

Handbook Mariner Supplement page 9-4 Section 2.
5.530 Float Tube Removal
a) Untie and remove the lacings at each landing gear strut.

Unbuckle the restraint belts.
b) Remove the bolts and nuts that attach the float tube
to the skid tube and skid extension.
NOTE
The bolts and nuts are sealed in
place and may be difficult to re-
move.
c) Remove the retainer strips from the girts. Carefully sep-

arate the girt from the skid tube extension.
NOTE
Sealant is installed between the
girt and the skid tube at each
bolt hole.
5.540 Float Tube Installation
NOTE
Remove the old sealant from the
skid tube, float tubes and re-
usable hardware before instal-
lation of the float tubes.
a) Position the float tube over the landing gear skid tube
and extension. Align the holes in the girt of the float
tube and the skid tube.

ROBINSON MAINTENANCE MANUAL MCDELR22
COVER ENTIRE BOLT HEAD WITH

B270-1 SEALANT (8 places) INBOARD >
A944-1, -2, -3, -4 STRIP
(LH or RH) tI
GIRT
/
SKID TUBE
ASSEMBLY A949-1, -2, -3, -4 STRIP
(LH or RH)
*BOLT LENGTH AND/OR WASHER THICKNESS MAY BE
VARIED AS HEQUIRED TO MAINTAIN 2-4 THREADS.
SHOWING BEYOND NUTS. SEAL UNDER HEAD AND \
NUT AND AROUND BOLT BETWEEN GIRTS AND SKID:
·TUBE WITH B270-1 SEALANT.
FIGURE 5-4 FLOAT TUBE ATTACHMENT

(LEFT SIDE SHOWN, VIEW LOOKING FORWARD)
TUCK EXCESS BELT

INTO POCKET TO
MINIMIZE FLAILING
IN FLIGHT.
TUCK IN EXCESS CORD

TO MINIMIZE FLAILING
IN FLIGHT.
FIGURE 5-5 RESTRAINT BELT INSTALLATION FIGURE 5-6 LACING INSTALLATION
Page 5.12 Change 21: JUN 2000

5.540 Float Tube Installation (cont'd)
b) Place the retainer strips in their proper positions.

Temporarily install NAS6604-32 or NAS1304-32 bolts to
hold the retainer strips and girts in place.
c) Complete one girt section at a time. Using 890-B2
sealant, thoroughly seal all around the bolt holes
between the girt and skid tube.
d) Install the correct length bolts in their proper positions
and seal under the bolt heads and nuts. Torque all the
NAS6604 or NAS1304 bolt to 100 inch-pounds plus nut drag.
e) After completing one girt section, move on to the next one
and repeat the process. Prime all exposed bolts and
nuts then paint black.
f) Lace the float tube to the landing gear strut using a
crossing pattern. Slide the restraint straps through
the outside pockets. Wrap the restraint belt under
the float tube making sure it passes over the skid
tube. Make one wrap around the landing gear strut.
Slide the strap through the pocket and into the
buckle. Pull tight and tuck the excess strap material
into the pocket.
g) Slowly inflate the float tube to its proper operating
pressure.
ICAUTION I
When inflating chambers individually
(without the use of a manifold), in-
crease pressure in each chamber in
.5 psig increments.
5.550 Float Tube Reoair

For float repair procedures refer to instructions included with
the Float Repair Kit.
Change 6: 28 JUL 89
Page 5.13
CHAPTER 6
POWERPLANT
Section Title Page
6.000 Powerplant And Related Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1

6.001 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1
6.002 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1
6.100 Powerplant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
6.110 Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
6.120 Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
6.130 Engine Shimming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6
6.200 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.9
6.210 Fanwheel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.9
6.220 Fanwheel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.12
6.230 (Reserved)
6.240 Balancing Fanwheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.13
6.250 Cooling Scroll Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.16A
6.300 Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.18
6.310 Oil Cooler Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.18
6.320 Oil Cooler Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.18
6.400 Induction System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.18
6.410 Carburetor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.18
6.420 Air Box Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.19
6.430 Air Box Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.19
6.435 Air Filter Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.21
6.440 Carburetor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.21
6.450 Carburetor Heat Scoop Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.22
6.460 Carburetor Heat Scoop Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.22
6.500 Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.22
6.510 Exhaust System Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.22
6.520 Exhaust System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.22
6.600 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.23
6.610 Low-Power Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.23
6.700 Throttle Control And Carburetor Heat Assist . . . . . . . . . . . . . . . . . . . . . . . . 6.25
6.710 Overtravel Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.25
6.711 Overtravel Spring Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.25
6.712 Overtravel Spring Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.25
6.720 (Reserved)
OCT 2014 Chapter 6 Powerplant Page 6.i

CHAPTER 6
POWERPLANT (Continued)
Section Title Page
6.730 Throttle Push-Pull Tube Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.26

6.731 Throttle Push-Pull Tube Assembly Removal . . . . . . . . . . . . . . . . . . . . . 6.26
6.732 Throttle Push-Pull Tube Assembly Installation . . . . . . . . . . . . . . . . . . . 6.26
6.740 Carburetor Heat Assist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.26
6.741 Carburetor Heat Control Cable Removal . . . . . . . . . . . . . . . . . . . . . . . 6.26
6.742 Carburetor Heat Control Cable Installation . . . . . . . . . . . . . . . . . . . . . 6.27
6.743 D334-5 Carburetor Heat Assist Bellcrank Removal . . . . . . . . . . . . . . . . 6.27
6.744 D334-5 Carburetor Heat Assist Bellcrank Installation . . . . . . . . . . . . . . 6.27
6.745 D334-5 Bellcrank Friction Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 6.29
Page 6.ii Chapter 6 Powerplant OCT 2014

CHAPTER 6
POWERPLANT
6.000 Powerplant and Related Systems
6.001 Introduction
This section includes instructions for removal and installation of engine and support
systems. Support systems include induction, cooling and exhaust systems. Refer to
engine and engine component manufacturer’s maintenance publications for product
specific inspection, repair, and maintenance procedures.
6.002 Description
R22-series helicopters are powered by one of four different Lycoming engines. O-320-
A2B or O-320-A2C engines are installed in standard model R22s and are normally rated
at 150 horsepower. O-320-B2C engines are installed in R22 HP, R22 Alpha, and R22
Beta models and are normally rated at 160 horsepower. Beta II/Mariner II helicopters
have an O-360-J2A engine capable of 180 horsepower, derated by Lycoming to 145
horsepower. All engines are derated to 124 maximum continuous horsepower (MCP) by
limitation of manifold pressure and RPM. Beta, Mariner, and Beta II/Mariner II helicopters
have a 5-minute takeoff rating of 131 HP (see Pilot’s Operating Handbook). Starting
assist for O-320-A2B engines is provided by an impulse coupling installed on the engine-
left (helicopter-right) magneto. Starting assist for O-320-A2C, O-320-B2C, and O-360-
J2A engines is provided by a starter vibrator system and retard points in the engine-left
magneto. Tachometer points in the engine-right magneto supply engine RPM information
to the governor controller and engine tachometer. At 104% engine tachometer indication
the engine is turning 2652 RPM.
Induction is through an air filter located in a carburetor-mounted air box assembly.

Carburetor heat is supplied by an exhaust-pipe-mounted scoop and duct. Carburetor heat
is controlled through a cable-operated guillotine valve in air box. Carburetor inlet air is
filtered, even with carburetor heat on. Provision for an obstructed air filter is provided
by a spring loaded bypass valve mounted on the air box cover, or by air box flexing. On
Beta II/Mariner II aircraft, application of carburetor heat is correlated with changes in
collective setting through a friction clutch to reduce pilot work load. Lowering collective
mechanically adds carburetor heat and raising collective reduces carburetor heat. The
pilot may override the friction clutch and increase or decrease carburetor heat as desired.
A latch is provided at the carburetor heat control knob to lock carburetor heat off when
not required.
Cooling is supplied by an engine-mounted fanwheel enclosed by a fiberglass scroll. The

scroll ducts cooling air to engine-mounted panels which in turn direct air to cylinders,
external oil cooler, alternator, and main rotor gearbox.
Power is transmitted through a vertically mounted sheave-and-belt system which is

engaged by an electric belt tension actuator.
Battery charging and electrical power is supplied by 60-amp belt-driven alternator. A 70-
amp alternator is optional.
OCT 2014 Chapter 6 Powerplant Page 6.1

6.100 Powerplant
NOTE
Refer to engine and engine component manufacturer mainte-
nance publications for product specific inspection, repair, and
maintenance procedures.
6.110 Engine Removal
NOTE
If engine is to be removed to facilitate a lower frame replacement,
engine mount change, or firewall repair, fanwheel can remain
installed. However, if engine is to be disassembled, remove
fanwheel per § 6.210.
1. Disconnect static line from and remove aft cowling, tailcone fairing, B429-5 frame.
NOTE
If aux tank installed, defuel helicopter. Remove aux tank.
2. Disconnect main rotor gearbox cooling duct and remove horizontal firewall access
panel (aft right-hand).
3. Remove clutch assembly per § 7.210.
4. Remove side skirts. Turn off fuel selector valve and disconnect fuel hose at carburetor.
Cap fuel hose and carburetor inlet port.
5. Disconnect carburetor throttle linkage at carburetor bellcrank, mixture control cable

at carburetor, carburetor heat control at air box, and carburetor air temperature probe
at quick-disconnect, located approximately four inches from probe in a heat shrink
sleeve. Remove carburetor and air box assembly.
NOTE
Air box and carburetor may be removed as a unit.
6. Disconnect oil pressure hose from elbow on accessory housing and cap exposed
connections.
7. Disconnect manifold pressure line from forward, left cylinder fitting and clamp and cap
exposed connections.
8. Identify for reinstallation and disconnect engine ground straps, alternator leads,
starter leads, oil pressure line, cylinder head temperature lead, and oil temperature
lead. Disconnect all clamps attaching wiring to steel tubular frames. Disconnect belt
tension actuator motor leads.
9. Disconnect cabin heater duct, if installed (optional equipment).
10. Disconnect primer line, if installed (optional equipment).
Page 6.2 Chapter 6 Powerplant OCT 2014

6.110 Engine Removal (cant' d)
HOIST
PROTECTIVE PADDING
1/r/
PROTECTIVE
;---
PROTECTIVE PADDING
DIRECTION OF
ENGINE REMOVAL
FIGURE 6-1 POWERPLANT REMOVAL
Change 26: APR 2007 6.3

6.110 Engine Removal (cont'd)
11. Install protective padding per Figure 6-1.
1 2. Connect MTO 1 6-1 /Jeff fitting to a minimum 500-pound capacity hoist and to
engine lifting lug per Figure 6-1. Take up any slack in chain or cable of hoist.
Engine mounting pads have shims placed between pads and engine mounts
for proper engine alignment. Note shim stack for each mount and record for
reinstallation.
13. Remove four engine mounting bolts. This will require removal of right-side (engine
-left) spark plug access cover.
14. Place a support stand under tail skid or remove tailcone.
1 5. Remove tubular steel strut at right rear corner of steel tube structure. With a
person on each side of engine, carefully remove engine. Vary height of engine as
required to clear aft cross tube during removal. Swing engine clear of helicopter.
Refer to Figure 6-1 .
6. 120 Engine Installation
a) Connect MT016-1 /Jeff fitting to a m1n1mum 500-pound capacity hoist and to

engine lifting lug per Figure 6-1. Carefully hoist engine and swing it into alignment
with engine mounting pads.
b) Select appropriate shims as recorded during engine removal. If no record is

available, install a 0.063-inch thick shim between both lower mounting pads
and engine and install a 0.190-inch thick shim between both upper mounting
pads and engine. Install engine mounting bolts, torque per Section 1.320. Torque
stripe per Figure 2-1. Install right rear tubular strut per Section 4. 222 h).
WARNING
Damage or failure of drive line components may result from

incorrect engine shimming.
c) Disconnect engine hoist, install horizontal firewall, right-hand spark plug access
panel, and aft cowling. Reconnect main rotor gearbox cooling duct.
d) Install carburetor using a new gasket and torque nuts per Section 1 .330. Install
palnuts, torque per Section 1 . 320, and torque stripe per Figure 2-1 .
6.4 Change 26: APR 2007

6. 1 20 Engine Installation {cont' d)
e) Reconnect throttle linkage to middle position of carburetor bellcrank. Refer to

Section 10.1 50 for throttle rigging. Reconnect mixture control and carburetor heat
control and rig these controls for 1 /16" spring back at each end of the control travel
{See Section 1 0 for rigging of throttle).
f) Reconnect engine grounding strap and torque engine oil sump bolts per Section
1.330. Connect oil line to oil pressure sender. Connect manifold pressure line to
engine and firewall connections.
g) Reconnect all electrical leads to oil temperature sender, cylinder head temperature
sender, alternator, magnetos, etc.
h) Install cabin heater ducting and all wire and oil line clamp connections.
i) Connect fuel line to carburetor and inspect engine compartment for proper installation
of all electrical connections, control attachment, ducting and routing.
j) Reinstall clutch assembly. {See Section 7. 200).
k) Reinstall engine access panels, compartment panels and aft cowling.
I) Before running engine, check following components for proper alignment:
1) Sheave alignment per Section 7 .230.
2) Tail rotor drive shaft shimming per Section 7 .330.
3) Cooling shroud-to-tailcone clearance 0.250 inch minimum.
4) Intermediate flex plate to tail rotor bellcrank clearance 0.250 inch minimum
with belts over 10 hours, 0.125 inch minimum with new belts.
5) Clutch shaft angle per Section 7.240.
6) Upper sheave centering per Section 7. 250.
NOTE
Fill engine to proper oil level.
Corrected
Change 25: JUN 2006 6.5
6.130 Engine Shimming
To facilitate sheave proper alignment, the engine must be shimmed to 3.55/3.65

inches, measured between ring gear top and bottom of upper frame's long cross tube
with clutch engaged.
1. Engage clutch.
2. Measure ring gear-to-upper frame cross tube dimension as shown in Figure 6-2. If
dimension exceeds 3.65 inches, an equal amount of shims must be added between
lower frames and both the lower-left and the lower-right engine rubber mount pads.
Use following formula to calculate required maximum shim thickness:
(Measured ring gear-to-upper frame dimension) - 3. 55 Calculated

2 shim thickness
Select shim(s) as required up to, but not exceeding, calculated shim thickness.
Shims are available in thicknesses of 0.032 inch, 0.063 inch, and 0.190 inch.
Removing an equal amount of shims from between both lower frames and the
lower-left and the lower-right engine rubber mount pads will increase ring gear-to-
upper frame cross tube dimension.
3. Disengage clutch
4. Remove side skirts.
5. Loosen upper-left and lower-left engine mount bolts. Leaving right engine mounts
torqued, install selected shim(s) between lower-left frame and lower-left engine
mount pad. Slotted shims, if used, may be stacked together but must be installed
between unslotted shims and safetied. See Figure 6-2A.
6. Torque engine-mount bolts per Section 1.320.
7. Remove right-side spark plug inspection panel. Loosen upper-right and lower-right
engine mount bolts. Leaving left engine mounts torqued, install selected shim(s)
between lower-right frame and lower-right engine mount pad.
8. Torque engine-mount bolts per Section 1 .320.
9. Engage clutch. Verify ring gear-to-upper frame cross tube dimension as shown in
Figure 6-2. Adjust as required.
10. Torque stripe nuts per Figure 2-1.
6.6 Change 25: JUN 2006

SHIM WASHERS
(Minimum one A141-25 adjacent A141-12 WASHER
to rubber mount) (1 Req d)1
MOUNT BOLT ~WASHERS AS REQUIRED

TO MAINTAIN 2-4 THREADS
PROTRUDING FROM NUT.
RUBBER
MOUNT PADS
SPACER
ADD SHIM WASHERS A141-12(0.190 inch), A141-24(0.032 inch), A141-25(0.063 inch)

AS REQUIRED TO SHIM ENGINE.
6-inch SCALE A020-2

UPPER FRAME
--, 3.55 - 3.65

inches
As an alternative to a scale,
locally fabricate a go/no-go
gage from rigid sheet metal.
Gage should measure 3.55 x 3.65
inches with a 2-inch diameter
hole in the center.
-, T -rr o
~ I I
I \ \ I ~
\ \. \ \ ,tl ,
I )..I' ........ '-..'\JI.. I\ ' I ,_
I '--. - _, --
~ -/I
/
FIGURE 6-2 ENGINE INSTALLATION
Change 24: APR 2005 Page 6. 7

B155-1 SHIM MUST BE

INSTALLED BETWEEN
TWO A141 SHIMS
I B155-1 SHIM (0.032 in.) A141

SHIM~
I MINIMUM A141-12 OR
4 -1 2 5 SHIM ADJACENT
TO RUBBER MOUNT
·--
J[
-------
~-
---
I INSTALL COTTER PIN OR SAFETY WIRE

AFTER INSTALLATION
FIGURE 6-2A 8155-1 ENGINE SHIM
NOTE
Engine mounting shims added or subtracted at two bottom

engine mounts will change engine ring-gear-to-frame dimension
by approximately twice the thickness of engine mount shim.
Example: Adding a 0.032-inch thick shim at each bottom engine
I mount will raise rear of engine approximately 0.064

inch.

6.130 Engine Shimming (continued)
NOTE
AN6- engine mount bolts are obsolete and must be replaced with
NAS1306- or NAS6606- series bolts when shimming engine.
11. Check clutch sheave alignment per § 7.230.

12. Reinstall engine inspection covers and side skirts.
13. Adjust throttle correlation rigging per § 10.150.
6.200 Cooling System
6.210 Fanwheel Removal
CAUTION
Do not engage actuator without scroll installed.
NOTE
If same fanwheel is to be reinstalled then orient starter ring gear
support to magneto timing position and mark fanwheel at split
line of scroll; this will minimize need for new balance weights.
See Figure 6-3B.
a) Remove fiberglass scroll-to-engine cooling panel perimeter screws and two bolts
attaching lower scroll to lower actuator bearing block. Scroll lower half may be
removed from scroll upper half at this time if desired.
b) Remove safety wire and roll pin from fanwheel retaining nut. Refer to Figure 6-3B.
Secure MT091-1 engine ring gear holding tool to ring gear support and hold ring gear
stationary. Remove fanwheel retaining nut.
CAUTION
Failure to secure MT091-1 tool to ring gear support may result
in damage to support.

FIGURE 6-3A FAN HUB ACCESS AND LOWER BEARING BRACKET ALIGNMENT
FIGURE 6-3B PULLING FANWHEEL

--- - - - - \
1_
MT092 FAN PULLER
MT091 RING GEAR HOLDER
FIGURE 6-3C FANWHEEL AND SCROLL REMOVAL

6.210 Fanwheel Removal (cont'd)
c) Refer to Figure 6-3A. Using an open-end wrench to hold bolt heads, remove every
other nut on center hub bolts and replace them with MT092-3 spacer nuts.
d) See Figure 6-38. Ensure MT092-1 fan wheel puller tool's large center bolt is
unscrewed sufficiently so it will not contact fan shaft. Attach fanwheel puller to
MT092-3 spacer nuts.
e) While holding ring gear stationary with MT091-1 tool, tighten fan wheel puller tool's
large center bolt against fan shaft until fan wheel hub is unseated.
CAUTION
Support fanwheel assembly to prevent dropping it.

Fanwheel may come off tapered shaft suddenly and
with a loud noise.
f) Remove MT092 fanwheel puller and install fan hub nuts on fan hub bolts. Torque
nuts per Section 1 .330.
6.220 Fanwheel Installation
CAUTION
Beta 11/Mariner II helicopters must use B 1 7 4-1 Rev F

( 1 2 NAS6603-6 cone-to-fanwheel attach bolts) or
subsequent fan wheels and A007-5 ( 1 11/16 inch
nut) or subsequent shaft assemblies.
I a) Clean tapered shaft and fanwheel hub with solvent. Verify no damage to shaft and
hub. Thoroughly inspect A 181 bearing; verify no roughness or dryness.
b) Place upper half of fiberglass cooling scroll on fanwheel and install fanwheel on
tapered shaft.
NOTE
Upper half of cooling scroll must be installed with

fanwheel as it will not clear tailcone or upper frame
with fanwheel installed first.
NOTE
If installing original fanwheel ensure starter ring gear

support is at magneto timing position and orient
fanwheel to align with marks noted in Section
6.21 O(a).
c) Coat threaded portion of tapered shaft and castellated nut face with A257-9 anti-
seize compound (thread lubricant). For A007-5 fan shaft, install MS20002 washer
against hub. Install AN960-series washers and nut. Exercise care so no lubricant
gets on tapered shaft.

6.220 Fanwheel Installation (cont'd)
d) Secure MT091-1 ring gear holding tool to ring gear support and hold ring gear
stationary. Torque nut per Section 1 .330 until roll pin can be installed in fan
shaft. Safety roll pin with 0.041 inch diameter stainless steel wire (number of
AN960-series washers may be adjusted to facilitate roll pin installation).
CAUTION
Failure to secure MT091-1 tool to ring gear

support may result in damage to support.
e) Install lower cooling scroll half (if removed) and insert two long bolts through
lower bracket and actuator bearing block until they enter upper bracket nut
plates. Align upper bracket nutplate by inserting screw driver in bracket notch
(see Figure 6-3A). Torque bolts per Section 1 .320.
NOTE
When replacing Revision I and prior fanwheels

with Revision J and subsequent fanwheels
(ref Figure 6-48), relocate 0339-4 cover to
coincide with different fanwheel bolt pattern
using Kl-1 24 Kit.
f) Install screws, nuts and washers around perimeter. Torque nuts to 15 in.-lb plus
nut drag.
g) Refer to Figure 2-9. Mark fanwheel with torque seal directly opposite each end
of fanwheel nut roll pin to allow detection of movement between fanwheel and
fan shaft.
h) Check 8229 lip to fan wheel inlet clearance per Figure 6-5C. If necessary, lip
clearance may be adjusted by elongating lip mounting holes.
i) Dynamic balance per Section 6.240 is required after fanwheel installation.
6. 230 Reserved
6.240 Balancing Fanwheel
NOTE
The following instructions pertain to Chadwick-

Helmuth Model 8350 and 177-series (Vibrex)
equipment. When using Chadwick-Helmuth Model
192- or 8500- series, MicroVib or equivalent
balancing equipment consult the equipment's
specific operating instructions.
Change 16: 19 SEP 97 Page 6.13

6.240 Balancing Fanwheel (cont'd)
a) Install accelerometer on lower actuator bearing left bolt per Figure 6-4A.
Accelerometer wire should be pointed down. A suitable bracket may be
assembled from two accelerometer brackets or may be fabricated.
b) Place 4270 target tape at one fan vane edge per Figure 6-4A.
c) Set Strobex mode to position B. Set Balancer RPM range to X 10 scale. Set the
Balancer RPM dial to 265.
d) Start engine and run helicopter at 104% with rotor system engaged.
WARNING
Use extreme care near tail rotor.
e) Point Strobex at fan wheel nut and pull trigger. Note target tape clock angle
(position).
f) Push Tune button on Balancer. Note change (if any) in target tape clock angle.
While pushing Tune button, adjust RPM dial to bring target tape back to clock
angle viewed in Step e). Release Tune button.
g) Repeat steps e) and f) as required until there is no change in target tape clock
angle when Tune Button is pushed and released (i.e. Balancer is tuned).
h) Note target tape clock angle after Balancer is tuned.
i) Note vibration reading on Balancer IPS meter.
j) Shut down engine.
k) If IPS exceeds 0.2, balance weights must be changed. Rotate fanwheel until
target tape is in position noted in step h). Increase balance weight by changing
washers under nut closest to 1 :00 position or by splitting required weight change
among two nearest nuts per Figure 6-4B. Alternatively, weight may be decreased
under nut closest to 7:00 position. Total washers under each nut must result in
two-four threads protruding past nut to ensure proper clamp-up. Access balance
weight bolt heads thru hole under 0229-4 cover (if installed; cover may be
retrofitted using P/N Kl-111 Kit) on forward side of lower scroll or thru oil cooler
access door (with a crowfoot on a flex handle) and rotating fanwheel as required.
Ensure NAS 1149F0316P washers (if installed, see Figure 6-5) are not dislodged
if NAS6603-6 bolts are removed. Torque NAS6603 bolts per Section 1.330.
Install 0229-4 cover.
I) Recheck fanwheel balance and adjust as required to obtain less than 0.2 IPS.
m) Remove accelerometer.
Page 6.14 Change 16: 19 SEP 97

SECURE ALL CABLES

WITH DUCT TAPE
AlBl-4 r:---~~~
------
1
I '-' ,-,. I I
BEARING L-~=-..b'b
I
ASSEMBLY : ::'-',
l : ',-~
I I
,.- - ..... ,
I I
I I I
., ' \
I I I \
I I I I
I I I I
I \
I
II ' ' ___ ., ., ,
I I
I I --
1 1,' '.
I I •,_J
I I
I
\------"
,- I
'I I
Al85-l
BRACKET
STROBE X
(USED INSTEAD
BALANCER OF PHOTOCELL)
FIGURE 6-4A EQUIPMENT INSTALLATION

ACCEROMETER/
VELOCIMETER
ADD WEIGHT BY INCREASING WASHER SIZE OPPOSITE ACCELEROMETER/ CABLE
ACCELEROMETER/VELOCIMETER. ALTERNATIVELY, RE- VELOCIMETER -;/
MOVE WEIGHT BY DECREASING WASHER SIZE ADJACENT SENSITIVITY AXIS f LIGHT
TO ACCELEROMETER/VELOCIMETER. DO NOT REMOVE 1 - - - - 1 SIDE
NAS6603-6 BOLTS.
AN960-10 WASHER = 0.05 IPS CHANGE
Al41-17 WASHER= 0.10 IPS CHANGE ,; ,,
AN970-3 WASHER = 0.20 IPS CHANGE ''
MIX ABOVE SIZES AS REQUIRED FOR BALANCE. /1 \ !' /
ENSURE 2-4 THREADS EXPOSED BEYOND NUT. ~~/r~{,
t ~ --' '--~
RADIUS R = 5.10 IN. ON REVISION

11 11
J AND SUBSEQUENT FANWHEELS;
\~'
~,',
j ~~~ l
~i;;;i)l~
R = 4.10 IN. ON REVISION 1
AND PRIOR FANWHEELS.
11 11
\\'W'O
' ,_1
I
L-~-_!____ J
-~~
~U1h
1
I
ROTATE FAN UNTIL TARGET

TAPE IS AT CLOCK ANGLE
~o
~ J
1/J
NOTED IN 6~240 (H) -"'-_------ ~:
II
.
............ #
----~ ~~~t· B174-1 FANWHEEL ASSY

FIGURE 6-48 FANWHEEL BALANCING I (LOOKING FORWARD)
I
HEAVY
Change 23: JAN 2005 SIDE Page 6.15
12
MINIMUM OF TWO WASHERS MUST
BE INSTALLED
\ ~'·
.
I I
2
\
11 14 11-P
1
I
\ t\ I
;·-D-D-tl
···- ___J
1f
I
I
I
23
NOTE
TORQUE ITEM #6 (BOLTS)
TO 300 IN-LBS
13
A__
NUMBER PART NO. DESCRIPTION NUMBER
---
PART NO. DESCRIPTION
1 Engine Flange 17 NAS679A08 Nut
I
2 Engine Ring Gear 18 8350-2 Spring Pin
3 A493-1 Lower Sheave 19 AN960-1616L (As req'd)Washer (For A007-3)
4 AN960-616L Washer AN960-1818L (As req 'd) Washer (For A007-5)
5 AN960-616 Washer 20 NAS679A3 Nut
6 NAS1306-24H Bolt 21 AN960-10 Washer
7 NAS1305-11 Bolt 22 NAS1303-3 Bolt
NAS1303-6*** Bolt (on 8174 Rev F
8 AN960-516L Washer and subsequent)
9 B174-1 Fanwheel Assy 23 A007-3 Shaft Assy
10 AN960-516 Washer A007-5 Shaft Assy (Must use in
Beta II and Mariner II)
11 NAS679A5 Nut 24 MS20002-18 Washer {For use with
12 A236-1 Scroll (Upper) A007-5)
13 A236-2* or 25 NAS1149F0316P*** Washer
A236-3** Sera 11 (Lower) 26 A187 Cone (Ref)
14 AN525-832R6 Screw
15 AN320-15 Nut (For use on A007-3) *Ship 0001 thru 0500
AN320-18 Nut (For use on A007-5) **Ship S/N 0500 and on
16 AN960-8L Washer ***Used on 8174-1 Rev "F" and
subsequent.
FIGURE 6-5 CENTRIFUGAL BLOWER INSTALLATION

6.250 Cooling Scroll Replacement
a) Remove the old scroll halves and actuator assembly, if installed.
b) Level the airframe laterally per Section 1.21 0. Assemble the A 185-1 bracket on the
bottom of the bearing housing with the A 185-2 on the upper left and the A 185-5
on the upper right. Use two AN 3-41 A bolts to secure the brackets (See Figure 6-
5A). Place a bubble level across the top surface of the lower actuator bearing.
Rotate the housing to level the bearing.
c) Place the upper scroll half (A236-1) and the engine cooling fan on the fanshaft. Do
not disturb the position of the lower actuator bearing. Finger tighten the fanshaft
nut. On Beta and Mariner ships with the larger oil coolers, the right-hand side of the
upper scroll sits on the oil cooler ledge. Adjust the upper half laterally to center the
lip of the fan and the edge of the inlet scoop, then clamp to the sheet metal
shrouds (See Figure 6-58).
d) Install the lower scroll half (A236-3) to the upper. Check the clearance between
the lip of the fan and the edge of the inlet scoop. The clearance should be
concentric all the way around the lip of the fan. Adjust both the halves as required
and clamp into position (See Figure 6-58).
e) Carefully mark the position of the lower actuator bearing and brackets on the scroll
halves. Mark the mounting holes on the scroll halves through the sheet metal
shrouds. Mark the top and sides of the scroll at the edge of the sheet metal
shrouds. Using a 90 degree angle drill, with a #18 drill bit, match drill as many
mounting holes as possible. Cleco clamp or install AN 525-832 sere ws to secure
the scroll as the holes are drilled. Match drill the two vertical mounting holes
through the oil cooler ledge.
f) Position the upper and lower 8229-2 lips at the inlet of the scroll. Adjust the
clearance to the edge of the cooling fan to 0.030-0.070 inch. Clamp into position
and match drill the lips to the scroll.
g) Remove the scroll and fan. Drill the remaining marked mounting holes, with a #18
drill bit. Assemble the A 185 brackets on the drill fixture. Position the brackets on
their alignment marks on the scroll. Drill through the brackets and scroll with a #40
drill bit. Position the reinforcing plates on the inside of the scroll. Enlarge the holes
in the brackets, scroll and reinforcing plates with a #30 drill bit. Disassemble and
de burr the holes. Reassemble and rivet the brackets and reinforcing plates using
MS20470AD4 rivets.
Change 11: 7 AUG 92 Page 6.16A

R 0 BIN soN MAINTENANCE MANUAL MODELR22
6.250 Cooling Scroll Replacement (cant 'd)
h) Position one NAS679A08 nutplate on upper scroll half at vertical mounting hole on
inboard right hand side. Drill and rivet nutplate in position with flush head rivets.
i) Trim top and side edges of scroll upper half parallel with sheet metal cool panel
flanges as required to maintain an edge distance of 0.01-0.02 inch
j) Trim upper scroll at lower actuator mounting bolt as necessary. No contact with
bolthead is permitted.
k) Epoxy prime and paint grey.
I) Install fanwheel per Section 6.220.
- - - - - - - - - - - - - - --.....
~ A236-4
LOWER SCROLL
I HALF
I
I
I
J
/
FIGURE 6-5A LOWER ACTUATOR BEARING INSTALLATION
(VIEW LOOKING AFT)

MATCH DRILL7
TO SHEET METAL MARK AND DRILL
SHROUD USING USING #18 BIT
#18 BIT.
FIGURE 6-58 COOLING SCROLL REPLACEMENT
Change 11: 7 AUG 92 Page 6.16C

I
~
-r'
MATCH DRILL THRU- ----- 1
FIBERGLASS 8 PLCS.
USING #18 BIT I
I
I
I
I Ill
I .l. Ill
I T Ill
---------~====~·===·~ol==~==============~~-------
1+111
I IJI
1 u'
I 11:
I 11 1
I II,
. ....
'"'
I
I
I I
I ,----------
A236-3 •- ..... J
LOWER SCROLL------~~
MOLDING
FIGURE 6-5C COOLING SCROLL REPLACEMENT

(FAN LIP POSITIONING)
Page 6 .16D Change 11: 7 AUG 92

A309
PANEL
ASSEMBLY (RH)
SCREW
FORWARD
OIL COOLER
DOUBLER
(4 Places)
SPACER
(4 Places)
'BOLT
90° ELBOW FITTING
90° ELBOW FITTING
OIL L I N E _ /
(Oil from engine)
FIGURE 6-6 OIL COOLER INSTALLATION
Change 26: APR 2007 6.17

6.300 LUBRICATION SYSTEM
NOTE
Refer to Pilot's Operating Handbook for grade and quantity of

oil required. Refer to the Textron-Lycoming Operator's Manual
for adjustment and maintenance of the lubrication system.
6.310 Oil Cooler Removal
1. Disconnect oil lines at cooler.
2. Remove four screws and nuts connecting support to panels.
3. Disconnect four mounting bolts and remove oil cooler and attached support. If
replacing cooler do NOT attempt to remove and transfer blue-anodized 90 degree
elbow fittings (steel fittings may be removed).
6.320 Oil Cooler Installation
NOTE
Seal elbows' pipe threads with 8270-6 sealant prior to installing

in oil cooler. Torque elbows per Section 1 .320.
CAUTION
Hold threaded fittings on oil cooler with wrench to react torque

when tightening elbows.
1. Install oil cooler and attached support to engine cooling panels using four mounting
bolts. Torque AN3 bolts per Section 1.320 and torque stripe per Figure 2-1.
2. Install four screws and nuts connecting support to cooling panels (See Figure
6-6).
3. Connect oil lines, torque nuts per Section 1 .330, and and torque stripe per Figure
2-1.
6.400 INDUCTION SYSTEM
6.410 Carburetor Removal
1. Disconnect air intake and carburetor heat hoses from air box.
2. Disconnect throttle linkage from carburetor bellcrank, mixture control cable from
carburetor and carburetor heat control cable from air box slider valve.
3. Disconnect carburetor air temperature probe wiring.
4. Remove palnuts and nuts securing carburetor to intake manifold and remove
carburetor and attached air box assembly.
6.18 Change 26: APR 2007

6.420 Air Box Removal
1 . Disconnect air intake hoses from air box.
2. Disconnect mixture control cable clamp(s) from air box.
3. Disconnect mixture safety spring from carburetor mixture control arm.
4. Open air box cover and remove air filter.
5. Disconnect carburetor heat control cable from air box and slider valve.
6. Cut safety wire and remove four bolts (or cap screws) securing air box to carburetor
and remove air box and rubber gasket.
6.430 Air Box Installation
1. With air inlets on right, install air box and rubber gasket on carburetor and secure
with bolts and washers (or cap screws and spacers on R22 S/Ns 25 71-2664 with
C057 air box). Torque fasteners per Section 1.330 and safety with 0.032 inch
diameter safety wire.
2. Connect mixture control safety spring to carburetor mixture control arm. Verify spring
moves arm to full rich position.
3. See Figure 6-7. Connect mixture control cable housing to air box. Push and pull on
cable housing and verify it does not slip in clamp(s).
4. See Figure 6-7. Connect mixture control cable inner wire to mixture control arm.
Verify mixture control moves carburetor mixture control arm stop to stop. Verify
0.03/0.10 inch clearance (spring-back) under knob at full-rich position. If required,
adjust position of inner wire in A462 fitting. Torque A462 fitting per Section 1 . 330.
Install palnut, torque per Section 1 .320, and torque stripe.
5. Connect carburetor heat control cable to air box. Connect carburetor heat control
cable inner wire to slider valve and torque A462 fitting per Section 1 .330. Verify
carburetor heat control fully opens and closes slider valve. Bend free end of inner
wire ninety degrees where it exits A462 fitting, then cut wire as required to leave
0.25/0.50 inch remaining. Install palnut, torque per Section 1 .320, and torque
stripe.
6. Install air filter, close cover, and secure. Tighten four long bolts only enough to
secure cover and eliminate looseness, then torque stripe. On R22 Mariners, seal air
box cover perimeter with aluminum tape. If installed, verify spring-loaded alternate
air door fully closes when released.
7. Connect air intake hoses to air box.
Change 26: APR 2007 6.19

FUEL INLET
AND
FUEL SCREEN
FIGURE 6-7 MIXTURE SAFETY SPRING INSTALLATION
6.20 Change 26: APR 2007

6.435 Air Filter Cleaning
NOTE
Replace B771-1 air filters after 5 years or 600 flight hours,

whichever occurs first.
1. Remove B771-1 air filter from airbox. Visually inspect filter and verify no obvious
damage. Inspect filter’s pleated media for cleanliness. If the media contains only
dust, clean media using compressed air or water. Clean heavily soiled media using
a mild soap & water solution.
a. Compressed air: Maintain at least one-inch distance between air nozzle and
pleated media and apply less than 40 psi compressed air thru media opposite
the normal direction of airflow.
b. Water: Apply less than 40 psi water stream thru media opposite the normal
direction of airflow. Dry filter thoroughly using less than 160°F warm air.
c. Mild soap & water solution: Apply less than 40 psi water stream thru media
opposite the normal direction of airflow. Soak filter in a mild soap and water
solution for more than 15 minutes but less than 4 hours. Gently agitate filter
in soap solution to help remove dirt. Apply less than 40 psi water stream thru
media in both directions. Dry filter thoroughly using less than 160°F warm air.
2. Using a bright light, examine pleated media and verify no holes or tears.
3. Verify filter sealing surfaces are a smooth, continuous circle and flat.
NOTE
Do not install a wet air filter. Do not apply oil to filter media.
4. Install filter in airbox.
6.440 Carburetor Installation
1. With carburetor butterfly bellcrank on left, install carburetor and new gasket on
mounting studs of engine sump and secure with washers and nuts. Special torque
nuts per § 1.330. Install palnuts, standard torque per § 1.320, and torque stripe.
2. Connect throttle push-pull tube to middle hole of carburetor butterfly bellcrank.

Standard torque bolt per § 1.320. Install palnut, torque per § 1.320, and torque
stripe.
3. See Figure 6-7. Connect mixture control cable inner wire to carburetor mixture control
arm. Lightly tighten A462 fitting, but do not torque; fitting will be torqued in following
step.
4. Install air box per § 6.430.
5. Verify idle RPM and idle mixture per § 2.210.
6. Check throttle correlation rigging per § 10.150.

6.450 Carburetor Heat Scoop Removal
1. Disconnect hose from carburetor heat scoop.
2. 0-320 engine: Remove six screws securing curved sheet metal and remove sheet.
0-360 engine: Remove two B277 clamps securing scoop assembly to exhaust
manifold and remove scoop.
3. 0-320 engine: Remove four bolts securing scoop assembly to bead clamp on exhaust
riser and remove scoop assembly. Remove additional clamp from
exhaust riser above bead clamp.
6.460 Carburetor Heat Scoop Installation
1. 0-320 engine: Install A694 clamp and angle on #4 cylinder exhaust riser and lightly
tighten. Attach scoop assembly on bead clamp and lightly tighten.
0-360 engine: Install scoop assembly, secure with B277 clamps, and lightly tighten.
2. Connect air inlet hose to scoop assembly.
3. 0-320 engine: Position sheet on mounts. Move A694 clamp and rotate bead clamp
(with attached scoop assembly) as required to minimize preload and
ensure clearance from surrounding structure. Tighten A694 clamp.
Standard torque bolts per § 1.320. Install sheet with six screws.
0-360 engine: Move scoop assembly as required to minimize preload and ensure
clearance with surrounding structure. Special torque scoop attach
clamps to 30 in.-lb.
6.500 Exhaust System
6.510 Exhaust System Removal
1. Remove carburetor heat hose and, if installed, disconnect heater hoses from muffler shroud.
2. Protect landing gear aft cross tube with suitable covering. Disconnect exhaust flanges
at cylinder heads and remove exhaust system and gaskets.
6.520 Exhaust System Installation
1. Position a gasket on each exhaust port.
2. Protect landing gear aft cross tube with suitable covering. Position exhaust system
on engine and connect riser exhaust flanges to cylinder heads with washers and nuts.
Remove protective cover from cross tube.
3. Loosen bead clamp on each riser. If required, remove curved metal sheet from carb
heat scoop assembly.
4. Special torque exhaust flange nuts per § 1.330. Install palnuts and standard torque
per § 1.320.
5. Install carburetor heat hose and connect heater hoses, if installed.
6. Standard torque bead clamp AN3 bolts per § 1.320. If removed, install curved metal
sheet on carburetor heat scoop assembly and reposition clamps as required to minimize
preload and ensure clearance from surrounding structure.
6.610 LOW-POWER CHECKLIST
When low engine power output is suspected, use the following checklist to verify:
1. Aircraft gross weight is not exceeded. Weigh aircraft if it was not weighed at last
overhaul.
2. Engine oil pressure, oil temperature, and CHT are within limits.
3. MAP gage indicates ambient pressure (engine off).
4. Proper grade of fuel per Pilot's Operating Handbook.
5. Main rotor blades are clean and smooth (no rough paint).
6. Exhaust is unobstructed.
7. Main rotor blade trim tabs are not excessively bent.
8. Carburetor heat valve closes fully in OFF position.
9. Induction system is unobstructed. Air filter and both inlet hoses (ambient and
carburetor heat) are clean, undamaged, unobstructed, and do not collapse in
flight. Carburetor-to-engine gasket is correct size.
10. Engine tachometer indication is correct. Verify with digital tachometer (such as
found in newer dynamic balancing equipment) or similar equipment.
11 . Oil screens or filter do not exhibit metallic debris consistent with internal engine
damage.
12. Proper cylinder compression (both leakage and direct) per Lycoming
recommendations.
13. Mixture neither excessively lean nor rich. Compare fuel flow. Verify fuel filter
cleanliness, check spark plug indications, check carburetor throttle body-to-float
bowl screw security per Lycoming SB 366.
14. Proper spark plug type and condition.
15. Proper magneto-to-engine timing. Verify engine-left (helicopter-right) magneto is

not operating in retard mode when ignition switch is in BOTH position (disconnect
retard terminal after starting engine and compare hover MAP indications; lesser
hover MAP with retard terminal disconnected indicates magneto was operating
retarded).
16. Proper fuel flow and unobstructed carburetor fuel inlet screen. Perform fuel-flow
check per Section 1 2.
17. If primer-equipped, verify fuel is not leaking past primer pump (ensure primer
pump is locked) and air is not leaking past fittings in cylinder head.
Change 22: MAR 2004 Page 6.23

R 0 BIN SON MAINTENANCE MANUAL MODELR22
I 6.610 LOW-POWER CHECKLIST (cont'd)
18. Carburetor or fuel control throttle lever contacts full-throttle stop (collective must
be raised slightly).
1 9. Carburetor or fuel control mixture arm contacts stop when mixture control is in
full-rich position and mixture arm does not exhibit springback at extremes of travel
when disconnected from control cable/safety spring (due to internal binding).
20. No induction/MAP system leaks. To check MAP system, disconnect MAP line at
cylinder head fitting and apply suction with syringe until MAP gage indicates 10
inches Hg. Monitor gage for one minute; indication should rise no more than 1
inch Hg. Verify carburetor throttle shaft bushings are not worn; check both axial
and radial clearances. Intake leaks can also occur due to loose intake pipe
connections in oil sump and/or cracked sump runner tubes. For 0-320-B2C
engines only, incorrect thin-flanged intake pipes P/Ns 61363, 61364, or 61365
used in place of correct P/Ns LW-16728, LS-16729, and LW-16730 can cause
leaks in conjunction with deep-counterbore flange P/N 74360.
21 . Proper exhaust valve guide clearance per Lycoming SB388B.
22. Proper dry-tappet clearance per Lycoming Overhaul Manual.
23. With lifters pumped up (valve lash removed), each intake valve should exhibit
equal travel during opening when measured with a dial indicator. Similarly, each
exhaust valve should exhibit equal travel during opening. Unequal travel indicates
damaged cam lobe(s).
24. Proper magneto internal timing.
25. Carburetor float bowl fuel level correct.
26. Cylinder head intake port has radiused edge where inlet airflow turns 90 degress
toward valve. If no radius exists, contact Lycoming Technical Support.
27. Proper crankshaft-to-camshaft timing: As #1 piston passes TDC on compression

stroke, the #2 intake valve should open while the #2 exhaust valve closes (valve
overlap position).
28. If 0-320/0-360/0-540 engine exhibits low-power immediately after overhaul,

verify correct 8.5:1 compression ratio piston P/N 75089 has been installed
(instead of 7.0:1 low compression piston P/N 75413).
Page 6.24 Change 22: MAR 2004

6. 700 THROTTLE CONTROL AND CARBURETOR HEAT ASSIST
The throttle control consists of a twist grip integral with the collective control, an overtravel
spring, throttle bellcrank, throttle push-pull tube, a carburetor throttle lever, and carburetor
heat assist factory installed on S/N 25 71 and subsequent.
6. 710 Overtravel Spring (Refer to Figures 8-6 and 10-8)
6. 711 Overtravel Spring Removal
1. Remove belly panel and vertical panel between seat backs.
2. Disconnect A327-1 overtravel spring's upper rod end from collective throttle
arm.
3. Disconnect A327-1 overtravel spring's lower rod end from bellcrank.
4. Remove overtravel spring.
6. 71 2 Overtravel Spring Installation
1. Connect overtravel spring's lower rod end to bellcrank and torque per Section
1 .32. Install palnut, torque per Section 1 .320, and torque stripe per Figure
2-1.
2. Connect overtravel spring's upper rod end to collective throttle arm. Raise
collective fully, and with throttle twist grip rotated full closed, verify dimension
shown in Figure 1 0-8; adjust upper rod position as required. Torque screw per
Section 1 .330. Install palnut, torque per Section 1 .320, and torque stripe per
Figure 2-1.
3. Install belly panel and vertical panel between seatbacks.
6. 720 (Reserved)
Change 26: APR 2007 6.25

6. 730 Throttle Push-Pull Tube Assembly
6. 731 Throttle Push-Pull Tube Assembly Removal
1. Remove cover enclosing bellcrank beneath left seat baggage compartment.

Disconnect throttle push-pull tube assembly from bellcrank.
2. Disconnect throttle push-pull tube assembly from carburetor and remove.
6. 732 Throttle Push-Pull Tube Assembly Installation (Refer to Figure 1 0-8)
1 . Insert throttle push-pull tube assembly forward thru firewall seal. Attach aft end
to middle hole of carburetor throttle lever and tighten bolt.
2. Attach throttle push-pull tube assembly to bellcrank and tighten bolt.
3. Adjust throttle correlation rigging per section 10.150. Torque push-pull tube jam
nuts(s) and palnut(s) (if installed), per Section 1 . 320 and torque stripe per Figure
2-1.
6. 7 40 Carburetor Heat Assist
A carburetor heat assist device is installed on R22s with 0-360 engines. The carb
heat assist correlates application of carburetor heat with changes in collective setting
to reduce pilot work load. Lowering the collective mechanically adds heat and
raising the collective reduces heat. Collective input is transmitted through a friction
clutch which allows the pilot to override the system and increase or decrease heat
as required. A latch is provided at the control knob to lock carburetor heat off when
not required.
6. 741 Carburetor Heat Control Removal
1. Open air box.
2. Remove horizontal cover between seats.
3. Drive out spring pin on cyclic friction knob using a pin punch. Remove cyclic
friction knob. Unscrew knob and collar from carb heat assist stem.
4. Raise cyclic cover and secure out of the way.
5. Remove and discard palnuts from carburetor heat slider valve fittings. Discard
pal nuts.
6. Loosen nut(s) securing carburetor heat control inner wire to valve.
7. Remove cotter pin and washer securing forward end of control to D334
bell crank assembly.
8. Pull center wire out of conduit.
9. Remove 8270-5 sealant surrounding conduit at vertical firewall. Remove

screws securing conduit to keel panel and airbox.
10. Remove outer conduit.
6.26 Change 26: APR 2007

6. 7 40 Carburetor Heat Assist (Cant' d)
6. 742 Carburetor Heat Control Cable Installation
1. Pull inner wire from new control. Route and secure conduit along keel panel,
thru vertical firewall, and into air box with retained hardware.
2. Replace 8270-5 sealant around cable at firewall pass-through.
3. Lubricate inner wire with A25 7-1 grease, insert into conduit. Connect forward
end to bellcrank, install washer, and temporarily install cotter pin.
4. Secure cyclic cover in place, install collar and knob on stem. Verify 0.10 to
0.25 inch clearance between fitting on inner wire and forward end of conduit
with control knob fully down. Reposition conduit as required.
5 Verify aft end of conduit has 0.00 to 0.1 5 inch protrusion into air box. As
required, remove inner wire and trim conduit. Install inner wire, connect
forward end to D334 bellcrank, install washer and secure with cotter pin.
6. Connect inner wire thru fitting(s) in carb heat slider valve. With knob fully
down and slider valve fully aft, trim inner wire 0.10 to 0.03 inch beyond aft
edge of fitting. Torque nuts on fittings per Section 1 .330. Torque stripe per
Figure 2-1.
7. Install air filter, close cover, and secure. Tighten four long bolts only enough
to secure cover and eliminate looseness, then torque stripe. On R22 Mariners,
seal air box cover perimeter with aluminum tape. If installed, verify spring-
loaded alternate air door fully closes when released.
6. 743 D334-5 Carburetor Heat Assist 8ellcrank Assembly Removal
1. Remove belly panel and horizontal panel between seats.
2. Disconnect carburetor heat assist control inner wire from bellcrank.
3. Disconnect carb heat assist push-pull tube from 8249 arm assembly. Remove
six screws securing bellcrank assembly to keel panel and 8368 stiffener.
4. Remove bellcrank assembly.
6. 744 D334-5 Carburetor Heat Assist 8ellcrank Assembly Installation
1. Position bellcrank assembly against, and with bearing block protruding thru,
right keel panel.
2. Secure plate to keel panel with screws.
3. Install A 142 screws thru stiffener into bearing block. Torque to 45 in.-lb and
torque stripe.
4. Attach A336 push-pull tube to 8249 arm assembly and torque bolt per Section
1 .320. Install pal nut, torque per Section 1 .320 and torque stripe per Figure
2-1.
5. Lubricate D333-3 fitting at forward end of carb heat control with A25 7-1
grease and secure to bellcrank with washer and cotter pin.
Change 26: APR 2007 6.27

NAS6603-7 80L T
AN960P01 OL WASHER (under head)
A 142-4 SCREW
NAS1149F0332P WASHER
A141-16 WASHER
(torque to 45 in.-lb; includes (0.688 in. outside diameter;
locking torque)
3 required)
2 places
8250-8 JOURNAL
(0.1 00 in. long)
NAS6606-1 6 80L T
NAS1149F0632P WASHER
MS21 042L6 NUT
A141-16 (torque to 280 in.-lb;
REF includes nut self-locking
torque)
8330-19 PALNUT
8250-51 -61 -71

-10 1 or -12 JOURNAL
(2 required*)
0333-1 8ELLCRANK
0333-11 PLATE
81 000-035-S SPRING WASHER
(2 required, orient as shown)
8250 Journal Lengths (thickness):
8250-5 : 0.059 inch long
A 141-35 WASHER
8250-6 : 0.062 inch long (2 required)
8250-7 : 0.065 inch long
8250-10 : 0.068 inch long NAS1149F0663P WASHER
8250-1 2 : 0.071 inch long
*Install 8250-5 -6 -7 -1 0 or -1 2 journals as required to produce a rotational

I I I I
friction of 10-12 inch-pounds. Journal dash numbers may be mixed. Measure

rotational friction by clamping long side of 0333-11 plate in padded vise
w/8249-7 arm assembly against vice jaws and rotating bolt head with dial-
indicating torque wrench.
FIGURE 6-8 0334 BELLCRANK ASSEMBLY

CARB HEAT ASSIST FRICTION ADJUSTMENT
(View looking aft)
6.28 Change 26: APR 2007

6. 745 0334-5 Bellcrank Friction Adjustment (Refer to Figure 6-8}
NOTE
Verify bolt head between arm and plate.
1 . Measure rotational friction per Figure 6-8.
2. Adjust friction as required by exchanging 8250 journals per Figure 6-8 (dash
numbers may be mixed}. Decreasing journal thickness increases friction.
Torque NAS6606 bolt per Figure 6-8.
3. Install palnut, torque per Section 1.320, and torque stripe per Figure 2-1.
Change 26: APR 2007 6.29

Intentionally blank
6.30 Change 26: APR 2007

CHAPTER 7
DRIVE TRAIN
Section Title Page
7.000 Drive Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1

7.001 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1
7.002 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1
7.100 Main Rotor Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1
7.110 Main Rotor Gearbox Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1
7.120 Main Rotor Gearbox Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
7.130 Leveling Main Rotor Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5
7.140 A006-5 or A908-4 Yoke Removal and Installation . . . . . . . . . . . . . . . . . . 7.7
7.141 Setting Hall Effect Sender Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7
7.150 Replacement of Main Rotor Gearbox Pinion Seal . . . . . . . . . . . . . . . . . . . 7.7
7.155 Replacement of Main Rotor Gearbox Sump O-Ring . . . . . . . . . . . . . . . 7.9
7.160 Main Rotor Gearbox Overtemp Inspection . . . . . . . . . . . . . . . . . . . . . . . 7.9A
7.170 Main Rotor Gearbox Chip Light Indicator . . . . . . . . . . . . . . . . . . . . . . . . 7.9B
7.180 (Reserved)
7.200 Clutch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.10
7.210 Clutch Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.10
7.211 A184 Bearing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.12
7.212 A184 Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.14
7.213 Clutch Assembly Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 7.15
7.214 Clutch Assembly Lubricant Inspection and Servicing . . . . . . . . . . . . . . 7.16
7.220 Clutch Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.19
7.230 Clutch Sheave Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.20
7.240 Clutch Shaft Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.23
7.250 Clutch Lateral Centering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.23
7.260 A907 Yoke Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.25
7.270 A195 Yoke Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.29
7.280 V-Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.29B
7.281 V-Belt Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.29B
7.282 V-Belt Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.29B
7.290 A007 Fanshaft and Bearing Assembly, Starter Ring Gear Support, Lower
Sheave and Alternator Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . 7.33A
7.291 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.33A
7.292 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.33A
7.300 Tail Rotor Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.34
OCT 2018 Chapter 7 Drive Train Page 7.i

CHAPTER 7
DRIVE TRAIN (Continued)

Section Title Page
7.310 Tail Rotor Drive Shaft Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.34

7.320 Tail Rotor Drive Shaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.35
7.321 Adjustment of Damper Friction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.37
7.330 Intermediate Flex Plate Installation and Shimming . . . . . . . . . . . . . . . . . . 7.40
7.340 Checking Tail Rotor Drive Shaft Runout . . . . . . . . . . . . . . . . . . . . . . . . . 7.40
7.350 Two-Piece Tail Rotor Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.44A
7.360 B224-1 Tail Rotor Drive Shaft Corrosion Removal . . . . . . . . . . . . . . . . . . 7.44D
7.400 Tail Rotor Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.45
7.410 Tail Rotor Gearbox Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.45
7.420 Tail Rotor Gearbox Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.45
7.430 Tail Rotor Gearbox Shimming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.46
7.440 Tail Rotor Gearbox Chip Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.46
7.450 A021 Tail Rotor Gearbox Output Shaft Seal Replacement . . . . . . . . . . . . 7.47
7.460 B021 Tail Rotor Gearbox Output Shaft Seal Replacement . . . . . . . . . . . . 7.48
7.470 B021 Tail Rotor Gearbox Input Shaft Seal Replacement . . . . . . . . . . . . . . 7.48B
7.500 Actuator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.49
7.510 Actuator Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.49
7.520 Actuator Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.49
7.530 Actuator Gearmotor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.49
7.540 Actuator Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.50
7.550 Switch and Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.53
7.551 Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.53
7.552 Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.53
7.600 Rotor Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.54
7.610 Rotor Brake Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.54
7.620 Rotor Brake Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.54
7.630 Rotor Brake Pad Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.55
Page 7.ii Chapter 7 Drive Train OCT 2018

CHAPTER 7
DRIVE TRAIN
7.000 Drive Train

7.001 Introduction
This section contains procedures for removal, installation, replacement, and maintenance
of drive train components.
7.002 Description (See Figure 7-1)
A steel-coated multiple-grooved aluminum pulley, known as the lower sheave, is bolted
directly to the crankshaft. Two banded-pair V-belts transmit power to the anodized
aluminum upper sheave; a steel-coated upper sheave is optional. The upper sheave has
an overrunning sprag clutch, also known as a freewheeling unit, in its hub through which
passes the clutch shaft. The clutch shaft receives power from the sprag clutch and
transmits power forward to the main rotor gearbox and aft to the tail rotor driveshaft.
Flexible couplings are located at input to the main rotor gearbox and at each end of the
long tail rotor driveshaft. The main rotor gearbox contains a single-stage spiral-bevel gear
set which is splash-lubricated. The tail rotor driveshaft has no hanger bearings but has
a lightly-loaded damper bearing. The tail rotor gearbox also contains a splash-lubricated
spiral-bevel gear set. Tail rotor gearbox input and output shafts are made of stainless
steel to resist corrosion. Other shafts throughout drive system are made of alloy steel.
7.100 Main Rotor Gearbox
7.110 Main Rotor Gearbox Removal
1. Remove main rotor per §§ 9.111 & 9.121.
2. Remove swashplate per § 8.411.
3. Remove mast fairing and aft cowling.
4. Disconnect rotor brake cable from brake lever.
5. Remove fuel tank(s) per § 12.100. Mark all wires for reassembly.
6. Remove jackshaft and support struts per §§ 8.311 & 8.321.
8. Disconnect chip detector, Hall Effect senders, rotor brake switch and overtemp sender
at quick disconnects. Disconnect ground wire. Mark all wires for reassembly.
9. Remove gearbox cooling hose and nozzle.
10. Remove four main rotor gearbox mounting bolts. Carefully lift gearbox up to clear
forward push-pull tubes and remove gearbox (see Figure 7-2).
WARNING
Leveling shims may be installed between gearbox mounts and
frame mounting pads. Shims should remain attached to frame,
or mark mounting pads with shim thickness for reinstallation.
OCT 2014 Chapter 7 Drive Train Page 7.1

FIGURE 7-1 DRIVE TRAIN
Page 7.2 Chapter 7 Drive Train OCT 2014

7. 1 20 Main Rotor Gearbox Installation
1. Ensure area is clear for installation of gearbox. One or two other people are needed
to help position gearbox.
2. If original shims unknown or a new upper frame has been installed, Level main
rotor gearbox mounting pads per Section 7. 130. Install proper shims on main rotor
gearbox mount pads before gearbox installation. Install main rotor gearbox attach
bolts and A650 fittings and torque per Section 1.330.
3. Install clutch assembly per Section 7 .220.
4. Install jackshaft support and jackshaft per Sections 8.312 and 8.322.
5. Install main rotor gearbox cooling hose and nozzle.
6. Install fuel tank(s) per Section 12.130 and 12.170.
7. Connect rotor brake cable to brake lever. Torque bolt per Section 1 .320 and
torque stripe per Figure 2-1. Verify rotor brake switch activates per Figure 7-16A
dimension.
8. Connect electrical leads at fuel tank(s) and main rotor gearbox.
9. Install aft cowling and clamp static line.
10. Install fairing lower rib and ensure it is aligned with helicopter's longitudinal ax1s.
Connect pitot tube to pitot line and install mast fairing.
11. Install swashplate assembly per Section 8.412.
12. Install main rotor system per Sections 9.112 and 9.122
13. Refer to Section 1.110 for new or overhauled gearbox servicing instructions.
CAUTION
Prior to operation of a new, overhauled, or repaired gearbox, or

if gearbox has ever been laid horizontally, 6 ounces of A25 7-
2 gear oil must be injected into vent hole (see Figure 7-1) on
top aft side of mast tube. Gearbox must remain vertical during
and after injecting oil. Fill gearbox with oil, via fill port, to level
indicated on sight glass decal.
Change 25: JUN 2006 7.3

ff..::.--=--~~=-=1
A261-5 RIB ~ ---

I
I
I~
1
I
a
~
A261-4 RIB~-------
lr ______ _
L~
-----
------ ----- \ \
\ \
\\
\-
\
---
FIGURE 7-2 MAIN ROTOR GEARBOX REMOVAL
7.4 Issued 5/22/87

7.130 Leveling Main Rotor Gearbox
1. Level aircraft per Section 1 .220.c.
2. Place A 796 shims as required on upper frame MRGB mounting pads such that
a level laid laterally or longitudinally between any two pads indicates ± 0.20°
or less. If unable to obtain ± 0.20°, level to within one 0.020 inch thick shim.
Maximum six shims per pad.
NOTE
Ensure at least one pad has no shims. As required after leveling,

remove equal number of shims from each pad.
3. Install main rotor gearbox per Section 7 .120.
Change 25: JUN 2006 7.5

Intentionally blank
7.6 Change 25: JUN 2006

7.140 A006-5 or A908-4 Yoke Removal and Installation
Yoke Removal:
a) Remove A947-1 flex plate and remove clutch per § 7.210 or support clutch shaft per
Figure 7-8.
b) Place a wooden block between horizontal firewall and yoke flange to counteract
torque when loosening nut.
c) Remove cotter pin and nut from main rotor gearbox pinion shaft and remove yoke.
Yoke Installation:
a) Install A006-5 or A908-4 yoke on main rotor gearbox pinion shaft. Install A141-10
washer and AN320-8 castellated nut.
b) Special torque nut per § 23-33 and install cotter pin. Place a wood block between
yoke flange and horizontal firewall to counteract torque.
c) Install clutch assembly, if removed, and connect forward flex plate per § 7.220.
WARNING
(identified by letter “E” or subsequent letter on two arms of
flex plate).
d) Check Hall Effect sender-to-yoke magnet gap per § 7.141 before run-up or turning
blades.
7.141 Setting Hall Effect Sender Gap

Hall Effect sender-to-magnet gap is 0.020 inch ± 0.005 inch. Gap is adjustable by
loosening sender jam nuts. Check gaps between bolt magnets at each sender. After
setting gap, tighten jam nuts and torque-stripe.
7.150 Replacement of Main Rotor Gearbox Pinion Seal

a) Ensure belt tension actuator is fully disengaged. Disconnect A947-2 intermediate flex
plate at tail rotor drive shaft. Note shim location(s) for reinstallation.
b) Remove A947-1 forward flex plate. Note shim location(s) for reinstallation.

Intentionally Blank

7.150 Replacement of Main Rotor Gearbox Pinion Seal (cont'd)
c) Rest forward end of clutch shaft on firewall. Remove yoke from pinion shaft per
Section 7 .140.
d) Cut safety wire securing pinion bearing end cover bolts and remove bolts.
e) Remove Hall Effect sender bracket(s) and gearbox overtemp sender bracket.
f) Carefully slide pinion bearing end cover off pinion shaft.
CAUTION
Do not remove shims under pinion bearing end cover as

they control bearing preload and gear backlash.
g) Press seal out of bearing end cover and press in new seal until it seats.
NOTE
Open face of seal lip must point toward gearbox.
h) Position bearing end cover on pinion shaft. Install Hall Effect and overtemp
sender brackets and remaining end cover bolts.
i) Torque bolts per Section 1.330 and safety wire.
j) Adjust Hall Effect sender gap per Section 7.141 .
k) Install A947-1 forward flex plate and connect A94 7-2 intermediate flex plate,
ensuring correct ship placement.
7.155 Replacement of Main Rotor Gearbox (MRGB) Sump 0-Ring
a) Drain MRGB.
b) Remove MRGB per Section 7.110.
c) Check and record MRGB gear backlash at and tangental to a gear tooth,
accessible via sight gage or filler plug hole.
d) Carefully note and record position of each fastener, washer and shim stack-
up at all A263-1 sump-to-A264-1 housing attach points (an equal number
of shims is installed between sump and housing at each attach point).
Remove, identify and retain fasteners, washers and shims.
e) Remove sump and o-ring.
f) Prelubricate new A214-172 o-ring with A257-2 oil and install on sump.
Ensure o-ring is not twisted in sump groove.

7.155 Replacement of Main Rotor Gearbox (MRGB) Sump 0-Ring (cont'd)
g) Carefully assemble sump to housing and secure finger-tight with fasteners,

washers and shims installed in same positions recorded in step d).
NOTE
Install ground wires under nut located aft of forward

right mount.
CAUTION
Verify all sump bolts have same shim stack as noted

during removal.
h) Torque fasteners as follows:
Eight nuts on AN4 bolts: 90 in.-lb (incl nut self-lock torque)

Two MS20074 cap screws: 60 in.-lb and safety wire
A 7260 chip det. housing: 150 in.-lb and safety wire
A 7260 chip detector: 75 in.-lb and safety wire
i) Check MRGB gear backlash exactly as performed in step c). Backlash

should be within 0.001 inch of value recorded in step c).
j) Install MRGB per Section 7 .120.
k) Fill MRGB with A257-2 lubricant.
7.160 Main Rotor Gearbox Overtemp Inspection
a) If "MR TEMP" warning light illuminates AND Telatemp indicates abnormally high
operating temperature:
1. Inspect gearbox cooling duct for obstructions and conditions. Clear

obstructions or replace duct as required.
2. Remove chip detector and inspect for chips. Return gearbox to RHC if
chips are found.
3. Drain gearbox oil and remove sight gage and filler plug. Observe gear
tooth surfaces thru filler plug and sight gage holes while rotating gearbox
pinion and inspect for damage. Return gearbox to RHC if damage is
detected or if gearbox does not rotate smoothly. If no damage is noted,
refill gearbox.
4. Replace Telatemp. Ensure old Telatemp adhesive is removed and new

Telatemp makes good contact with gearbox.
5. If gearbox overtemp indications continue, return gearbox to RHC.
Page 7 .9A Change 16: 19 SEP 97

7.160 Main Rotor Gearbox Overtemp Inspection (cont'd)
b) If "MR TEMP" warning light illuminates but Telatemp indicates normal operating
temperature, replace gearbox overtemp sender and perform steps a) 1, 2, & 5
above.
c) If Telatemp indicates 240°F/116°C but "MR TEMP" warning light does not
illuminate, test "MR TEMP" warning circuit and perform steps a) 1, 2, 4, & 5
above.
NOTE
Light illuminates at 240 ± 5o F.
7.170 Main Rotor Gearbox Chip Light Indicator
If "MR CHIP" light illuminates:
a) Drain and flush gearbox per Section 1 . 1 20 except strain oil (a paint filter works
well) while draining and examine any particles found in oil or on chip detector.
b) Particles larger than 0.12 inch long or 0.02 inch wide are cause for concern and
should be identified as ferrous or non-ferrous with a magnet. If particles are
ferrous return main rotor gearbox to RHC for repair along with particles. If
particles are non-ferrous, drain and flush gearbox per Section 1. 120.
c) If "MR CHIP" illuminates again within next 100 hours time-in-service a gearbox
failure may be imminent. Return gearbox to RHC for repair.
7.180 (Reserved)

7.200 CLUTCH ASSEMBLY
7. 21 0 Clutch Assembly Removal
1. Remove A94 7-2 intermediate flex plate.
2. Turn Master Battery switch on and disengage clutch switch. Adjust actuator
down-limit stop screw (see Figure 7-15) for maximum drive belt slack. Turn
Master Battery switch off.
CAUTION
Belt tension actuator must be fully disengaged prior to

removing clutch assembly.
3. Disconnect A94 7-1 forward flex plate.
WARNING

bonded washers. If a bonded washer separates from an
A94 7 flex plate, flex plate is unairworthy and cannot be
repaired.
4. Disconnect A 1 84 upper actuator bearing assembly from actuator.
5. Disconnect clutch lateral centering strut from upper frame.
6. Disconnect actuator wiring.
7. Pivot actuator to right. Lower clutch to allow drive belt removal.
CAUTION
Mark drive belt fore and aft positions and direction of

rotation per Figure 7-8 if reinstalling drive belts.
8. Remove drive belts from clutch and remove clutch per Figure 7-3.
9. When returning clutch to RHC, remove and retain both yokes, centering strut,
and attaching hardware.
Page 7. 1 0 Change 21: JUN 2000

STEP 1
STEP 2
FIGURE 7-3 CLUTCH REMOVAL

7.211 A 184 Bearing Removal
a. Refer to Figures 7-3A and 7-38. Remove A 184 bearing:
1. If a press is available, assemble MT303-5 lower puller assembly between

A 184 bearing and upper sheave per Figure 7-3A. Press clutch shaft out
of bearing.
CAUTION
Ensure A018 assembly does not fall when bearing is

removed.
2. If press is not available, assemble MT303-2 upper puller assembly with

MT303-5 lower puller assembly on clutch per Figure 7-38. Install
MT303-16 plug in short end of clutch shaft and secure with MT303-13
pin. Ensure extractor bolt threads are lubricated with anti-seize. Remove
bearing by holding handle and tightening extractor bolt.
WARNING
A64 7-4 bearing in A 184-3 upper bearing assembly

has internal clearance modified by RHC. DO NOT
SUBSTITUTE.
Page 7.12 Change 18: 3 MAR 99

PRESS
FIGURE 7-3A
METAL AlB 4
PLATE BEARING
~~r- I
Removing A184 Bearing in shop
MT303-5 using hydraulic press and MT303-5
-L ..u
rr;; J 1.--:------.._
Lower Puller Assembly.
-~
1
ro
FIGURE 7-3B
Removing A184 Bearing in field

using hand tools and MT303-5 and
MT303-2 Upper Puller Assembly.
- ·/
il A184 BEARING
mi
I
I
Change 18: 3 MAR 99 Page 7.13

7. 21 2 A 184 Bearing Installation
1. Remove loose paint and clean mating area on shaft.
2. Heat A 1 84 bearing assembly. A heat lamp placed one foot from bearing may
be used. Ensure temperature of bearing does not exceed 180° F by
monitoring Telatemp installed on bearing.
3. Apply zinc-chromate or epoxy primer, or 8270-10 adhesive, to bearing mating

area of shaft. While primer or adhesive is still wet, install bearing on clutch
shaft:
NOTE
Ensure bearing is installed with lateral centering strut

attachment ear to left side and actuator attachment on
bottom per Figure 7-3F.
I. If press is available: If installed, remove A907 forward yoke. Position

MT303-1 9 tube against A 1 84 bearing assembly inner race and press
assembly onto clutch shaft per Figure 7-3E until bearing is at dimension
shown in Figure 7-3D.
CAUTION
Do NOT support clutch assembly by sheave while pressing

or internal bearing will be damaged.
Do NOT press bearing beyond dimension shown in Figure

7-3D.
II. If press is not available: Install MT303-4 bearing press assembly and
handle from MT303-2 upper puller assembly per Figure 7-3G. Lubricate
threaded shaft portion of MT303-4 bearing press assembly with anti-
seize compound then insert drilled end into clutch shaft. Align clutch
shaft holes with threaded shaft hole and insert MT303-13 pin. Hold
handle and tighten nut on MT303-4 bearing press assembly until bearing
is at dimension shown in Figure 7-3D.
4. Remove bearing press tooling.
5. Check bearing for smooth operation.
6. Seal bearing inner race-to-shaft juncture with primer to minimize corrosion.
7. Torque stripe inner race of bearing to clutch shaft two places, 180° apart.
8. Install new Telatemp on A 184 bearing housing if original was altered by

heating.

7.213 Clutch Assembly Seal Replacement
2. If replacing aft seal, remove A184-3 bearing assembly from clutch shaft per § 7.211.
Remove loose paint and clean shaft.
NOTE
Orient clutch assembly vertically with leaking seal up.
3. Remove inner circle of six (6) bolts from leaking seal retainer.
a. If seal retainer is circular with two opposing half-moon-shaped cutouts: Remove
four (4) bolts in outer row, but not two (2) bolts with large-area washers (which
holds inner clutch assembly together).
NOTE
DO NOT REMOVE two bolts holding the inner clutch assembly
together. Further disassembly is not approved.
b. If seal retainer has two socket-head cap screws: Remove six bolts in outer
row, and two socket-head cap screws.
4. Lift retainer plate with seal off shaft per Figure 7-3C. Remove exposed 0-ring from
clutch housing and discard.
5. Press damaged seal out of retainer.
6. Measure retainer seal bore. If bore measures over 1.687 inches, retainer must be
replaced.
7. For “National” brand seals coat seal bore of retainer with B270-3 sealant and press
seal in at room temperature. For “CR” brand seal with green coating on seal outer
diameter, heat retainer to 150°F and press seal in dry. Press new seal into retainer
flush with outside lip.
8. Fill sprag and bearing cavity with A257-4 oil until oil level is flush with top of
bearing races (see Figure 7-3D). Rotate shaft while filling to ensure complete filling
of inner shaft and sprag assembly.
9. Lightly lubricate new 0-ring with A257-4 oil and place it in clutch housing groove.
10. Lightly lubricate seal inner lip with A257-4 oil and slide retainer over shaft.

7.213 Clutch Assembly Seal Replacement (continued)
11. a. If seal retainer is circular with two opposing half-moon shaped cutouts: Position
retainer so cut outs fit over two (2) A141-14 washers holding clutch assembly
together. Install six (6) inner and remaining four (4) outer bolts in retainers with
heads toward shorter end of clutch shaft.
b. If seal retainer has provisions for two socket-head cap screws: Install cap screws
with washers and tighten only enough to clamp retainer to o-ring. Install six
inner and six outer bolts with heads toward shorter end of clutch shaft.
12. Using a criss-cross pattern, standard torque nuts per § 23-32 and torque stripe.
13. If installed, fully tighten cap screws and torque stripe.
14. If removed, install A184-3 bearing assembly per § 7.212.
15. Install clutch assembly per § 7.220.
7.214 Clutch Assembly Lubricant Inspection and Servicing

©-SEAL
FIGURE 7-3C
RETAINER
CAUTION
RHC does not recommend using A 170-1 or -2 Revision N or

prior upper sheaves with A493-1 Revision T or later lower
sheaves. Such combinations may cause excessive drive belt
vibration. Refer to Figure 2-9.
T
1.480
1.490
u
A184
BEARING
ASSEMBLY ~.....c~=:=~:;::a.I.-1"
A170 Ul-PPER SHEAVE\
0.92 inch for~ \

"deep-groove" ·~-....-
Rev N and prior
upper sheaves;
0. 71 inch for
"shallow-groove"
Rev 0 and sub-
sequent upper
sheaves
,r:=;:.===ro"""'~ BEARING
~
I !
-SEAL
hfrPLUG
FIGURE 7-30
<t
Change 24: APR 2005 Page 7.17
FIGURE 7-3E
INSTALLING A 184 BEARING USING

MT303-19 BEARING PRESSING TOOL
lr-, ~ MT303-19 STEEL TUBE

WARNING I
::J ii o! I
H Do not press across sheave or

bearings will be damaged.
HARDWOOD
OR
SOFT METAL FIGURE 7-3F
0
0
LATERAL
CENTERING
I I FITTING
FORWARD
MT303-4 ACTUATOR
/ BEARING PRESS ATTACHMENT
A184
c::--~W~-..../ BEARING
FIGURE 7-3G
INSTALLING A 184 BEARING IN THE
FIELD USING MT303-4 BEARING
PRESS TOOL
eL
I r
/ HANDLE FROM MT303-2

7.220 Clutch Assembly Installation
1. If removed, install A195 and/or A907 yokes per §§ 7.260 & 7.270.
2. If removed, connect clutch lateral centering strut to A184 bearing assembly and
standard torque fasteners per § 23-32.
3. Ensure actuator is fully disengaged.
4. Identify type (deep-groove or shallow-groove) of upper and lower sheaves. Refer to
Figures 7-3D & 2-11.
CAUTION
RHC does not recommend using A170-1 or -2 Revision N or prior
5. Install clutch assembly and pull belts over clutch aft yoke. Install belts in proper fore/
aft order with proper direction of rotation.
6. Attach clutch assembly to clutch actuator. Standard torque fasteners per § 23-32.
7. Install A947-1 flex plate. Standard torque fasteners per § 23-32.
WARNING
A947-1 flex plate must be marked with letter “E” (or subsequent
letter) on two adjacent arms.
8. Connect clutch lateral centering strut from clutch assembly to upper frame. Standard
torque fasteners per § 23-32.
9. Check clutch sheave alignment per § 7.230 and adjust as required.
10. Install A947-2 intermediate flex plate per § 7.330.
11. Adjust actuator down-limit stop screw (see Figure 7-15) for V-belt deflection shown
in Figure 7-7A.
12. Perform run-up per § 2.210. Adjust actuator down-limit stop screw as required and
tighten down-limit stop screw jam nut.
13. Torque stripe fasteners per Figure 2-1.

7.230 Clutch Sheave Alignment
1. Check engine shimming installation limits per § 6.130. Ring-gear-to-frame dimension
must be within specified limits before sheave alignment is checked.
2. Engage clutch (fan and scroll must be installed).
3. Check clutch shaft angle per § 7.240.
4. Hold MT331-4 sheave alignment bar against aft face of lower sheave extending bar
upward to horizontal center line of clutch assembly upper sheave.
5. Measure left and right gaps per Figure 7-5. Both gaps must be within noted limits and
left gap must be 0.010–0.030 inch larger than right gap. If left gap is not 0.010–
0.030 inch larger than right gap, adjust clutch lateral centering per § 7.250 or adjust
engine shims.
If either gap exceeds maximum limit, clutch assembly is too far forward or engine is
too far aft. Engine may be moved forward by removing an equal amount of shims from
each engine mount, subject to § 6.130 minimum shim requirement. Alternatively,
the clutch assembly may be moved aft by shimming at forward flex plate and/or
adjusting A907 yoke length. Shimming is accomplished by installing a maximum of
one AN960-516L washer between A947-1 flex plate and both arms of A907 and/or
A908 yoke; AN960-516L washers installed on either yoke will decrease right and left
gaps an amount equal to the washer’s thickness. A907-4 and -5 yokes each have two
sets of mounting holes which change effective yoke length by 0.120 inch. A907-5
yoke is 0.120 inch or 0.240 inch longer than long position of A907-4 yoke, depending
on mounting holes used. Right and left gaps will decrease by 0.120 inch with each
0.120 inch increase in A907 yoke length.
If either gap is smaller than minimum limit, clutch assembly is too far aft or engine is
too far forward. Engine may be moved aft by adding an equal amount of shims to each
engine mount, subject to § 6.130 maximum shim allowance. Alternatively, clutch
assembly may be moved forward by removing shims (if installed) at forward flex plate
and/or adjusting A907 yoke length. Removing AN960-516L washers from between
A947-1 flex plate and both arms of A907 and/or A908 yoke will increase both gaps
an amount equal to washer’s thickness. A907-4 and -5 yokes each have two sets of
mounting holes which change effective yoke length by 0.120 inch. A907-4 yoke is
0.120 inch or 0.240 inch shorter than short position of A907-5 yoke, depending on
mounting holes used. Right and left gaps will each increase by 0.120 inch with each
0.120 inch decrease in A907 yoke length.
CAUTION
Disengage clutch prior to shimming A947-1 flex plate.
A907-4 yoke replaces A907-1 and -2 yokes. A907-5 yoke replaces A907-3 yoke and
includes an additional set of mounting holes.

7.230 Clutch Sheave Alignment (continued)
6. Check intermediate flex plate shimming per § 7.330 if shims were added or removed
at A947-1 flex plate or if A907 yoke position changed.
7. Adjust V-belt guide per Figure 7-8A.
8. Check throttle correlation rigging per § 10.150 and adjust as required.
NOTE
Shortening clutch lateral centering strut simultaneously increases
left gap and decreases right gap. Lengthening clutch lateral
centering strut decreases left gap and increases right gap.
FIGURE 7-5 SHEAVE ALIGNMENT

FIGURE 7-6 MEASURING CLUTCH SHAFT ANGLE

7.240 Clutch Shaft Angle
Verify correct engine shimming per § 6.130 prior to checking clutch shaft angle.
1. See Figure 7-6. Orient main rotor blades perpendicular to centerline of helicopter.
Position protractor atop main rotor hub facing right side of helicopter as shown.
Zero protractor to main rotor hub.
2. Turn master switch on and engage clutch. Check angle of clutch shaft per Figure 7-6.
3. Clutch shaft angle limits with clutch engaged are 2.5 to 5.0 degrees.
Flex plate has zero vertical misalignment when angle is 3.5 degrees. If clutch shaft
angle is not within limits, drive V-belts must be replaced.
7.250 Clutch Lateral Centering

1. Clutch actuator fully engaged.
2. Check sheave alignment on left and right side per Figure 7-5.
3. To facilitate sheave alignment, left gap should be 0.010 to 0.030 inch larger than right
gap. Clutch lateral centering strut may be adjusted (with clutch engaged) to obtain
gap differential provided following clearances are met:
a. Minimum 0.030 inch between clutch actuator motor and upper frame tube.
b. Minimum 0.150 inch between V-belts and right side frame guard (actuator engaged).
4. If alignment cannot be adjusted within required measurements, contact Robinson
Helicopter Company Technical Support.
5. Standard torque attach bolts and jam nuts per § 23-32.

FIGURE 7-6A A907 YOKE REMOVAL

7.260 A907 Yoke Removal and Installation
To remove yoke:
2. Remove bolts and clamping blocks securing A907 yoke to clutch shaft. Mark which
set of yoke attachment holes are used.
3. Remove A907 yoke:
a. (Preferred method) If a press is available, position clutch assembly in press per
Figure 7-6A. Ensure brass or aluminum drift fits against outer rim of clutch
shaft and not against inner spacer. Press clutch shaft out of yoke.
CAUTION
Ensure clutch assembly does not fall when yoke is removed.
b. If a press is not available, apply penetrating oil to yoke-shaft juncture. Gently

clamp A907 yoke in a padded vise per Figure 7-6B. Twist clutch shaft out of
yoke by turning upper sheave. If difficulty is encountered, discontinue attempt
and arrange use of press as described in preceding step.
CAUTION
Avoid bending loads on clutch shaft when A907 yoke is clamped
in vise as yoke can be damaged.
To install yoke:
1. Remove paint from and clean mating area on clutch shaft.
2. Remove paint from A907 yoke bore, from A907 yoke exterior at clamping block
attachment areas, and from clamping surfaces of clamping blocks.
3. Coat A907 yoke bore and mating portion of clutch shaft with § 23-70 approved
zinc-chromate or epoxy primer. While primer is still wet, install yoke on clutch shaft
and align marked holes on yoke (if applicable) with clutch shaft holes.
CAUTION
Use only specified primers to install yoke; do not use any other
lubricants.
4. While yoke primer is still wet, secure yoke to shaft with clamping blocks coated
with approved zinc-chromate or epoxy primer and bolts. Standard torque bolts per
§ 23-32. Install palnuts and standard torque per § 23-32.
5. Clean all exposed bare metal fasteners and joints, and prime with zinc-chromate or
epoxy primer. Ensure formation of primer fillets at all joints for sealing out moisture.
6. Torque stripe fasteners.

FIGURE 7-6B A907 YOKE REMOVAL

Intentionally Blank

FIGURE 7-6C A195 YOKE REMOVAL

7.270 A195 Yoke Removal and Installation
2. Remove bolts and clamping blocks securing A195 yoke to clutch shaft.
CAUTION
A195 yoke arms are easily bent. Exercise care when removing
or installing yoke. Always remove A195 yoke when shipping
or transporting clutch assembly.
3. Remove A195 yoke:

a. If a press is available, assemble MT303-5 lower puller assembly around clutch
shaft between A184 bearing and A195 yoke. Flat face of puller must be towards
yoke. Refer to Figure 7-6C. Insert MT303-16 plug thru A195 yoke bore into
clutch shaft and press shaft out of yoke.
b. If a press is not available, assemble MT303-5 lower puller assembly with MT303‑2
upper puller assembly per Figure 7-6C. Flat face of puller must be towards yoke.
Insert MT303-16 plug thru A195 yoke bore into clutch shaft. Place a deep
socket (or similar) between MT303-16 plug and extractor bolt. Tighten bolt and
remove A195 yoke.
To install yoke:
1. Remove paint from and clean mating area on shaft.
2. Remove paint from A195 yoke bore, from A195 yoke exterior at clamping block
attachment areas, and clamping surfaces of clamping blocks.
3. Coat inside of A195 yoke and mating portion of clutch shaft with § 23-70 approved
zinc chromate or epoxy primer. While primer is still wet, slide A195 yoke onto clutch
shaft and align mounting holes.
4. While yoke primer is still wet, secure yoke to shaft with clamping blocks coated
with approved zinc-chromate or epoxy primer and bolts. Standard torque bolts per
§ 23‑32. Install palnuts and standard torque per § 23-32.
5. Clean all exposed bare metal fasteners and joints, and prime with zinc-chromate or
epoxy primer. Ensure formation of primer fillets at all joints for sealing out moisture.
6. Torque stripe fasteners.

FIGURE 7-7A V-BELT DEFLECTION (ACTUATOR DISENGAGED)
FIGURE 7-8 V-BELT AND ACTUATOR REMOVAL
Page 7.29A Chapter 7 Drive Train OCT 2018

7.280 V-Belts
7.281 V-Belt Removal

a. Remove fanwheel per § 6.210.
b. Fully disengage belt tension actuator. Place a six-inch wooden block between clutch
shaft and horizontal firewall per Figure 7-8. Block will prevent excessive sheave
drop and protect forward flex plate.
c. Disconnect clutch lateral centering strut from upper frame and remove intermediate
flex plate.
d. Mark drive belts for “fore” and “aft” position and direction of rotation if they will be
reinstalled.
CAUTION
Used belts must be reinstalled in proper order due to individual
differences in belt stretch.
e. Loosen belt guide and position guide to remove v-belts.

f. Disconnect actuator wiring.
g. Remove belts from sheave and pull over aft yoke.
7.282 V-Belt Installation

1. Evaluate alternator belt(s) condition and replace as required.
2. Inspect upper and lower actuator bearings per §§ 2.502 & 2.503 (lubricate as required).
3. Identify type (deep-groove or shallow-groove) of upper and lower sheaves. Refer to
Figures 7-3D & 2-11.
CAUTION
RHC does not recommend using A170-1 or -2 Revision N or prior
4. Inspect both sheaves. Replace any sheave showing corrosion, pitting or flaking
of the metalized or anodized coatings, wear through anodized coating, grooves,
roughness, or sharp ridges.
CAUTION
Rough or corroded grooves in the upper or lower sheave can
cause V-belts to roll, break, or come off.
OCT 2018 Chapter 7 Drive Train Page 7.29B

7.282 V-Belt Installation (continued)
5. Paint lower sheave grooves with a thin coating of zinc-chromate or epoxy primer
(ref. § 23-70). Sheave may be primed without removal by using an aerosol can or
air brush.
6. Inspect belts per § 2.507.
7. Install belts on sheaves. Ensure belts are installed in proper fore/aft order with
proper direction of rotation.
WARNING
V-belts are a matched set. Only install V -belts as matched set.
8. Connect actuator wiring.

9. Connect lateral centering strut bolts and standard torque per § 23-32.
10. Install fanwheel and scroll per § 6.220.
11. Measure belt defection with actuator disengaged. Using a scale and finger pressure,
belts must deflect inward 1.4–1.6 inches per Figure 7-7A. Adjust actuator down-
limit stop screw (see Figure 7-15) as required to obtain correct dimension. Tighten
down-limit stop screw jam nut.
CAUTION
Belts which are too tight can damage flex plates during start
and belts which are too loose can jump out of grooves during
engagement.
NOTE
A delay of more than 5 seconds between clutch switch
engagement and rotor turning indicates excessive slack. If
rotor rotates when cranking engine, belts may not have enough
slack. Actuator down limit screw adjustments are required
more frequently with new belts.

13. Shim and connect intermediate flex coupling per § 7.330.
14. Rotate drive train by hand with actuator disengaged. Verify minimum 0.125
inch clearance with new belts (0.25 inch after approximately 10 hours) between
intermediate flex coupling and A331-1 tail rotor bellcrank-to-A121-17 push-pull tube
attach bolt. If clearance less than minimum, shim engine per § 6.130.
15. Position V-belt guide to maintain clearance specified in Figure 7-8A. Standard torque
attach hardware per § 23-32.

16. If required, install protective clamp on upper frame per Figure 2-4C.
17. Ground run or hover helicopter for at least one-half hour.
18. At end of half-hour run, inspect primer wear pattern in lower sheave grooves. A
similar wear pattern in all four grooves indicates compatible belt/sheave combination.
A noticeably different wear pattern from groove to groove indicates combination is
not compatible. Refer to § 2.508 for allowable wear pattern limits.
19. If belt/sheave combination is not compatible, re-check sheave alignment, replace
belts, and repeat installation procedure. If belt/sheave combination is still not
compatible, it may be necessary to replace lower sheave. Wear pattern in all four
grooves must be similar before aircraft is released for flight.
20. Check clutch shaft angle per § 7.240.

Intentionally Blank

FIGURE 7-8A V-BELT GUIDE
CAUTION
Position guide to 0.18 inch clearance with clutch engaged.

Guide to be flushed with front face of sheave. Maintain 0.18
inch clearance between P/P tube and guide attach bolts.
NOTE
A020-2 upper frame S/N 0501 and subsequent have guide
bracket welded to frame.

7.290 A007-3 & -5 Fanshaft and Bearing Assembly, Starter Ring Gear Support,
Lower Sheave and Alternator Belt Replacement
7.291 Removal
a. Remove fanwheel and fiberglass scroll per § 6.210.
NOTE
Fanwheel and fiberglass scroll may be removed without splitting
scroll.
b. Support clutch shaft assembly at horizontal firewall with a wooden block.

Remove lower bolt connecting belt tension actuator to A181-4 lower bearing
assembly.
c. Label drive belts (forward & aft) for reinstallation.
d. Cut safety wire and remove six NAS6606-24H bolts. Note number and thickness
of washers under each bolt head.
e. Remove A007-3 or -5 fanshaft and bearing assembly. Temporarily secure lower

sheave if it is not to be removed.
f. To remove lower sheave, tap it with a soft mallet while pulling.
g. Removal of starter ring gear support is required to change alternator belt or gain
access to engine nose section.
1. Loosen alternator belt tension.
2. Note “0” mark on the starter ring gear support at one crankshaft flange
bushing. Mark this bushing to ease reinstallation.
3. Remove starter ring gear support.
7.292 Installation
a. Install new and spare alternator belts if required. Install starter ring gear support.
Align “0” mark on ring gear support with marked bushing. Bushing and hole
marked 0 are slightly larger than other five holes.
b. Install lower sheave and fanshaft assembly. Ensure one AN960-616 and one
AN916-616L washer is installed under each NAS6606-24H bolt head. Torque
bolts per § 1.320 in a crossing pattern. Safety wire bolts in pairs with 0.041
inch diameter stainless steel safety wire.
CAUTION
One AN960-616 washer and one AN960-616L washer must
be installed under each NAS6606-24H bolt head for proper
fanshaft-sheave-crankshaft clamp-up.
Page 7.33A Chapter 7 Drive Train OCT 2014

7.290 A007-3 & -5 Fanshaft and Bearing Assembly, Starter Ring Gear Support,
Lower Sheave and Alternator Belt Replacement (cont'd)
7.292 Installation (cont'd)
CAUTION
RHC does not recommend using A 170-1 or -2 Revision N or

prior upper sheaves with A493-1 Revision T or later lower
sheaves. Such combinations may cause excessive drive belt
vibration. Refer to Figures 2-9 and 7-38.
c) Place drive belts in correct forward and aft order on upper and lower
sheaves. Install lower bolt connecting belt tension actuator to lower
actuator bearing assembly, and torque per Section 1 .320.
d) Install fanwheel per Section 6.220.
e) Remove wooden block supporting clutch assembly. Adjust alternator belt

tension per Lycoming Service Instruction 1129 (current revision).
WARNING
Bearings in A007-3 and A007-5 fanshaft bearing assemblies

have internal clearance modified by RHC. DO NOT
SUBSTITUTE any other bearing.
Change 22: MAR 2004 Page 7.33B

7.300 TAIL ROTOR DRIVESHAFT

7.310 Tail Rotor Driveshaft Removal
a) Disconnect the tail rotor shaft at the intermediate flex-
plate. Leave the flexplate connected to the aft clutch
yoke. Use 4-inch block under the driveshaft near the
forward end to support the driveshaft in the tailcone.
This prevents damage to the aft flexplate.
b) Remove the tailcone per Section 4.311.
c) Use a 3-foot socket extension with a 3/8-inch socket to
disconnect the two NAS1303 bolts which hold the drive-
shaft to its mounting bracket.
d) Disconnect tail rotor push-pull tube from tail rotor gearbox
bellcrank arm. If push-pull tube length is not changed,
rerigging is not required.
e) Remove the four bolts (one NAS1304-8, three MS20074-04-
06) that hold the tail rotor gearbox to the tailcone
casting. Hold the forward end of the driveshaft while
the gearbox is pulled out of the tailcone casting far
enough to allow removal of the flex coupling bolts.
f) Mark aft end of driveshaft and flexplate for reassembly.
Disconnect driveshaft from flexplate, leaving flexplate
connected to gearbox. Reinstall bolts, spacers and nuts
on flexplate so none will be lost or misplaced.
g) The driveshaft can now be pulled out of the forward end
of the tailcone.

7.320 Tail Rotor Drive Shaft Installation
Also applies to Tail Rotor Gearbox Installation to Tailcone.
a) Insert tail rotor drive shaft into tailcone and pull aft end of shaft through
tailcone's aft casting.
b) Reconnect flex plate to tail rotor gearbox. Bonded washers on flex plate must
be directly against flange of gearbox input shaft. Torque NAS1304 bolts per
Section 1.320. (See Figure 7-9)
CAUTION
Improper installation of flex plate can damage tail

rotor drive shaft and gearbox.
c) Support forward end of drive shaft and push flex coupling forward through aft
casting.
d) Reconnect the four bolts that hold the gearbox to the casting. Torque
NAS1304 bolt per Section 1.320. Torque the MS20074-04-06 bolts per
Section 1.330 and safety with 0.032 inch diameter safety wire.
I
e) Connect damper assembly to tailcone frame and torque attach bolts per
Section 1.320. Through inspection holes on side of tailcone, determine
longitudinal alignment of damper clip (or arm) with tailcone's attachment
bracket. If clearance or interference between clip (or arm) and bracket is
greater than 0.12 inch, contact RHC Technical Support. Ensure damper is
oriented per Figure 7-11 B.
f) Install tailcone per Section 4.312.
g) Connect the A 121-17 aft push-pull tube and torque fastener per Section
1.320.
I
h) Install and shim intermediate flex plate per Section 7.330.
i) Perform tail rotor drive shaft run-out check per Section 7.340.

0.469 in. dia hole
0.252 in. dia hole (two places, 180° apart)
NUMBER DESCRIPTION
1 Pal nut
2 Nut
3 Washer
4 T.R. Driveshaft
5 Spacer
6 Flexplate
7 Washer
FIGURE 7-9
8 Bolt
AFT FLEXPLATE INSTALLATION 9 T.R. Gearbox Assy.
10 Bolt
*A197 T.R. Driveshaft no longer available. See R22

Parts Catalog for replacement with proper 8224-1
T.R. Driveshaft and B223 Yoke combination.

7.321 Adjustment of Damper Friction
a) Remove tail rotor drive shaft from tailcone per Section 7.31 0.
b) Disassemble damper per Figure 7-10 or Figure 7-1 OA, as applicable. I

c) Inspect the following parts for wear and replace worn parts:
1. Inspect A041-5 DU washers for worn Teflon® coating (dark gray

face).
2. Inspect A 141-15 washers and A041-3 arm for indications of wear

or grooving.
d) Assemble damper per Figure 7-10 or Figure 7-1 OA, as applicable. Install
spring washers with concave face toward A041-5 DU washers.
I
CAUTION
The Teflon® (dark gray) face of the A041-5 DU

washer must be placed against the A 141-36 washer
or A041-3 arm. Remove plastic or tape coating, if
installed.
e) Torque nuts per Section 1.320.
f) Using a spring scale or dead weight, measure pivot frictions per Figure 7-
11 A. If friction is less than specified, bend A041-6 spring washer until it
has a 0.070 ± 0.010 inch total height. If spring washer height is within
limits but friction is still too low, lap metal from end of A 105-9 journal. If
friction is greater than specified, flatten A041-6 spring washer slightly or
replace A 105-9 journal.

FIGURE 7-10
DAMPER ASSEMBLY
15
5
NUMBER PART NUMBER DESCRIPTION
1 NAS6603-8 Bolt
2 AN960-10L Washer
3 A141-18 Washer
4 A041-3 Arm
,A'\.~.: ..
5 A041-10 Dowel Pin
6 A041-5 DU Washer
7 A105-9 Journal
8 04DU04 Bushing
9 A041-8 Clip
10 A041-9 Spacer
11 A041-6 Spring Washer
12 A041-15 Washer NOTE: A041-7 clip and
13 AN960-10 Washer
14 NAS679A3 Nut
15 B330-7 Pal nut
16 A041-11 Bearing Assembly
17 A041-7* Clip *No longer available. Order A041-9
spacer along with A041-8 clip for
18 A041-4* Spacer replacement.

FIGURE 7-lOA
A041-12* DAMPER ASSEMBLY
NUMBER PART NUMBER DESCRIPTION NUMBER PART NUMBER DESCRIPTION

1. NAS6603-3 Bolt 11 A041-6 Spring Washer
2 AN960-10 Washer 12 A105-9 Journal
3 A041-13 Ann 13 04DU04 Bushing
4 B288-8 Support (Ref) 14 A041-3 Ann
5 B330-7 Pal nut 15 AN960-10L Washer
6 MS21042L3 Nut 16 NAS6603-8 Bolt
7 A141-18 Washer 17 A041-ll Bearing Assembly
8 A041-10 Dowel Pin 18 A041-12* Damper Assembly
(Includes items
9 A141-15 Washer 3, and 5-17)
10 A041-5 DU Washer *Ship S/N 2571 and on, and
ships equipped with A023-22
or A023-23 tailcones.
Change 15: 26 JUL 96 Page 7.38A
This page intentionally left blank.

ROBINSON MAINTENANCE MANUAL MOOELR22
A
B c
1. 5 to 2. 5 1 bs
1.5 to 2.0 lbs to
to move clip move clip tmeasured VIEW LOOKING AFT
(measured at at point B and ro-
point A rotat- tating about point C)
ing about point B)
FIGURE 7-llA
-------
A041-8
CLIP
I
I I
'
'
\
\
\
'
VIEW LOOKING AFT
~
A041-1 DAMPER ASSEMBLY A041-12 DAMPER ASSEMBLY
ORIENTATION ORIENTATION
FIGURE 7-llB

7.321 Adjustment of Damper Friction (cont'd)
CAUTION
Do not adjust damper drag by changing bolt

torque.
f) Torque MS21 042L4 nut per Section 1.320 and recheck damper drag.
I Install 8330-13 palnut and torque stripe.
g) Install tail rotor drive shaft per Section 7.320.
7.330 Intermediate Flex Plate Installation and Shimming
Measurements taken with intermediate flex plate removed.
a) Engage clutch actuator.
b) Rotate tail rotor drive shaft yoke and A 195 yoke so yoke arms are horizontal.
c) Insert NAS1304 bolt through tail rotor shaft yoke and A 195 yoke at 9 o'clock
position. Measure gap between yoke arms at 3 o'clock position.
d) Insert bolt at 3 o'clock, remove bolt at 9 o'clock, and measure gap at 9 o'clock.
Measurements in sequence c and d are measurement 1.
e) Remove bolt and rotate tail rotor drive shaft 180 degrees. Repeat steps c) and
d). This will be measurement 2.
NOTE
Measurement 1 and 2 should be similar. If measurements

are not similar one or both yokes are bent.
f) Record difference between 3 o'clock and 9 o'clock gaps in measurement 1 and

in measurement 2. Difference between 3 o'clock and 9 o'clock gap must not
exceed 0.050 inch in either measurement 1 or measurement 2. If difference
exceeds 0.050 inch adjust clutch lateral centering strut length as required and
align sheaves per Section 7.230.
g) Use following formula to obtain calculated dimensions for proper intermediate flex
plate shimming.

TABLE 7-1
INTERMEDIATE FLEX PLATE SHIM TABLE
CLUTCH SIDE TR DRIVE SHAFT SIDE
Calculated dimension Shim required Shim required

in inches from between A947-2 flex between A947-2 flex plate
Section 7.330(g) plate and A 195-1 yoke and 8223-X yoke
2 places. 2 places.
0.135 or more Remove TRGB shims or

shim A94 7-1 flex plate** or
change A907 yoke length**
or install longer 8223 yoke
0. 1 34 to 0. 1 0 5 AN960-416 washer AN960-416 washer
0.104 to 0.075 AN960-416 washer AN960-416L washer
0.074 to 0.045 AN960-416L washer AN960-416L washer
0.044 to 0.015 AN960-416L washer None
0.014 to -0.015 None None
-0.016 or greater Shim TRGB aft (max. 0.080

negative number inch*) or remove shims at
A947-1 flex plate** or
change A907 yoke length**
or install shorter 8223 yoke
*When shimming tail rotor gearbox, replace MS2007 4-04-04 bolts with
MS20074-04-06 bolts. If over 0.040 inch shims used, change washers
under bolt heads to AN960-416L. Total shims must not exceed 0.080
inch. Torque bolts per Section 1.330.
**Requires clutch sheave alignment check per Section 7.230.

7.330 Intermediate Flex Plate Installation and Shimming (cont'd)
NOTE
Use measurement with smaller difference between 3 and

9 o'clock gaps.
9 o'clock reading + 3 o'clock reading =

Divide by 2 =
Subtract *
Calculated Dimension =
*Measure A947-2 flex plate thickness across bonded washers four places and
average.
Shim as required per Table 7-1.
NOTE
When shims are installed or removed between tail

rotor gearbox and tailcone casting, lengthen A 121-
17 push-pull tube by 1 /2 turn of rod end for each
0.018 inch that tail rotor gearbox is shimmed aft;
shorten A 121-17 push-pull tube by 1 /2 turn of rod
end for each 0.018 inch of shims removed.
h) Install A947-2 flex plate using shims determined above. Torque attach bolts per
Section 1.320. Install palnut and torque stripe.
NOTE
Use AN960-416L or AN960-416 washers under

nuts as required to expose two to four threads
beyond nut.
WARNING
A 193 flex plates, which do not have bonded

washers, are obsolete and must be replaced with
A947 flex plates having bonded washers. If a
bonded washer separates from an A947 flex plate,
flex plate is unairworthy and cannot be repaired.
i) Check clearance between A331 bellcrank-to-A 121-17 push-pull tube forward rod
end attach bolt and flex plate (0.250 inch minimum) with actuator disengaged.

7.340 Checking Tail Rotor Drive Shaft Runout
Excessive tail rotor drive shaft runout can cause intermediate flex coupling or
damper assembly failure. To check runout:
a} Remove tailcone inspection covers on tailcone right side. Engage clutch.
b) Assemble MT260-6 tool and suitable dial indicator.
NOTE
The dial indicator included in the Robinson MT122

bolt stretch gauge can be used.
c) Insert dial indicator through farthest aft inspection hole on right side of tailcone.
Press dial indicator firmly against tailcone with extension riding on drive shaft.
d) Have someone rotate drive train at A 166 clutch shaft at least three full
revolutions. Dial indicator may vary somewhat with each revolution so it will be
necessary to take an average.
e) Repeat procedure in steps c) and d) at next inspection hole forward.
f) Remove extension from MT260 tool and, using longer extensions, check drive
shaft at remaining inspection holes.
g) Maximum runout at any location must not exceed 0.025 inch. If runout is
excessive, drive shaft must be repaired or replaced.

HOLD DIAL INDICATOR HOUSING

I FIRMLY AGAINST TAILCONE.
[
II II If It FWD
.012 11 .010 11 .005" .002 11
Sample of measurements taken.
FIGURE 7-12 TAIL ROTOR DRIVESHAFT RUNOUT CHECK

7.350 Two-Piece Tail Rotor Driveshaft
a) The two-piece tail rotor driveshaft consists of a

B224-1 driveshaft, B223-l, -2, -3, or -4 yoke assembly,
A041-1 damper bearing assembly, A553-2 block and two
A207-4 blocks. See Figure 7-12A.
b) The A041-1 damper bearing assembly is field replaceable

only with the two-piece tail rotor driveshaft.
c) The B224-l driveshaft is produced in one length only.

The overall length of the driveshaft assembly may be
adjusted with various length B223 yokes. The yokes
are produced in .150 inch length increments. See
Figure 7-12B.
d) Al97-1 one-piece driveshaft assemblies may be replaced

with the two-piece driveshaft per the table below:
One-Piece Overall B223 Yoke

Driveshaft Length Req. w/
(inches) B224 D.S.
A197-7 140.25 -1
Al97-4 140.40 -2
Al97-5 140.55 -3
Al97-6 140.70 -4
Al97-l Varies As Required
e) If the length of the driveshaft cannot be measured or

is unknown, use the following procedure to determine
the correct B223 yoke to use:
1. Install the intermediate flexplate onto the

Al95-l yoke on the clutch shaft. For this
measurement procedure, no shims should be
installed between the beveled washers or the
bonded washers on the flexplate and the
Al95-1 yoke.
2. Install the A553-2 block into the forward end

of the driveshaft. Align the two bolt holes
in the block and the driveshaft.
3. Consult the appropriate section of this manual

for the following installation steps. Connect
the B224-1 driveshaft to the aft flexplate and
the tail rotor gearbox input yoke. Install the
gearbox on the tailcone. Connect the damper as-
sembly to the clip on the inside of the tailcone.
Install the tailcone on the upper steel tube
frame. Engage the actuator.
Change 2: 4/15/88 Page 7.44A

7.350 Two-Piece Tail Rotor Driveshaft (cont'd)
4. Hold the driveshaft centered on the intermediate

flexplate. Measure the distance from the flexolate
to the center of the forward hole on the driveshaft.
Subtract .032 inches from this measurement, which is
the thickness of the beveled washer or the bonded
washer. This will be the Calculated Dimension.
Select the B223 yoke which is closest to but does
not exceed the Calculated Dimension. Shims may be
added or subtracted between the tail rotor gearbox
and the tailcone aft casting to adjust the driveshaft-
to-flexplate dimension. See Figure 7-12B. The
difference between the Calculated Dimension and the
length of the B223 yoke will be taken up with shims
per Section 7.330 of this manual.
5. Install A553-2 block in yoke end of T.R. driveshaft.

Removal of primer to install block is allowed. If
primer is removed, swab wet primer inside the T.R.
driveshaft before installing block. After instal-
lation, prime inside of T.R. driveshaft to cover
tube and seal edges of block.
6. Install the correct length B223 yoke onto the forward

end of the driveshaft. Align the two bolt holes.
Install two NAS1304-21 bolts with a washer and a
B207-4 block under the bolt heads and the nuts.
Torque the nuts to 100 inch-pounds plus nut drag
(add 10% for the total torque-110 inch-pounds).
Install and tighten the palnuts.
7. Use Zinc Chromate or epoxy primer to form fillets

at all joints for sealing moisture out. Paint as
required.
Page 7.44B Change 9: 5 JUL 90

r.r.:mlin
NAS1304-21 BOLT
(2 PLACES)
AN960-416L WASHER
FLANGED SIDE OF BEARING
HOUSING FACES WELDED
END OF DRIVE SHAFT.
I
111
1'1 l 11111 11
-l
·t-l-l1111
(4 PLACES)
~~u. rilL
,_1 NAS679A4 NUT
I
ltn
II (2 PLACES)
II
II
8330-13 PALNUT
II (2 PLACES) DRIVESHAFT
II
II
II
r.,- ~""' I I
~~-~~ It
-f. ____}---~:
I
II
.-~----~... ___11
•.._--=,.J
,, If
II
It
':".r.=r.; I 1
l--- I·
0.03~1
II
II
II
1-96.59±
inches
INSTALL BEARING ONTO SHAFT USING
8270-10 ADHESIVE. SEAL JUNCTURE
OF DRIVE SHAFT AND BEARING INNER
RACE WITH ZINC-CHROMATE OR EPOXY
FIGURE 7-12A PRIMER .
...,.,--- B223 YOKE

B224-1 DRIVESHAFT
(l-.032 = CALCULATED DIMENSION)

8223
YOKE DASH # LENGTH
Al93-2 FLEXPLATE -1 0.900
OR -2 1.050
A947-2 FLEXPLATE -3 1.200
-4 1.350
-6 0.750
FIGURE 7-128
Change 15: 26 JUL 96 Page 7.44C

7.360 B224-l Tail Rotor Driveshaft Corrosion Removal
,..
~1.50----1
I inches I
~ .001 inch maximum m3terial removal

-
...,.._IE---- from shaft surface at any point ------1.-~l
(.002 inch maximum reduction in
\
v .I diameter) .
I
.032 inch minimum wall
thickness this area after
material removal.
a) No power tools allowed.
b) Remove only the minimum amount of material necessary to

clean up damage; do not exceed limitations shown.
c) Sand or polish parallel to the shaft's long axis.
d) Polish reworked areas with 400 grit or finer wet-or-dry

sandpaper.
e) Zinc chromate or epoxy prime bare metal surfaces.
Page 7.44D Change 11: 7 AUG 92

7.400 Tail Rotor Gearbox
7.410 Tail Rotor Gearbox Removal

1. Mark tail rotor hub and blades and tail rotor pitch links to their respective pitch control
arms before disassembly. This will facilitate reinstallation and eliminate re-rigging tail
rotor if push-pull tube lengths are not altered.
2. Remove tail rotor assembly. Leave pitch control links attached to tail rotor blades.
3. Disconnect A120-1 bellcrank from push-pull tube.
4. Disconnect A120 bellcrank from gearbox and reassemble bellcrank hardware to
bellcrank. Slide pitch control, with bellcrank attached, off gearbox output shaft.
5. Disconnect gearbox chip detector wire at quick disconnect.
6. Remove tail rotor driveshaft per § 7.310.
7. Remove aft flex plate from gearbox. Reinstall bolts, spacers, and nuts on flex plate to
prevent loss.
7.420 Tail Rotor Gearbox Installation

1. Install tail rotor drive shaft per § 7.320.
WARNING
2. Install tail rotor pitch control and bellcrank. Check bellcrank to pitch control shimming
per § 8.562.
3. Connect A121-17 push-pull tube to aft bellcrank.
4. Install tail rotor assembly per § 9.213.

7.430 Tail Rotor Gearbox Shimming
Shimming of gearbox at mounting flange is only required when intermediate flexplate gap
between clutch shaft yoke and tail rotor drive shaft forward yoke is too small to allow
installation of flexplate. Gearbox may be shimmed aft a maximum of 0.080 inch. If shims
are installed (3) MS20074-04-06 and (1) NAS1304-8 bolts must be used for gearbox-to-
casting installation. If more than 0.040 inch shims are used, change NAS1149F0463P
washers under bolt heads to NAS1149F0432P. If tail rotor system is rigged and shims
are subsequently installed, extend A121-17 push-pull tube aft rod end 1/2 turn for each
0.018 inch the gearbox is shimmed aft; retract rod end 1/2 turn for each 0.018 inch of
shims removed.
7.440 Tail Rotor Gearbox Chip Indicator

If “TR CHIP” light illuminates:
1. Drain and flush gearbox per § 22-23 except strain oil (a paint filter works well) while
draining and examine any particles found in oil or on chip detector.
2. Particles larger than 0.09 inch long or 0.02 inch wide are cause for concern and
should be identified as ferrous or non-ferrous with a magnet. If particles are ferrous
return gearbox to RHC for repair along with particles. If particles are non-ferrous,
drain and flush gearbox per § 22-23.
3. If “TR CHIP” illuminates again within next 100 hours time-in-service a gearbox failure
may be imminent. Return gearbox to RHC for repair.

7.450 A021 Tail Rotor Gearbox Output Shaft Seal Replacement
1. Drain gearbox oil. Clean and inspect chip detector. Clean sight gage as required.
Reinstall chip detector and sight gage, torque per Section 1 .330 and safety wire.
2. Remove tail rotor per Section 9.21 0.
3. Remove pitch control per Section 8.561 and clean gearbox output shaft.
4. Verify tailcone-to-upper frame attach bolts are torqued per Section 1 .320.
5. See Figures 7-13A and 7-138. Slide MT295-1 0 mandrel on output shaft until it
contacts seal. Tape mandrel to gearbox to maintain position when punching holes
in seal.
6. Using small holes in MT295-1 0 mandrel as a guide, punch four holes in output
shaft seal with MT295-3 punch.
CAUTION
MT295-1 0 mandrel is designed to guide and limit MT295-3

punch protrusion into gearbox. Punching seal using other
tools may damage gearbox case, output shaft, and/or
bearings.
7. Remove tape holding MT295-1 0 mandrel. Rotate mandrel to align large holes in
flange with punched holes in output shaft seal. Install a 924 70A 113 screw thru
each large hole in flange into matching hole in seal. Tighten screws until heads
contact mandrel flange; do not overtighten screws.
CAUTION
Do not use screws longer than 0. 75 inch; longer screws

may damage bearing.
8. See Figure 7-13C. Lubricate MT295-6 screw threads with anti-seize and install in
end of MT295-1 0 mandrel. Tighten screw to remove seal. Remove mandrel and
seal.
9. Carefully clean seal seating surfaces in gearbox and on output shaft with a solvent-
dampened cloth, dry, and inspect for damage. Verify output shaft shoulder has a
smooth edge and will not damage seal lip. Do not polish or alter seal seating
surfaces. Return gearbox to RHC for repair if damage is noted.
10. See Figure 7-13D. Lubricate new A966-2 seal inner lip and output shaft seal seat
area with A257-2 lubricant. Do not lubricate seal outside edge and its mating
surface in gearbox; they must remain clean and dry. Slide seal on output shaft
with cupped face toward gearbox until seal contacts gearbox.

7.450 A021 Tail Rotor Gearbox Output Shaft Seal Replacement (cont' d)
11. Remove MT295-6 screw and old seal from MT295-1 0 mandrel and slide
mandrel on output shaft until it contacts seal.
12. See Figures 7-13A and 7-138. Determine if gearbox output shaft seal
installation is recessed type or flush type. Install flush-type seal until it is flush
with seal bore; install recessed-type seal until MT295-1 0 mandrel contacts
gearbox face. Lightly tap end of mandrel with soft-face hammer until seal is
properly positioned.
13. Remove mandrel.
14. Service tail rotor gearbox with A257-2 lubricant. Verify filler-vent plug vent
holes are clear. Install filler-vent plug and torque per Section 1 .330.
15. Install pitch control per Section 8.562.
16. Install tail rotor per Section 9.212 or 9.213, as applicable.
17. Inspect seal for leaks after dynamic balancing tail rotor.
7.460 8021 Tail Rotor Gearbox Output Shaft Seal Replacement
1. Drain gearbox oil. Clean and inspect chip detector. Clean sight gage as required.
Using new 0-ring(s) install chip detector and sight gage, torque per Section 1 .330,
and safety wire.
3. Remove pitch control per Section 8.561 and clean gearbox output shaft.
4. Cut safety wire and remove four drilled-head bolts securing 8552-1 retainer and
slide retainer off output shaft.
CAUTION
Do not alter shim stack-up between retainer and bearing or

bearing preload may be adversely affected.
5. Remove seal and 0-ring from 8552-1 retainer.
6. Carefully clean and dry retainer seal seating surface and 0-ring groove.
7. With seal lip toward gearbox, press new A966-4 seal into retainer bore
I 0.140/0.160 inch below external flat surface. Lubricate new 0-ring with A257-2
gear oil and install in retainer groove without twisting.
8. Lubricate seal seating area of output shaft with A257-2 gear oil.
9. Carefully slide retainer over output shaft. Align retainer and gearbox bolt holes and
press retainer into gearbox. Install four drilled-head bolts, torque per Section
1.330, and safety wire.

FIGURE 7-138 PUNCHING HOLES

FLANGE INDICATES IN FLUSH SEAL
RECESSED SEAL
SMALL
FIGURE 7-13A
MT295-10 MANDREL
(MT295-6 SCREW REMOVED)
FIGURE 7-13C REMOVING SEAL
MT295-10 MANDREL
(MT295-6 SCREW REMOVED)
FIGURE 7-130 TAIL ROTOR OUTPUT SHAFT

SEAL INSTALLATION
Change 17: 31 DEC 98 Page 7.48A

7.460 8021 Tail Rotor Gearbox Output Shaft Seal Replacement (cont'd)
10. Install pitch control per Section 8.562.
11. Install tail rotor per Section 9.212 or 9.213, as applicable.
12. Inspect for leaks after dynamically balancing tail rotor.
I 7.4 70 8021 Tail Rotor Gearbox Input Shaft Seal Replacement
1. Drain tail rotor gearbox lubricant.
2. Remove tailcone per Section 4.311
3. Remove tail rotor drives haft per Section 7. 31 0.
4. Remove aft flex plate from gearbox.
5. Remove nut & washer securing splined 8546 input yoke on gearbox input
shaft. Remove yoke.
6. Cut safety wire from 8549 retainer and remove retainer and adjacent A 117
shim from gearbox.
7. Remove and discard seal and o-ring from retainer.
8. Remove A266 spacer and underlying o-ring from input shaft. Discard o-ring.
9. Clean parts and inspect. Verify no grooves in A266 spacer, no scoring on

A 11 7 shim (such as from rotating), and no wear steps on input yoke & shaft
splines.
10. Coat input shaft splines with 8270-21 protectorant and allow to dry.
11. Press new A966 seal 0.030 inch deep beyond flush into chamfered inner end
of 8549 retainer, with solid side of seal toward opposite hexagonal end.
12. Prelubricate new o-ring with A257-2 lubricant and install in groove around
8549 retainer.
13. Slide A 117 shim over input shaft until it contacts input bearing outer race.
14. Prelubricate new o-ring with A257-2 lubricant and slide over input shaft until it
contacts input bearing inner race.
15. Lubricate outside diameter of A266 spacer with A257-2 lubricant and slide it,
inner-chamfered end first, over input shaft until spacer inner chamfer seats on
o-ring.
16. Coat threads of 8549 retainer with A257-9 anti-seize and install on gearbox.
Torque retainer per Section 1.330 and safety wire.
17. Install input yoke on input shaft. Apply 8270-11 adhesive to input shaft
threads and install washer and nut. While adhesive is still wet, torque nut per
Section 1 .330 and torque stripe.

7.500 Actuator Assembly
7.510 Actuator Removal

1. Remove tailcone fairing.
2. Full disengage clutch.
3. Remove fanwheel per § 6.210.
4. Put a four-inch wood block under clutch shaft just forward of upper sheave on horizontal
firewall. This keeps sheave from drooping and prevents damage to forward flex plate
per Figure 7-8.
5. Disconnect two wiring connections to actuator.
6. Remove upper and lower NAS6604 bolts connecting actuator to bearings and remove
actuator.
7.520 Actuator Installation

1. Connect actuator to A184 bearing and standard torque bolt per § 23-32. Install
palnut, standard torque per § 23-32, and torque stripe per Figure 2-1.
2. Install lower attach bolt with head facing aft. Use one NAS1149F0432P washer
under bolt head and one NAS1149F0463P washer under nut. Standard torque bolt
per § 23-32. Install palnut, standard torque per § 23-32, and torque stripe per Figure
2-1. Remove wooden block.
3. Install fanwheel per § 6.220.
4. Connect motor and switch assembly electrical leads.
CAUTION
Do not engage actuator without scroll installed.
7.530 Actuator Gearmotor Replacement

Actuator Gearmotor can be replaced with actuator on helicopter.
1. Disconnect gearmotor electrical leads.
2. Cut safety wire from and remove four gearmotor attaching screws. Exercise care
not to drop either safety wire or screws in V-belt sheaves.
3. Slowly slide gearmotor assembly from housing. An unscrewing motion may be
necessary.
4. Lightly lubricate worm gear on new gearmotor assembly with A257-1 grease before
installing. Install o-ring onto gearmotor nose piece.

7.530 Actuator Gearmotor Replacement (continued)
5. Install new gearmotor into housing with wire leads pointing down. Verify no gap
exists between housing and gearmotor mounting flange before installing screws; do
not use screws to draw gearmotor into housing as motor flange can break.
6. Secure gearmotor to housing with four mounting screws and safety wire with 0.020-
inch diameter wire using single strand method.
7. Connect gearmotor electrical leads. Engage clutch, listen for binding, and verify
actuator fully tensions drive belts.
8. Seal all fasteners, seams and openings around gearmotor with B270-8 sealant.
9. Ty-rap gearmotor electrical leads as required.
CAUTION
Severe damage to actuator and drive belts can occur if gearmotor
electrical leads are installed incorrectly in wiring connector
(gearmotor will operate backwards and down-limit switch and
spring switches will not shut off gearmotor current).
7.540 Actuator Adjustment

1. Engaged Limit
The actuator engaged limit is determined by column springs which control drive belt
tension. Column springs may only be adjusted by the factory.
2. Disengaged Down-Limit Adjustment (see Figure 7-15)
The down-limit switch is activated by the down-limit stop screw which can be
adjusted using long 3/8-inch open-end and ¼-inch box-end wrenches. Adjust down-
limit stop screw to maintain proper belt deflection per § 7.282 with actuator fully
disengaged. Minimum clearance between screw heads at scissors is 0.005 inch.
3. Maximum Extension (see Figure 7-15)
Maximum engaged extension is 1.85 inches measured between top of column spring
block and bottom of screw housing. Drive V-belts must be replaced when maximum
extension is encountered.

Intentionally Blank

FIGURE 7-15 ACTUATOR MAXIMUM
ENGAGED (EXTENSION) LIMIT
AND
MINIMUM DISENGAGED
(RETRACTION LIMIT

7.550 Switch and Fuse Replacement
7.551 Switch Replacement

1. Remove actuator from helicopter per § 7.510.
NOTE
Switches may be replaced as a complete harness assembly or
replaced individually by soldering wire connection and installing
heat shrink.
2. Remove each switch by removing attaching screw, nut, washer, and spacing washers
between switch and plate.
NOTE
Bond the four spacing washers to the new switch(es), if
necessary, to ease reassembly.
3. Replace complete switch and wire harness assembly or, if installing a single switch,
cut faulty switch from harness wiring. Cut wires as close to switches as possible.
4. Slide heat shrink over each cut wire. Solder wires to switch and install heat shrink
over solder connection.
5. Reassemble switch(es) to plate. Two spacing washers are installed between switch
and plate at each attach screw and one under nut. Do not over tighten screws or
plastic switch housing may crack.
6. Reinstall actuator on helicopter per § 7.520.
7.552 Fuse Replacement

An in-line fuse holder is installed in clutch actuator motor power circuit. Fuse holder is
mounted on test switch panel. Replace fuse with 1.5 amp (AGC 1.5) fuse.

7.600 Rotor Brake
7.610 Rotor Brake Removal

1. Remove tailcone cowling. Remove forward flex plate. Mark and record any shim
washers installed between flex plate and main rotor gearbox input yoke and/or clutch
shaft yoke.
WARNING
(identified by letter “E” or subsequent letter on two adjacent
arms of flex plate both sides).
2. Remove cotter pin and nut securing input yoke on main rotor gearbox. Remove yoke.
Disconnect brake spring from firewall angle.
3. Disconnect cable from lever. Disconnect wiring to micro switch at three-pin connector.
4. Cut and remove safety wire, then remove three bolts securing rotor brake. Remove
rotor brake assembly.
7.620 Rotor Brake Installation

1. Place rotor brake assembly over splined input pinion shaft of main rotor gearbox.
2. Place one each of two small (A130-41) spacers in place between rotor brake assembly
and pinion end cover. Install one each NAS1149F0432P washer on three NAS1352-
4H30P bolts. Insert first bolt through rotor brake assembly and A130-41 spacer. Insert
second bolt through Hall Effect sender plate, rotor brake assembly and A130-41 spacer.
3. Insert third bolt through Hall Effect sender plate and long A130-41 spacer. Finger
tighten three bolts into gearbox, then special torque bolts per § 23-33 and safety with
0.032 inch diameter safety wire. Attach spring to the firewall angle.
4. Coat splines of pinion shaft with B270-21 protectant before installing yoke. Place
A908-4 yoke on pinion shaft. Install one each A141-10 washer and AN320-8 nut on
pinion shaft. Special torque nut per § 23-33 as required to align castellations on nut
with hole through pinion shaft. Do not exceed 410 in.-lbs. Install one MS24665-210
cotter pin.
5. Set Hall Effect sender-to-magnets gap per § 7.141.
6. Attach cable to lever. Reconnect wiring to micro switch at three-pin connector.

7.620 Rotor Brake Installation (continued)
7. With brake engaged, adjust gap between NAS428-3-12 bolthead on B109-1 arm and
A130-43 spacer to 0.030–0.035 inch. Lock adjustment by tightening MS21042L3 nut.
8. With brake in the released position, measure gap between B112-1 lever and B110-1
arm assembly. The gap measurement should be 0.030–0.170 inch. Adjust length of
bead chain as required to obtain proper gap. One bead is approximately 0.150 inch.
9. Adjust micro switch to open and close at a gap of 0.20–0.30 inch between B112-1
lever and B110-1 arm.
10. lnstall forward flex plate.
12. Install intermediate flex plate per § 7.330.
7.630 Rotor Brake Pad Replacement

1. Minimum pad thickness is 0.030 inch.
2. Brake pad replacement is accomplished by replacing B110-1 and B109-1 arm
assemblies.

Intentionally Blank

ROBINSON MAINTENANCE MANUAL MCOELR22
FIGURE 7-16A ROTOR BRAKE ADJUSTMENTS

AND CLEARANCES
.030-.170 in. GAP BET-
WEEN B112-l LEVER AND
- Bll0-1 ARM ASSEMBLY.

CHAPTER 8
FLIGHT CONTROLS
Section Title Page
8.000 Flight Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1

8.001 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1
8.002 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1
8.100 Cyclic Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1
8.110 Cyclic Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1
8.111 Removal of Cyclic Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1
8.112 Installation of Cyclic Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
8.120 Cyclic Grip Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7
8.121 Removal of Cyclic Grip Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7
8.122 Installation of Cyclic Grip Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 8.8
8.130 Cyclic Lateral (Right) Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.10
8.131 Right Trim Spring Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . 8.10
8.132 Right Trim Spring Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . 8.10
8.133 Right Trim Spring Replacement and Shimming . . . . . . . . . . . . . . . . . . 8.11
8.140 Cyclic Longitudinal (Fore-Aft) Elastic Trim Cord . . . . . . . . . . . . . . . . . . . 8.15
8.141 Longitudinal Trim Cord Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.19
8.142 Longitudinal Trim Cord Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 8.19
8.150 Cyclic Friction Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.20
8.151 Cyclic Friction Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.20
8.160 A121-7 Push-Pull Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.21
8.161 A121-7 Push-Pull Tube Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.21
8.162 A121-7 Push-Pull Tube Inspection/Repair . . . . . . . . . . . . . . . . . . . . . 8.21
8.163 A121-7 Push-Pull Tube Sleeve Installation . . . . . . . . . . . . . . . . . . . . . 8.22
8.164 A121-7 Push-Pull Tube Sleeve Inspection . . . . . . . . . . . . . . . . . . . . . 8.22
8.165 A121-7 Push-Pull Tube Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 8.23
8.200 Collective Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.25
8.210 Collective Stick Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.25
8.211 Collective Stick Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.25
8.212 Collective Stick Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.26
8.220 Collective Spring Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.30
8.221 Collective Spring Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.30
8.222 Collective Spring Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.32
8.223 Collective Spring Adjustment for A038-1 thru -4 Assembly . . . . . . . . . 8.33
8.224 Collective Spring Adjustment for A038-5 and -6 Assembly . . . . . . . . . 8.34
OCT 2014 Chapter 8 Flight Controls Page 8.i

CHAPTER 8
FLIGHT CONTROLS (Continued)

Section Title Page
8.225 Collective Friction Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.34

8.230 RPM Governor System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.34A
8.231 Governor Controller Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.34A
8.232 Governor Controller Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.34A
8.233 Governor Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.34A
8.234 Governor Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.34C
8.239 Governor Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.34C
8.300 Jackshaft and Support Struts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.35
8.310 Jackshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.35
8.311 Jackshaft Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.35
8.312 Jackshaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.35
8.320 Strut Assembly (Jackshaft Support) . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.35
8.321 Strut Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.35
8.322 Strut Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.38
8.400 Swashplate and Main Rotor Pitch Links . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.39
8.410 Swashplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.39
8.411 Swashplate Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.39
8.412 Swashplate Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.40
8.413 (Reserved)
8.414 (Reserved)
8.415 (Reserved)
8.416 Shimming Upper (Unflanged) Spherical Sleeve with Aluminum Ball . . . . 8.48
8.500 Tail Rotor Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.48
8.510 Tail Rotor Pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.48
8.511 Tail Rotor Pedal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.48
8.512 Tail Rotor Pedal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.52
8.520 A317-1 Lower Bellcrank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.52
8.521 A317-1 Lower Forward Bellcrank Removal . . . . . . . . . . . . . . . . . . . . 8.52
8.522 A317-1 Lower Forward Bellcrank Installation . . . . . . . . . . . . . . . . . . . 8.53
8.530 A316-1 Upper Bellcrank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.55
8.531 Bellcrank Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.55
8.532 Bellcrank Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.55
8.540 A331-4 Intermediate Bellcrank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.56
Page 8.ii Chapter 8 Flight Controls OCT 2014

CHAPTER 8
FLIGHT CONTROLS (Continued)

Section Title Page

8.550 A120-3 Aft Bellcrank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.57
8.560 A031-1 Pitch Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.57
8.561 Pitch Control Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.57
8.562 Pitch Control Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.57
8.570 Tail Rotor Pitch Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.58
8.571 Tail Rotor Pitch Link Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.58
8.572 Tail Rotor Pitch Link Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.58
8.600 A203 Yoke and A205 Fork Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.60
8.610 Bearing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.60
8.615 C648-2 Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.60
8.620 A139-1 Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.60
8.630 B115-1 Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.62
8.640 Yoke and Fork Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.63
OCT 2014 Chapter 8 Flight Controls Page 8.iii

Intentionally Blank
Page 8.iv Chapter 8 Flight Controls OCT 2014

CHAPTER 8
FLIGHT CONTROLS
8.000 Flight Controls
8.001 Introduction
This section covers removal and installation procedures for cyclic controls, collective
controls, tail rotor controls and their related components.
WARNING

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.
8.002 Description (See Figures 8-1 and 8-2)
Dual controls are standard equipment and all primary controls are actuated through push-
pull tubes and bellcranks. Bearings used throughout the control system are either sealed
ball bearings or have self-lubricated Teflon liners.
Flight controls are conventional. The cyclic stick appears to be 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.
The collective stick is also conventional with a twist grip throttle control. When the
collective is raised, the throttle is opened by an interconnecting linkage. An electronic
governor makes minor throttle adjustments required to maintain RPM.
8.100 Cyclic Controls
8.110 Cyclic Assembly
8.111 Removal of Cyclic Assembly
a. Remove left seat back, center horizontal and vertical panels.
b. Remove collective assembly per § 8.211.
c. Remove screws holding mixture and carburetor heat control cable covers to cyclic
box cover.
d. Remove roll pin from cyclic friction knob and remove knob.
e. Unscrew right trim knob from trim shaft.
f. Remove screws holding cyclic box cover to cyclic box and to side panels.
g. Lift cyclic box cover and disconnect post light wire.
OCT 2014 Chapter 8 Flight Controls Page 8.1

FIGURE 8-1 MAIN ROTOR FLIGHT CONTROLS
Page 8.2 Chapter 8 Flight Controls OCT 2014

RCBINSCN MAINTENANCE MANUAL MOOELR22
~--
"'
/
.\ ~-------"....._
• · : Al20-1
r---_11 ~~~~~~-:~K ~= o---~~
j Al24-l
I PITCH CONT.
----- HOUSING
A330-2 A AlOl-4 ROD END
PEDAL ASSY ill Al02-4 ROO END
A330-l
PEDAL ASSY. &_ Al25-l PITCH CHANGE STUD
/ A316-! T. R. BELLCRANK ASSY.
Al21-13 P/P TUBE ASSY.
Al21-9 P/P TUBE ASSY.
)
~
-- ----
A317-l BELLCRANK
~ A755-2 & -4 FOR REMOVABLE CONTROLS

Al21-ll ~ A755-l & -3 FOR REMOVABLE CONTROLS
P/P TUBE ASSY.
FIGURE 8-2 TAIL ROTOR FLIGHT CONTROL

8.111 Removal of Cyclic Assembly (cont'd)
h) Remove screws holding cyclic box assembly to the keel

panels.
NOTE
Unscrew from nutplate but DO NOT
remove the two cyclic friction
attach bolts or friction spacers
may fall out.
IF FIREWALL PLUG INSTALLED FOLLO\.J STEPS i AND j
i) Move cyclic stick full fwd. and disconnect bolt holding
the Al27-3 rod end to the aft fork of the cyclic pivot.
j) Remove stainless steel hole plug from rt. side of vertical
firewall. Remove bolt holding the Al21-7 P-P tube rod ends
to the aft fork of the cyclic pivot.
IF FIREWALL PLUG NOT INSTALLED FOLLOW STEPS k &~D 1
(PLUG CAN BE INSTALLED FOLLOWING INSTRUCTIONS IN RHC
KIT II KI-21).
k) Disconnect both forward push-pull tubes from the swash-
plate and the forward push-pull tube from the jackshaft.
1) Unscrew the three push-pull tubes from the rod ends attached
to the aft end of the cyclic assembly.
m) Disconnect 6-pin electrical connection at bottom of
stick.
n) Remove cyclic assembly from rotorcraft,
8.112 Installation of Cyclic Assembl
IWARNING I
Rigging must be checked if the
following has occurred:
1. Replacement of the cyclic assy.
2. Replacement of the A338-l cyclic
oox or A320-l cyclic stick.
3. Replacement or change of A205-l
Yoke (between collective and
cyclic).
4. If the rod ends have been re-
moved from the push-pull tube
or push-pull tube length was
changed on the Al21-l,-3,-5 or
-7 push-pull tubes.
5. Jackshaft support length is
changed.

8.112 Installation of Cyclic Assembly (cont'd)

NOTE
On cyclic installation ensure right
trim end cap fits flus·h into left keel
panel hole. Ensure cyclic friction
stackup is not misaligned and the
friction is on, to hold stackup in place.
a) Install cyclic assembly. Attach cyclic box to keel
panels.
NOTE
Ensure friction assembly clears all
wires on installation.
b) Attach cyclic friction assembly to cabin. Torque
NAS1030 attach bolts to 40 in-lbs. plus locking torque.
IF P-P TUBE ROD ENDS DISCONNECTED FROM FO~~ USING
PLUGGED HOLE IN FIRE\.JALL, FOLLmv STEP c) AND d) .
c) Attach the Al21-7 P-P tubes to the fork of the cyclic pivot.
Install the AllS-1 spacers outboard of the rod ends and
the long spacer in between, torque nut and install palnut.
d) Move cyclic stick full fwd and connect Al21-3 P-P tube to
the cyclic stick fork bellcrank. Spacers to be installed
on each side of rod end, lockwasher under the nut and torque.
I WARNING I
Smaller diameter of the AllS-1 spacer
must be against the rod end ball.
IF FIREWALL PLUG NOT INSTALLED, FOLLOW STEPS e) and f)·

e) Screw the Al21-3 P-P tube onto the aft rod end of the
Al75 bellcrank assembly. (See Figure 8-3)
f) Screw the two Al21-7 P-P tubes onto the two aft rod
ends attached to the cyclic fork.
NOTE
No palnut required on rod end of A205 fork
g) If A205-l fork was removed from forward rod end of Al75
bellcrank, screw the fork onto the rod end to 3.45 inches
from center of rod end hole to center of attaching bolt
hole. (See Figure 8-3)
h) Install collective stick (standard or removable) (See
Section 8.212).
i) Attach the A205-l yoke connecting the cyclic stick assembly
and the collective stick assembly. (See Section 8.212)
j) Connect Al21-3 P-P tube to the jackshaft. (See Section 8.312)
k) Connect both Al21-7 P-P tubes to the swashplate. (See
Section 8.412).

CYCLIC CONTROL STICK
Al21-5 P/P TUBE
LEVEL TO
M.R.HUB
00-.50
A337-l
JACK SHAFT
COLLECTIVE CONTROL STICK
A333-l
COLLECTIVE
STOP
~ ~£ = -=----:=------- ---
~======~---- A211-l
CYC. CONTROL STOP PLATE
_______, ____ 23.24 _ _ _ _ _ _ _ ___..

Al21-l P/P TUBE
Al21-7 P/P TUBE
A175-1 BELLCRANK
(STANDARD & HP)
FIGURE 8-3 CYCLIC AND COLLECTIVE CONTROL OR
A958-1 BELLCRANK
(ALPHA, BETA, &
MARINER)
Page 8.6
Issued 5/22/87
8.112 Installation of Cyclic Assembly (cont'd)
j) Install cyclic box cover.
1. Connect post lightwire and ty-rap clear of controls,
2. Insert right trim shaft through cover and install

knob.
3. Attach power plant controls to the cyclic box

cover.
4. Install cyclic box cover and tighten the attaching

screws.
k) Install cyclic friction knob.
See Section 8.150 for adjusting cyclic friction assembly.
1) Move flight controls throughout complete travel. Verify

no binding or clearance problems.
m) Rig flight controls per Section 10.000.
I WARNING I
Ensure all jarnnuts and attaching
hardware has been torqued per
Section 1.300 Fastener Torques.
n) Install all seat backs and inspection covers.
8.120 Cyclic Grip Assembly (Standard or Removal)
8.121 Removal of Cyclic Grip Assembly.
This may be accomplished, if necessary, without removal

of complete cyclic assembly from rotorcraft.
a) Remove bottom center inspection panel.

Disconnect 6-pin connector and use pin
extractor to remove the pins from the
connector.

8.121 Removal of Cyclic Grip Assembly (cont'd)
b) Remove end cap from the cyclic grip pivot.
c) Remove cotter pin, nut and Al41-14 washer.
d) Gently tap cyclic grip shaft (DO NOT damage threads)

and remove cyclic grip assembly from A320-l stick.
NOTE
DO NOT damage bearings in removal.
NOTE
The six wires are grouped into

two sets of three wires each on
the bottom right side of the
cyclic stick with heat shrink
around all six to prevent chafing.
e) Remove the heat shrink and attach two pieces of
0.032" or 0.020" safety wire. One piece of safety
wire on one of the wires in each group. Pull
each wire group out of the stick, but leave the
two pieces of safety wire protruding from each
end.
8.122 Installation of Cyclic Grip Assembly (Standard or

Removable )
a) Cyclic grip assembly may be installed without removal

of complete cyclic box assembly from rotorcraft.
NOTE
Mark wire numbers near pins for

later re-installation.
1. Remove bottom center belly panel.

2. Remove pins from connector.
NOTE
Rigging check not required after

cyclic grip installation.
b) Ensure rollpin is installed in the grip assembly.

Heat shrink and two grommets should already be in-
stalled over the six wires coming out of the grip
assembly.

8.122 Installation of Cyclic Grip Assembly (cont'd)
NOTE
The six wires are to be grouped

into two sets of three wires each.
One group will extend through the
forward right side of the cyclic
stick and the other will extend
through the aft right side.
c) Using two pieces of safety wire extending from the

top aft electrical hole in the cyclic, one through
the bottom right forward side of the stick and the
other through the bottom right aft side, stagger
and tape three wires onto each safety wire. Carefully
pull the safety wire and wires through the cyclic
stick.
d) Attach heat shrink around all six wires and slide

shrink tubing into stick as far as possible to pre-
vent chafing.
e) Reinstall pins on each wire into proper position

connector.
Housing Pin Location l 2 3 4 5 6

Standard Cyclic Wires 231 232 233 234 235 236
Removable Cyclic Wires 277 280 281 234 235 236
f) Reconnect the cyclic wiring connector.
g) Slide grip assembly into bearings in stick assembly.

Install Al41-14 washer and castellated nut.
I CAUTION I
Secure nut until there is no ax-
ial movement of bearings and cy-
lic grip assembly. DO NOT over-
tighten assembly as it will dam-
age the bearings.
h) Install cotter pin and end cap.
i) Install bottom rotorcraft inspection panels.

8.130 Cyclic Lateral (Right) Trim
The function of the cyclic lateral trim spring is to remove

the left stick force in cruise conditions. It is actuated by
pulling up on the black knob located forward of the cyclic stick.
The trim spring (two sizes available) may be changed or shimmed
to create the force necessary to balance the cyclic control
laterally. This usually is required after a main rotor blade
change. Use the following procedures to remove, change, shim
and replace the trim spring assembly:
8.131 Right Trim Spring Assembly Removal
a) Remove right trim knob.
b) Remove cyclic friction knob.
c) On the in-flight adjustable lateral trim assemblies,

remove the lateral trim adjustment knob located on the
left side of the console.
d) Remove four (4) attaching screws holding the power-

plant control cables (mixture and carb heat) .
e) Remove cyclic box cover attaching screws.
f) Disconnect cyclic box cover post light at disconnect.
g) Disconnect right trim assembly attach bolt.
h) Firmly grasp the spring assembly, tip the cyclic stick

to the right to relieve some of the spring pressure.
Pull up and to the right to remove the assembly.
8.132 Right Trim Spring Assembly Installation
a) Move the cyclic stick to the right to relieve some of

the spring tension for installation. Firmly grasp the
spring assembly and insert the right trim spring cap
flush into the left keel panel while ins~alling the
spring assembly. Pivot into the cyclic stick pivot
forks.
b) Install bolt to connect assembly. Torque attaching

nut to 100 in.-lbs plus nut drag.
c) Connect cyclic cover post light wire and ty-rap clear

of moving controls.
d) Install cyclic box cover to airframe. Tighten all

attaching screws.

8.132 Right Trim Spring Assembly Installation (cont'd)
e) Tighten four attaching screws holding the powerplant

control cables (mixture & carb heat).
f) Install right trim knob.
g) Install cyclic friction knob. Install rollpin and

safety wire.
h) On the in-flight adjustable lateral trim assemblies,

install the adjustment knob on the trim assembly shaft
located on the left side of the console.
8.133 Right Trim Spring Replacement & Shimming (See Fig. 8-4)
a) Spring Replacement
1. Remove the right trim assembly per Section 8.131.
2. Remove the cotter pin from the clevis pin.
3. Squeeze the spring and remove the clevis pin.
4. Remove the A581-l arm, A588-l spacer, and A583-1 spring

cap.
5. Replace the spring as indicated by flight testing.
NOTE
Changing of the trim spring will

create a large change in trim.
Shimming of the springs may be re-
quired to obtain the desired trim
forces.
On the in-flight adjustable lateral trim assemblies,

remove the A584-l bearing support and Al30-46 spacer.
Remove the A583-2 cap by unscrewing it from the
assembly shaft.
6. Reinstall the A581-l spring cap, A588-l spacer, and

A583-l arm.
7. Install the clevis pin and cotter pin.

install the A583-2 cap on the shaft, then the Al30-46
spacer, then the A584-l bearing support.
8. Install the right trim assembly per Section 8.132.


1 4901-1032 Knob
2 A587-1 Stem
3 A589-1 Guide
4 A586-1 Fork
5 MS24665-138 Cotter Pin
6 MS20392-1Cl3 Pin
7 AN960-4 Washer
8 A585-1 Shaft
9 A581-1 Arm
10 A588-1 Spacer
11 A583-1 Cap
12 A618-1 or -2 Spring
13 AN960-416 or 416L Washers (As required for shimming)
14 5100-25 Retaining Ring (Circlip)
15 A104-3 Bearing
16 A584-1 Bearing Support
17 NAS1303-18 Bolt
18 AN960-416L Washers
19 A582-1 Plate
20 AN960-10L Washers
21 NAS679A3 Nut
22 A177-1 Pivot
23 NAS1304-17 Bolt
24 NAS1291-4 Nut
25 A587-2 Stem
26 52-022-094-0625 Roll Pin
27 A58 5-2 Shaft
28 ABYT4 Bearing
29 MS24665-132 Cotter Pin
30 A586-2 Fork
31 NAS1352-08LE6 Screw
32 A583-2 Cap
33 B160-1 Pin
34 AN340-8 Nut
35 NAS1291-08 Nut
36 A130-46 Spacer
37 Al30-45 Spacer
38 AN960PD10L Washer
39 A483-1 Knob

r SHIM AT THIS
11 LOCATION
\ 14
12 ~ - ) I
J
8
SHIM AT THIS 11
-----25 LOCATION
1s I
16
FIGURE 8-4 RIGHT TRIM ASSEMBLY

b) Shimming Right Trim Spring (See Fig. 8-4)
1. Remove the right trim assembly per Section 8.131.
2. Remove the trim spring per Section 8.133.
3. Slide the A583-l lower spring cap off the rod.
4. Install shim washers between the A583-l lower spring

cap and circlip as necessary to adjust trim force.
remove A584-l bearing support, the A130-46 spacer,
the A583-2 cap, the A618 spring and the A583-1 cap.
Install shims between the A588-1 spacer and the
A583-1 cap.
NOTE
When shimming the A618-1 (primer
colored) spring (10.7 lb-in.) the
maximum allowable shimming is (8)
I
AN960-416 washers. When shimming
the A618-2 (black colored) spring
(14.5 lb-in.) the maximum allowable
shimming is (5) AN960-416 washers.
NOTE
On the in-flight adjustable lateral
trim assemblies, only the B056-l
assembly with the primer (green)
colored spring may be shimmed. The
maximum number of shims is 3 AN960-
416 washers. The B056-2 adjustable
lateral trim assembly with the
black colored spring must not be
shimmed.
I CAUTION I
Shimming in excess of that indi-
cated in the above NOTES will cause
the trim springs to bottom prevent-
ing full left cyclic travel.
5. Slide the A583-l lower spring cap, spring, A583-1

uppercap, A588-1 spacer, and A581-1 arm onto the
rod. See Figure 8-4C.
6. Install the clevis pin and cotter pin.
7. Reinstall the trim spring assembly per Section

8.132.
after the shims have been installed, reinstall the
A583-1 cap, the A618 spring, the A583-2 cap, the
Al30-46 spacer, and the A584-1 bearing support.
Page 8.14 Change 2: 4/15/88
8.140 Selecting Longitudinal Elastic Trim Cord

The Elastic Trim Cord is used to cancel out most longitu-
dinal stick forces during cruise flight.
If the cyclic grip moves forward in cruise flight, a weaker
elastic trim cord is required. If the cyclic stick grip
moves aft in cruise flight, a stronger elastic trim cord
is required.
a) Remove the elastic trim cord per Section 8.141 and
determine the strength of that cord; either by the
I.D. tag attached or by the diameter of the cord and
the length of cord from inner lock ring of one ena--
to inner lock ring at the other end.
NOTE
The R22 parts catalog lists
the elastic trim cords by part
number and dash numbers also
length, diameter and (force)
load when installed.
b) Following the statement above, and the amount of addi-

tional force required to keep the cyclic centered for
level cruise flight, select an appropriate elastic
trim cord.
c) Install per Section 8.142.
d) Test fly helicopter to determine if proper cord was
selected; repeat above procedure as required to find
cord which will balance longitudinal cyclic stick
forces.

ROBINSON MAINTENANCE MANUAL MCCEL R22

FIGURE 8-4A SHORT ELASTIC TRIM CORD
FIGURE 8-48 LONG ELASTIC TRIM CORD

FIGURE 8-4C CYCLIC RIGHT TRIM ADJUSTMENT
WASHER FOR RIGHT TRIM ADJUSTMENT
INSTALL AN960-416 OR
AN960-416L WASHER HERE
\•
NOTE
WHEN INSTALLING LARGER (1.1 in.)
BELLEVILLE WASHERS (4 ea.) THE
SPACERS A130-18 AND A130-19 MUST -Al30-19
BE SANDED TO THE LENGTH INDICATED. SPACER
Al30-18 NEW LENGTH- .105/.115 in.
A130-19 NEW LENGTH - 4.51 in.
Page 8.18 Change 11: 7 AUG 92

8.141 Longitudinal Trim Cord Removal
NOTE
For inspection criteria of trim

cord, See Section 2.410, Item 4.
a) Remove the screws holdin3 the cabin bottom fore-aft

inspection panel.
NOTE
If transponder antenna is installed

on this inspection panel, slowly
lower panel and disconnect the antenna
lead and ground wire to the anten-
na, pull XPDR circuit breaker and
tag C.B. with"Antenna Rmvd."
b) Push cyclic stick full forward.
c) If short elastic trim cord installed as shown in

Figure 8-4A, unhook trim cord at front tab of Al21-l
push-pull tube and at clip mounted to support to
remove trim cord.
d) To remove long elastic trim cord installed as shown in

Figure 8-4B, disconnect bottom hook and relieve tension
on cord to remove the top hook connected to front tab
of Al21-l push-pull tube.
8.142 Longitudinal Trim Cord Installation
a) Ensure clamp and clip are installed per Figure 8.4A
b) For short cord installation see Figure 8-4A
c) For long cord installation see Figure 8-4B
d) Check clearances of trim cord hooks to push-pull tube~

wire bundle and comm. wires out of bottom of cyclic
stick.
IWARNING I
Ensure clearance is maintained between
the trim cord hooks and the push-pull
tubes and wiring throughout entire cyclic
control travel.
e) Connect XPDR antenna lead and ground wire if installed

on inspection panel.
f) Install panel and tighten attachment screws.
g) Remove tag and engage circuit breaker.

8.150 Cyclic Friction Assembly
Cyclic Friction is located in the front left corner of

the cyclic box cover. Turning the knob clockwise applies
friction to both the longitudinal and lateral cyclic. If
friction cannot be applied by turning knob clockwise,
adjustment of friction may be required.
8.151 Cyclic Friction Adjustment
a) Turn friction knob counter-clockwise until it stops.

b) Remove the roll pin.
c) Lift knob off shaft.
d) Install a thick or thin washer (AN960-416 or 416L) as

required to give the proper friction at the center of
the cyclic grip measured in a lateral direction. See
Figure 8-4C.
System friction with right trim off,

fore and aft trim cord removed, and
CYCLIC FRICTION OFF:
0-5 lb. - Lateral

0-7 lb. - Fore and Aft
CYCLIC FRICTION ON:
7-13 lb. - Lateral
e) Replace knob and install roll pin.
f) Move flight controls throughout complete travel.

Verify no binding or clearance problems.
NOTE
If friction assembly will not tighten

install larger (1.1 inch) belleville
washers (4 ea.) Bll25-078 and change
length of spacers per Figure 8-4D.
I CAUTION I
New friction knob which has roll pin
hole drilled thru knurled section of
knob must be used with (1.1 inch)
belleville washers.
Page 8.20 Change 7: 12 JAN 90

8.160 Al21-7 Push Pull (P-P) Tube

8.161 Al21-7 Push-Pull Tube Removal
a) Remove belly panel, vertical panel between seat backs and

mast fairing, disconnecting pitot line at pitot fitting.
b) Remove vertical firewall maintenance hole plug to remove

Al21-7 P-P tubes.
NOTE
IF HOLES NOT PRESENT, INSTALL USING

RHC KIT KI-21.
c) Remove NAS1304-44 bolt attaching -7 P-P tube rod ends to

cyclic fork.
d) Disconnect bolts holding Al21-7 P-P tubes at swashplate.
e) Tape sheet metal edges to prevent P-P tube removal damage.
f) Position swashplate and rotor to slide Al21-7 P-P tube up

and clear. Mark right and left tubes if they are to be
reinstalled.
g) Inspect P-P tubes and sleeves for damage.
h) Inspect P-P tube guide for wear. The guide should be replaced
if excessively worn or if fretting evident between guide
material and riveted aluminum support.
NOTE
If P-P tube replaced, adjust rod ends

to obtain same center-to-center
length or M.R. Flight Controls will
require rigging per R22 Maintenance
Manual Section 10.
8.162 Al21-7 Push-Pull Tube Inspection/Repair
1. Nicks, cuts or scratches in the tube which are longitudinal

not more than 0.010 inches deep, or across the tube and not
more than 0.005 inches deep may be polished out.
2. Dented or flattened tube of more than five percent of its

diameter must be replaced.
3. Maximum tube wear at guide 0.015 inch per wall after smooth-
ing wear ridges. Epoxy primer repair surfaces before
sleeve installation. Any tube wear requires sleeve ins-
tallation.
4. Replace tube worn in excess of 0.015 inch after polishing.

8.163 Sleeve Installation Onto Al21-7 Push-Pull Tube
NOTE
Repair any wear damage on Al21-7

P-P tube per Section 8.162 prior to
the P-P tube sleeve installation.
a) Clean P-P tube by lightly using MEK or acetone.
b) Apply tape to restrict adhesive to 6.5 inch area located 31

inches from end of P-P tube (not end of rod end).
c) Test paint for paint bubbling; apply l-inch band of adhesive

to one end of 6.5 inch area. If paint bubbles, remove paint
and apply epoxy primer to area before applying adhesive to
whole 6.5 inch area.
IWARNING I
Adhesive to be applied to complete
area under P-.P tube sleeve.
d) Apply adhesive supplied in kit to whole 6.5 inch area. (It

will set and become stringy very quickly. Brush thin coat
of adhesive without large lumps as rapidly as possible).
NOTE
Sleeve must be installed within two

minutes after adhesive applied.
e) Slide sleeve onto tube and center of adhesive.
f) Rotate tube and apply heat using up to 1200-watt heat gun to

evenly shrink sleeve producing smooth surface.
I CAUTION I
DO NOT APPLY HEAT CONTINUOUSLY TO
SAME AREA.
g) Allow to cool and apply adhesive to seal end of sleeve.

Do not have adhesive at ends above surface of sleeve or
sleeve will be damaged or will not enter guide during instal-
lation.
8.164 Push-Pull Tube Sleeve Inspection
a) Visually inspect sl,eeve for wrinkles, pin holes. bubbles,

gouges, torn areas. etc. Replace sleeve if any damaged or
suspect areas are found.

8.165 Al21-7 Push-Pull Tube Installation
a) Inspect P-P tube guide for wear. The guide should be replaced
if excessively worn or if fretting evident between guide
material and moveable guide plate.
NOTE
Old-style guide bushings which are

riveted to fuselage must be replaced
with moveable guide kit (RHC Kit
KI-19A) if Al21-7 Push-Pull tubes
are worn. Reference RHC Service
Bulletin :fj36.
b) Loosely (snug) install moveable guide on underside of

airframe support A439-l per Figure 8-4E.
I CAUTION I
Extreme care must be taken when
installing Al21-7 P-P tube into
guide to prevent damage to P-P tube
sleeve.
c) Install Al21-7 P-P tube, ensure spacers installed properly.

Reference Figure 8.4E.Torque attach bolt 100 in.-lb. plus
nut drag.
d) Attach Al21-7 P-P tubes to swashplate. Torque attach bolts

100 in.-lb. plus nut drag.
e) Raise collective approximately seven (7) inches (measured

from pilot throttle handle to center panel) with cyclic neutral.
f) Tighten guides three attach bolts to slight friction and

verify Al21-7 P-P tubes are centered in guide bore. Torque
guide attach bolts 40 in.-lb. and torque stripe nuts.
g) Remove protective tape from sheet metal edges used to pro-

tect P-P tubes during installation.
h) Check full travel clearances of flight controls.
1) Upper frame forward two boltheads at horizontal firewall

to Al21-7 P-P tubes minimum clearance .010 inch.
2) Fuel tank top inboard flange to left Al21-7 P-P tube
minimum clearance .10 inch.

8.165 Al21-7 Push-Pull Tube Installation (cont'd)

i) Verify fasteners disconnected are retorqued per R22
Maintenance Manual Section 1.300.
j) Reinstall panels, fairings and firewall plugs.
k) If rod ends were unscrewed from P-P tubes, main rotor rigging
must be re-checked per Section 10.
"V" Bulkhead
Fwd.
FIGURE 8-4E PUSH-PULL TUBES AND GUIDE

8.200 COLLECTIVE CONTROL
8. 210 Collective Stick Assembly (Standard or Removable)
8.211 Collective Stick Removal
a) Remove vertical center panel, right and left seat

backs and collective boot.
b) Remove collective spring guard in aft left baggage

compartment.
c) Place collective in full down position. Use

either the MT294-1 collective spring tool
or Q.032"safety wire to remove the spring
assembly. If safety wire is used, twist
wire around rod end to rod end several times
to assure that the spring assembly can be
removed safely.
IWARNING I
Spring is under compression and
failure to comply with above pro-
cedure can cause bodily harm and/
or damage to rotorcraft.
d) Remove bottom spring attach bolt slowly while moving

collective slightly to put spring tension onto re-
s training safety wire. When belt is removed, swing
the spring assembly forward for more clearance during
removal.
e) Disconnect collective stop at the A348-l seat belt

anchor.

8.211 Collective Stick Removal (cont'd)
NOTE
To prevent damage, rotate collective stop slider in line with

collective handle and tape in place.
I f. Disconnect A205 yoke from collective stick.
g. Disconnect A327-1 overtravel spring from collective throttle arm.
If installed, disconnect aft end of carb heat assist push-pull tube from collective
stick.
i. Disconnect two NAS 1 304 attach bolts at either end of collective stick.
j. Remove collective stick assembly.
8.212 Collective Stick Installation
a. Assemble A332-1 friction lever per Figure 8-5. The spring washers, item 14,
should be assembled with their concave sides together. The two washers, item
13, are installed with the grey Teflon®-coated surface against the A333-1 stop
(item 12). The A332-1 lever is threaded onto the NAS1352-4-24P screw as the
screw starts to protrude from the attachment fitting.
NOTE
See collective friction adjustment for finalizing friction assembly

after completion of collective installation. Refer to Section
8.224.
b. (Reference if not installed). Install A205-1 fork to the forward rod end of the
A 175-1 bellcrank on the cyclic fork.
NOTE
Dimension of A205-1 fork should be 3.45 inches from center of

rod end hole to center of attaching bolt hole. No palnut
required on this rod end.
NOTE
If new A 139-1 bearings installed, ream to 0.375 I 0.376 inch

inner diameter with dead sharp reamer (see Section 8.600).

I
8
19~
18
FIGURE 8-5 COLLECTIVE FRICTION ASSEMBLY

NUMBER PART NUMBER DESCRIPTION NUMBER PART NUMBER DESCRIPTION
1 AN525-832R6 Screw 13 Al41-20 Washer

2 A332-1 Lever 14 80500-022-S Belleville Washer
3 A431-l Knob 15 NAS1352-4-24P Screw
4 AN960-8L vJasher 16 AN960-416 Hasher (A/R)
5 NAS1291-08 Nut 17 AN960-416L t~asher (A/R)
6 NAS1352-08-12 Screw 18 AN960-10L vJa sher

7 A959-1 End Cap 19 NAS1303-5 Bolt
8 A348-1 Anchor 20 NAS679A3 Nut
9 A601-l Grab-On Grip 21 MS27151-7 Pal nut
10 A757 or A758 Collective Assy
11 A130-4 Spacer
12 A333-1 Stop

10
FIGURE 8-6
UPPER OVERTRAVEL SPRING INSTALLATION
1 A341-1 Spacer
2 C342-1 Arm Assembly
3 A141-16 Washer
4 A335-1 Torque Tube
5 52-018-078-0750 Roll Pin
6 AN 960-lOL Washer
7 NAS 679A3 Nut
8 MS27151-7 Pal nut
9 A486-1 Screw
10 A327-1 Overtravel Spring Assembly
11 MS20995C32 0.032 in. dia Safety Wire

8.212 Collective Stick Installation (cont'd)

c) Install collective stick into rotorcraft.
d) Connect collective inboard and outboard attach bolts.
NOTE
Special All5-l spacer required
against the A329-l bearing block
assembly. Smaller end against in-
ner ball; larger end against bolt-
head.
Torque to 100 in~bs. plus nut drag. Install palriuts.
Attach A205-l fork to the collective stick. Torque
to 100 in-lb. plus nut drag. Install palnut. Verify
smooth operation of fork pivot.
e) Install lower end of A333-l stop to the A348-l seat
belt anchor. When installing A333-l stop onto the
Al30-4 spacer, add AN960-416 and 416L washers on
either side of stop as required to prevent binding
and to obtain zero to .031 inch axial play. Torque
nut to 27 in.-lb. plus nut drag. Install palnut.
Check for binding and axial play.
f) Connect collective spring and install cover per Sec-
tion 8.
IWARNING I
Failure to remove restraining
safety wire after collective
spring is installed can limit
control travel creating a
safety-of-fligh.t hazard.
g) Install the A327-l overtravel · spring to the end

hole of the A342-l collective arm. (See Fig. 8-6).
NOTE
Use special A486-l screw and A341-l
spacer. With screw head against
rod end, install spacer with large
diameter against collective arm.
Torque to 28 in.-lb. plus nut drag.
Install palnut.

8.212 Collective Stick Installation (cont'd)
WARNING
Improper installation can cause binding, rod end damage or rod

end separation with subsequent loss of engine throttle control
If installed, connect aft end of carb heat assist push-pull tube to flat side of
collective arm.
i. Adjust throttle correlation rigging per Section 10.150.
j. Install panels and seat backs.
8.220 Collective Spring Assembly (See Figure 8-8)
The collective spring assembly is installed to balance in-flight main rotor collective
control forces. A038-1 thru -7 spring assemblies may be adjusted or springs changed
to rebalance collective control using the following springs and procedure:
Assembly P/N Spring P/N Spring Color Spring Constant
A038-1 A429-1 (old) Silver 89 lb/in.

A038-2 A429-2 (old) Primer 35 lb/in.
A038-3 or -5 A429-3 Grey 50 lb/in. (weak)
A038-4 A429-4 (old) Black 70 lb/in.
A038-6 A429-5 Gold 50 lb/in. (standard)
A038-7 A429-8 White 71 lb!in. (strongest)
Adjust A038-1, -2, -3, and -4 spring assemblies per Section 8.223. Adjust A038-5, -
6 and -7 spring assemblies per Section 8.224.
NOTE
A038-5 spring assembly replaces A038-2 assembly. A038-6

assembly replaces A038-1, -3, & -4 assemblies.
WARNING
Exercise extreme care when working with compressed

collective springs. Always relieve spring compression slowly.
8.221 Collective Spring Removal
a. Remove left seat back. Remove fuel valve handle.

1 A038-1 through -4
~ \ COLLECTIVE SPRING
2---11::'@'(@ ASSEMBLY
3~~
7
~l0s \ A038-5, -6, & -7
COLLECTIVE SPRING
/rj~-10
8~~\\ 4 @ ASSEMBLY
UP 9""y -~~\ 5 2/;@_~~3 4

~~6
·I 3 /u~
h-.---.l.A:...--- - .032" STAINLESS 14 I
•
T.....___
@ 5
STEEL
SAFETY r-r-:5'"6
4.30/4.00"
WIRE
1r"15
'~~ ---,0
'~ 7
ft!n~
MT294-1 COLLECTIVE SPRING
TOOL INSTALLED
4
;.----18
\ 1\J'
'-._\
---~~'--
~1
FIGURE 8-7
A038-1 THROUGH -4 FIGURE 8-8 COLLECTIVE SPRING
COLLECTIVE SPRING ASSEMBLY
ASSEMBLY
NUMBER PART NUMBER DESCRIPTION NUI~BER PART NUMBER DESCRIPTION

1 A0127-3 Rod End 10 A428-1 Rod
2 NAS679A3 Nut 11 A429-l thru -4 Spring
3 AN960-10L Washer 12 A426-4 Plate
4 NAS6603-6 Bolt 13 AN960-10 Washer
5 NAS679A06 Nut 14 B292-3 Rod End
6 AN960-6 Washer 15 A426-5 Cap
7 AN315-3R Nut 16 · A429-3, -5, or -8 Spring
8 A426-3 Plate 17 A426-6 Cap
9 MS24665-69 Cotter Pin 18 MS27151-7 Pal nut
8.221 Collective Spring Removal (cont'd)

attach screws and fuel valve plate.
b) Remove the collective spring cover. Loosen - DO NOT
REMOVE screw located on aft vertical firewall stiff-
ener. Remove screw at top of cover from nut or nut
clip. Slide cover from under loosened screw and re-
move.
c) Place the collective in the full down position. Use
either the MT294-1 collective spring tool or .032 in.
safety wire to remove the spring assembly. If safety
wire is used, twist wire around rod end to rod end
several times to assure that the spring assembly can
be removed safely.
I WARNING I
Spring is under compression and
failure to comply with procedures
can cause bodily harm and/or damage
to rotorcraft.
d) Remove bottom spring attach bolt slowly while moving

collective slightly to put spring tension onto restraining
wire.
e) Disconnect upper spring assembly attach bolt and remove the

spring assembly.
8.222 Collective Spring Installation
NOTE
Overall compressed length for installation
to be 4.30/4.00 in. between centers of the
roq ends. The nut end of the rod guides to
be pointing up (See Figure 8-7).
I WARNING I
When installing the A038-5 or -6 spring
assembly, both rod ends must be bottomed
(B292-3 rod end has left-hand thread) .
Failure to bottom both rod ends can cause
either one to run out of threads during
adjustment and can cause bodily harm.
a) Insert collective spring assembly into the collective stick

attachment arm. Install bolt and torque to 40 in.-lbs.
plus nut drag.
b) Move collective to align rod end into lower mount. Install

bolt and torque to 40 in.-lbs. plus nutplate locking drag.

8.222 Collective Spring Installation (continued)
c) On installation of the spring assembly, be sure to cut and remove the restraining
safety wire.
d) Check to make sure that the spring coils are not binding with collective stick full down.
Adjust spring assembly as required per § 8.223 or 8.224. Install collective cover.
WARNING
Failure to remove the safety wire or allowing the spring coils to
bind can limit the control travel creating a safety-of-flight hazard.
e) Install co-pilot seatback. Tighten seatback screws. Tighten four (4) fuel valve
plate attach screws.
WARNING
Ensure proper fuel valve handle orientation.
f) Install fuel valve handle. Verify proper orientation using gascolator drain. (See Fuel
Flow Check § 12.600.)
8.223 Collective Spring Adjustment for A038-1 thru -4 Assembly

a) Small force adjustments may be made by screwing the lower rod end in or out.
Install the MT294-1 collective spring tool. Remove the lower bolt and loosen the
adjustment. After reinstallation, ensure that the spring coils do not bottom out with
the collective full down. The maximum extension for the bottom rod end is 1.1
inches provided the spring coils do not bottom (See Figure 8-7).
b) Remove the collective spring per § 8.221.
c) Place spring assembly in a soft-jawed vise.
d) Compress the spring slightly and cut the safety wire.
e) Carefully open the vise to relieve the spring tension and remove the spring.
f) Install a spring selected from the table in § 8.220 to obtain the desired trim force.
g) Compress the spring assembly in a vise to a dimension of 4.30/4.00 inch between
the rod end center lines. Safety wire with 0.032 inch diameter stainless steel
safety wire (see Figure 8-7).
h) Reinstall the collective spring assembly per § 8.222.

8.224 Collective Spring Adjustment for A038-5, -6, or -7 Assembly
Large spring force adjustments are made by changing spring. Small spring force
adjustments may be made as follows:
a. Remove collective spring cover.
b. Loosen palnut and jamnut on lower rod end.
c. With collective up, rotate spring by hand to increase or decrease spring force
(lower rod end is right-hand thread; upper rod end is left-hand thread). Screwing
rod end in decreases collective-up force. Extending rod ends increases collective-
up force.
WARNING
Ensure that spring coils are not binding with collective stick full
down after making adjustment. Binding spring coils can limit
flight control travel.
d. Standard torque jamnut and palnut per § 23-32.

e. Install collective spring cover.
8.225 Collective Friction Adjustment (see Figure 8-5)

To adjust collective friction:
a. Loosen nut (item 5) on friction lever and position lever in locked position.
b. Turn screw (item 15) in threaded collective attachment fitting clockwise to
increase friction, counter-clockwise to decrease friction.
c. Adjust locked friction to 12 to 20 pounds measured at collective grip, using a
spring scale pulling up from bottom of travel.
WARNING
Collective friction greater than 20 pounds may prevent aircraft
from entering autorotation.
d. Tighten nut (item 5) on friction lever.

8.230 RPM Governor System
The governor system senses engine RPM and applies corrective input forces to the
throttle; when RPM is low, governor increases throttle and vice versa. Throttle inputs
are through a friction clutch which can be easily overridden by the pilot. The governor
is active from 80% - 115% engine RPM and can be switched on or off by the pilot
using the toggle switch on the end of the right seat collective control.
The governor system is designed to assist the pilot in controlling the RPM in the
normal operating range. It may not prevent over- or under-speed conditions generated
by aggressive flight maneuvers. Within the active range there is a 3%-wide deadband
from 102.5% - 105.5% where the governor will not take action provided the rpm is
steady.
The governor system consists of the following major components:
1. The 8286-2 governor controller, a solid-state analog-circuit control unit mounted

behind the left seat back. The controller senses engine RPM via tachometer points
in the engine right magneto (helicopter left side) and provides a corrective signal to
the governor assembly.
2. The 824 7-5 governor assembly, attached to the collective stick assembly behind
the left seat back. When activated by the governor controller, the governor
gearmotor and attached worm gear drives a friction clutch connected to the
throttle.
8.231 Governor Controller Removal
1 . Remove left seat back assembly to gain access to controller.
WARNING
No external adjustment of controller is available. If controller

fails to operate correctly, remove and return it to RHC.
2. Disconnect electrical connector.
3. Remove four screws securing governor controller to left seat back assembly.
8.232 Governor Controller Installation
1 . Secure governor controller to left seat back assembly.
2. Connect electrical connector.
3. Install seatback panel. If fuel valve handle has a hexagonal mating recess,
perform fuel flow check per Section 12.260.
8.233 Governor Assembly Removal
The governor assembly is behind the left seat back assembly, attached to the
collective stick.
1. Remove collective stick per Section 8.211.
Change 22: MAR 2004 Page 8.34A

- ,t= t ROUTE -576 AND -577 WIRES WITH EXISTING

MAIN WIRING HARNESS USING MS3367-4-9 OR
MS3367-5-9 TV-RAPS.
/
--I " \
/
GOVERNOR y<=9L_____)I_ _ __ I
'\
ON-OFF -+--t-
:¢·- SWITCH
----j
LEFT KEEL PANEL
1
/
I
-
-577
WIRE B297-2 CIRCUIT BREAKER
-- -576 WIRE WITH
B260-2 TERMINAL ~
\
(
~tt:~; \..: ; ~ B804-2 HARNESS ASSEMBLY
II§SJ:r~· ,: () @I
~S3116Fl2-10SX
w-~,._.-A-65-4--7-o-o-Ec_A_L l·o- g. ®1
~' N !• I WIRES TO 1
MICRO SWITCH 1 PLUG
AND POSITION TO B286-2 CONTROLLER
LIGHT
L
_;i \
__...:..;,..;,..:_ COLLECTIVE STICK-ACTIVATED
MICRO SWITCH
,! ~- FIGURE 8-8A
\S:7
LEFT POSITION LIGHT (VIEW LOOKING DOWN)
FIGURE 8-8B
RPM GOVERNOR INSTALLATION
8247-5
GOVERNOR
ASSEMBLY

R 0 BIN SON MAINTENANCE MANUAL MOCELR22
8.233 Governor Assembly Removal (cont'd)
2. Remove three screws securing governor assembly to collective stick.
3. Remove bolt securing governor assembly's output arm to link assembly.
WARNING
No adjustment of friction clutch is permitted. No field

replacement of gearmotor is permitted. If friction setting is
incorrect, or if gearmotor operates incorrectly, remove governor
assembly and return to RHC.
8.234 Governor Assembly Installation
1. Connect governor assembly's output arm to link assembly. Ensure:
a. NAS6603-7 bolt head toward collective grips and no washer under bolt
head.
b. AN960-1 0 or NAS620-1 0 washer between governor output arm and rod

end.
I
c. AN960-1 OL washer between rod end and nut. Torque nut and palnut per
Section 1.320.
NOTE
Link assembly length must be 2.47-2.53 inches rod end center-

to-center.
2. Ensure governor assembly's output arm points upward towards collective's

throttle connecting rod. Attach governor assembly to collective stick.
Torque NAS1351-4-28P screw per Section 1.320. Torque both AN503-8-4
screws to 27 in.-lb and safety wire with 0.020 inch diameter safety wire.
3. Rotate throttle grips. Verify smooth operation and no interference.
4. Install collective stick per Section 8.212.
8.239 Governor Troubleshooting
The majority of governor problems are caused by the engine's right (helicopter left
side) magneto tachometer contact assembly (points) being out of adjustment or
faulty. Refer to TCM Master Service Manual for tachometer contact assembly
installation and adjustment.
When operating in the 80%-115% active range, the R22 governor will attempt to
maintain engine rpm at 104%±1.5% (102.5%-105.5%). The edges of this
governed 3%-rpm wide window, called a "deadband", may be detected as follows:
1. Start engine and run-up helicopter per Pilot's Operating Handbook.

Collective must remain fully down during this and following steps.
Change 22: MAR 2004 Page 8.34C

,8.239 Governor Troubleshooting (cont'd)
2. Gently hold throttle and very slowly increase rpm (do not exceed 1 07%).
Note and record engine rpm indication when governor input (subtle throttle
resistance) is encountered.
3. Gently hold throttle and very slowly decrease rpm (do not go below 97%).
Note and record engine rpm indication when governor input (subtle throttle
resistance) is encountered.
4. Subtract Step 3 indication from Step 2 indication. Result should be

approximately 3%.
A result of 3% but centered beyond 1 04 ± 0. 5% is indicative of a governor

controller problem.
Results greater than 3% but still centered on 104% are usually indicative of
excessive throttle linkage friction or insufficient governor friction.
Check throttle friction by disconnecting overtravel spring assembly upper rod end
from C342 arm and attaching a spring scale to the rod end. With carburetor
throttle arm in idle position, slowly pull up overtravel spring assembly with spring
scale and note maximum 4 pounds moving friction prior to full-open throttle at
carburetor. Excessive throttle linkage friction can be caused by binding rod ends,
control interference, carburetor throttle shaft bushing elongation, or binding
carburetor accelerator pump (typically binds in one direction only).
Check governor friction with collective down, collective friction on, overtravel
spring assembly upper rod end disconnected from C342 arm, and C342 arm
positioned horizontally. Attach a spring scale to hole in C342 arm and, with scale
held tangential to arm, slowly pull on scale and note both the breakaway and the
moving frictions. Breakaway friction is typically 0-0.5 pound greater than moving
friction. Breakaway friction 1 pound or greater than moving friction may indicate
damaged or contaminated governor friction clutch. Moving friction must be
minimum 8 pounds until arm stops moving. Insufficient moving friction can be
caused by wear, contamination, or loss of spring rate.
Proper governor operation requires a minimum 2:1 ratio of governor friction-to-

throttle linkage friction.
Erratic operation is usually indicative of tachometer contact assembly problems or

wiring damage. Wiring damage may be evidenced by crushing, pinching, or
abrasion, all of which can result in grounding of one or both center wire
conductor(s) to the shielding or to structure. Tachometer contact assembly
problems may be caused by contamination, oxidation, or loose contact(s), in
addition to installation or assembly errors.
Contamination can be caused by over-lubrication of cam follower felt, engine oil

leaking past oil seal, or moisture intrusion thru vent plug. Oxidation can be caused
by an obstructed vent plug or by engine oil leaking past the oil seal.
When flying in turbulence, or if the engine is lightly "loaded" (drive train almost
freewheeling), a fluctuating MAP indication is expected.
Any loose connection in throttle linkage (including worn carburetor throttle shaft
bushings) will result in both RPM & MAP oscillations.

8.300 JACKSHAFT AND SUPPORT STRUTS
8.310 Jackshaft (See Figure 8-9)
8.311 Jackshaft Removal

NOTE
Rigging check should not be ne-
cessary if jackshaft support strut
rod ends or push-pull tube rod ends
are not loosened or removed.
a) Disconnect the push-pull tubes from the jackshaft.
b) Disconnect the two (2) jackshaft support bolts at the

upper support strut rod ends.
c) Remove jackshaft.
8.312 Jackshaft Installation
Install jackshaft to strut rod ends. Aft support rod

end requires a safety washer A214-3 between the rod
end and bolthead. Both upper strut attach boltheads
point aft. Torque nut to 100 in.-lbs plus nut drag.
Install palnut.
Connect the Al21-3 and -5 push-pull tubes to jackshaft.

Both push-pull tube attach boltheads point forward.
The forward Al21-3 push-pull tube rod end requires a
safety washer A214-3 and All5 spacer between the rod
end and bolthead. Torque nuts to 100 in.-lbs plus
nut drag. Install palnut.
Verify no binding or interference with control movement
throughout flight control travel.
8.320 Strut Assembly (Jackshaft Support)
8.321 Jackshaft Strut Removal
a) Remove jackshaft per Section 8.311
b) Remove the aft support strut. Disconnect horizontal

strut assembly at the 'V' bulkhead. Disconnect the
lower strut rod end at the aft main rotor gearbox
fitting.

ROBINS'ON MAINTENANCE MANUAL MOCEL R22
NUf~BER PART NUMBER DESCRIPTION

1 NAS1304-23 Bolt
2 A214-3 Washer
3 A343-1 Strut
4 AN960-416L Washer
5 NAS679A4 Nut
6 MS27151-13 Pal nut
7 A121-5 Push-Pull Tube
8 NAS1304-7 Bolt
9 NAS1304-21 Bolt
10 A121-3 Push-Pull Tube
11 All 5-1 Spacer
12 A337-1 Jack shaft
13 A347-1 Brace
14 NAS1304-2 Bolt
15 AN960-416 Washer
16 AN525-832R6 Screw
17 AN960-8L Washer
18 A437-2 Tab
19 NAS679A08 Nut

A347-5
SHIP S/N 0436
' and higher
I '
......___12
FORWARD
10
FIGURE 8-9 JACK SHAFT INSTAllATION
Corrected
8.321 Jackshaft Strut Removal (cont'd)
NOTE
For ease of installation later, DO NOT disassemble the long

horizontal strut from the vertical strut.
c. Forward support strut removal: To remove, it will be necessary to disconnect

upper rod end installed through a fuselage tab, DO NOT remove lower rod end
from support if possible.
NOTE
For ease of installation later, measure length of strut from center

of rod ends and tag strut with length for later reference.
8.322 Jackshaft Strut Installation
NOTE
Two (2) AN960-516L washers are installed on forward supports;

one between upper forward rod end jamnut and fuselage tab,
other between upper aft jamnut and A34 7 horizontal strut.
1. Install forward support strut.
a. Connect forward vertical support strut lower rod end to forward-right gearbox
fitting. Verify minimum preload between bulkhead-mounted jackshaft brace
tab and top of strut; adjust strut height as required. Verify proper rod end
engagement via strut witness hole.
b. Install strut upper rod end , with palnut and jam nut installed, thru brace tab
into top of strut. Adjust rod end center-to-center dimension to previously
recorded measurement, if applicable. Verify proper rod end engagement via
strut witness hole.
2. Connect aft-vertical strut lower rod end to aft-right main rotor gearbox
fitting. Connect vertical diagonal strut to aft-left gearbox fitting, or connect
horizontal diagonal strut to Vee-bulkhead, as applicable.
3. Torque bolts per Section 1 .320. Install palnuts, and torque per Section 1.320.
Torque stripe per Figure 2-1.
4. Install jackshaft and push-pull tubes per Section 8.312.
5. If aft-vertical strut was disassembled or length changed, adjust aft strut and/
or forward strut to achieve jackshaft level to helicopter keel panel within
± 0.5°. Verify proper rod end engagement through witness hole in strut.
6. Verify proper rod end centering and all bolts, jamnuts, and palnuts are torqued
per Section 1 .320 and torque striped per Figure 2-1.
8.38 Change 25: JUN 2006

8.400 Swashplate and Main Rotor Pitch Links
8.410 Swashplate
8.411 Swashplate Removal
NOTE
Rigging check is not required if push-pull tube rod end bearing
center-to-center dimension has not changed.
1. Remove main rotor hub and blade assembly per §§ 26-20 and 26-10.
2. Disconnect and remove A203 yoke halves.
3. Remove droop stops and elastic teeter stops.
4. Remove swashplate boot.
5. Disconnect three push-pull tubes and rod end of lower A205 fork assembly from
lower, non-rotating swashplate.
6. Lift swashplate off slider tube.

8.412 Swashplate Installation
CAUTION
Swashplate plastic balls are obsolete and must be replaced.
1. Verify swashplate rotates freely.

2. On swashplate ear opposite interrupter, attach pitch link’s lower rod end with five
AN970-4 washers and two AN960-416L washers under bolt head, one A115-1
spacer on each side of rod end, with the small washers between spacer and large
washers. Install additional AN960-416L washer on bolt inboard of inner A115-1
spacer and insert bolt into swashplate ear. Washer stack-up must be located on
outside of ear. Install washers under nut as required to expose two to four threads
after torquing. Standard torque nut per § 23-32. Install palnut, standard torque per
§ 23-32, and torque stripe per Figure 2-1.
3. On interrupter-side swashplate ear, attach pitch link with an A214-3 washer under
bolthead, one A115-1 spacer on each side of pitch link rod end, and one AN960-
416L washer between A115-1 spacer and swashplate ear.
4. On interrupter-side swashplate ear, install A115-1 spacer on protruding length of
bolt, then A205 fork assembly rod end (rod end shank pointing up), another A115-1
spacer, one A214-3 washer, and the nut. Standard torque nut per § 23-32. Install
palnut, standard torque per § 23-32, and torque stripe per Figure 2-1.
5. Attach A204 arm to A205 fork installed in previous step. If fork has plastic A139-
1 bearings, line ream and spot face bearings for correct fit per § 8.600. If fork has
C648-2 bearings (dark-brown colored face & bore), install a combination of A117-
45, -46, and/or -47 shims between A105-17 journal and A141-43 washer on nut
side to provide 0.010/0.001 inch axial play in joint. Refer to Figure 2-8. Verify 2.5
in.-lb maximum pivot friction.
6. Install swashplate and attached pitch links, fork, and arm onto slider tube assembly
atop main rotor gearbox.
7. Slide boot over A251 main rotor shaft and set in place.
8. Install A203 yoke assembly onto A251 shaft using A210-1 key to position yoke on
shaft. Radiused edge of A210-1 key goes into flange slot in A251 shaft. Standard
torque nut per § 23-32. Install palnut, standard torque per § 23-32, and torque
stripe per Figure 2-1.
CAUTION
Tighten and torque bolt through A210-1 key first.

8.412 Swashplate Installation (continued)
9. Install opposite clamping bolt in chord-arm side of yoke. As applicable, special
torque NAS1305 or NAS6605 bolt per § 23-33, or standard torque NAS1304 or
NAS6604 bolt per § 23-32. Install palnut, standard torque per § 23-32, and torque
NOTE
A small space between chord-arm side yoke halves adjacent to
driveshaft is normal. Do not exceed bolt torque limits.
10. Connect A204-1 arm to A203 yoke assembly. If yoke has plastic A139-1 bearings,
line ream and spot face bearings for correct fit per § 8.600. If yoke has C648-2
bearings (dark-brown colored face & bore), install a combination of A117-45, -46,
and/or -47 shims between A105-17 journal and A141-43 washer on nut side to
provide 0.010/0.001 inch axial play in joint. Refer to Figure 2-8. Verify 2.5 in.-lb
maximum pivot friction.
11. Install A255 counterweights and AN970-4 washers on A203 yoke arm as required
for balance.
12. Attach lower A205 fork’s rod end to left side of middle of three lugs grouped
together on lower swashplate. Connect forward push-pull tube rod ends to left
side of remaining two forward lugs. Aft push-pull tube rod end attaches to right
side of lower swashplate aft lug. A214-3 safety washer required between bolthead
and A115-1 spacer. A115-1 spacers are required on each side of all rod end balls.
Standard torque bolts per § 23-32. Install palnuts, standard torque per § 23-32, and
13. Position boot on upper swashplate and ty-rap in place. Ensure upper portion of boot
clamps on shaft between upper flange and A203 yoke halves.
14. Temporarily install teeter hinge bolt and journals. Install droop stops and elastic
teeter stops. Ensure teeter stop brackets are oriented per Figure 26-5. Standard
torque bolts per § 23-32. Install palnut, standard torque per § 23-32, and torque
stripe per Figure 2-1. Remove teeter hinge bolt and journals.
15. Verify no binding or interference with control movement throughout flight control
travel.
16. Install main rotor hub and blades per §§ 26-20 and 26-10.
17. Track and balance main rotor per § 10.200.
8.413 Reserved
8.414 Reserved
8.415 Reserved

Intentionally Blank

Intentionally Blank

Intentionally Blank

Intentionally Blank

Intentionally Blank

This page intentionally left blank. I

8.416 Shimming Upper (Unflanged) Spherical Sleeve with Aluminum Ball
Measure space between top of upper spherical sleeve to top surface of lower
swashplate. Determine required A209 spacer thickness by installing a spacer that
will completely fill the space. (A209 spacers are available in increments of 0.005
inch.)
a) Install shield plate. Torque screws to 17 in-lbs.
b) Use a spring scale (MT359-1 or equivalent) to pull down at bolt hole in

upper swashplate arm as shown in Figure 8-12A. The force required to tilt
I the swashplate must be free-without-looseness to five pounds maximum,
measured while moving; do not use breakaway reading.
c) Use a thicker or thinner A209 spacer to adjust swashplate tilting force.

Increase spacer thickness to increase force required to tilt swashplate.
8.500 TAIL ROTOR CONTROLS
8.510 Tail Rotor Pedals (Standard or Removable)
8.511 Tail Rotor Pedal Removal
a) Remove the landing light cover, belly cover and cabin cover between the
seats (horizontal).

SWASHPLATE
A209 INNER SCREWS A209
SPACER SWASHPLATE SPACER
OUTER SCREWS
UPPER
SWASHPLATE SPHERICAL
SLEEVE
(UPPER)
SPHERICAL SLEEVE
(LOWER)
SAFETY
WIRE
SWASHPLATE CUTAWAY
SCREW--J A209 SPACER (SHIM}
UNFLANGED SLEEVE
WASHER--.~
I
I
GUARD
SAFETY
WIRE
I
~SCREW
WASHER
WOODEN BLOCKS
FIGURE 8-12
SWASHPLATE SHIMMING WITH A209 SPACER
Change 22: MAR 2004 Page 8.49

FIGURE 8-12A MEASURING SWASHPLATE

'~
SPRING SCALE
TILTING FORCE
Page 8. 50 Issued 5/22/87

8.511 Tail Rotor Pedal Removal (cont'd)
b) Drill out the pop rivets holding the landing light

bracket to the fiberglass chin with a #30 drill bit
and remove.
c) Remove the two NAS1304-9 bolts holding the tail rotor

push-pull tubes to the A317-l tail rotor bellcrank
(lower).
d) Pull the left tail rotor pedal aft, then working

through the landing light access in the chin, dis-
connect the NAS1304-9 bolt that holds the Al21-ll
push-pull tube to the left pedal assembly.
e) Leaving the left pedal in the full aft position, pull
the right pedal fully aft and disconnect the NAS1304-
9 bolt that holds the Al21-9 tube to the right pedal
assembly.
f) Remove both push-pull tubes from the aircraft through

the chin access.
g) Lift carpet carefully from the floor on both sides

and remove from the cabin.
h) Remove the eight (8) screws that hold the access

plates between the pedal assemblies and remove the
plates.
i) The next step will require two (2) people. With some-
one holding the NAS1303-20 bolts from above that hold
the A318-1 bearing block halves together, reach through
the chin access and remove the NAS679-A3 nuts.
j) Remove the lower bearing block halves.
k) Remove the tail rotor pedals one at a time by lifting

one end and allowing the other to drop into the chin.
They can be removed from either the right or the left
side.
NOTE
On reassembly the right pedal as-

sembly is mounted forward in the
bearing blocks and the left is
mounted aft.

8.511 Tail Rotor Pedal Removal (cont'd)
NOTE
Pedal blocks (upper and lower)

are machined matched set as in-
dicated by matching letter or
number on the upper and lower
portion of blocks. DO NOT MIX
THEM or alignment problems may
develop on installation.
8.512 Tail Rotor Pedal Installation
a) Fill the grooves in the pedal bearing blocks with

A257-l grease.
b) Install the pedal assemblies into the bearing blocks

and torque the bearing block attach bolts to 40 in.-lb
plus nut drag.
NOTE
If a force greater than 5 lbs is

required to move pedals, check
the bearing blocks to ensure
they are matched correctly.
c) Install the Al21-9 and 11 push-pull tubes. The Al21-

9 will connect to the upper A317-l bellcrank attach
point and the left pedal assembly. The A121-11 will
connect to the lower A317-1 bellcrank attach point
and the right pedal assembly. Torque the attach
bolts to 100 in.-lb plus nut drag. Install palnuts.
NOTE
The bolts attaching the push-

pull tubes to the pedal assem-
blies must have their head to-
ward each other for clearance.
d) Install the pedal cover plates and carpeting.
e) Pop rivet the landing light bracket to the chin and

install the landing lights.
8.520 A317-1 Lower Bellcrank
8.521 A317-l Lower Bellcrank Removal
a) Remove lower belly panel.
b) Disconnect the attaching hardware to the Al21-9 and

-11 push-pull tubes at the A317-l bellcrank.
8.521 A317-1 Lower Bellcrank Removal (cont'd)

c) Disconnect the A315 support holding the A317 bell-
crank by removing the 4 attach bolts and swing
assembly forward.
d) Remove bolt attaching A317 be1lcrank to the A315
support.
8.522 A317-1 Lower Bellcrank Installation
This procedure also covers rigging of the lower push-
pull tubes and pedal assemblies. If re-checking of rigging
is not required, disregard rigging portions and follow in-
stallation sequences.
a) Install A130-12 spacers and two A105-3 journals in-
side A316 bellcrank, A141-3 washers are installed
against the Al05-3 journals upon assembly to the
A315 support outside of aircraft. Excess gap bet-
ween A315 support attaching flanges and the Al41-3
washers next to the assembled bellcrank may be
filled with either A214-3 or Al41-3 washers.
NOTE
When A317 bellcrank is installed,
the 3/16"dia. rigging pin hole
will be above the pivot point and
the bellcrank itself will be aft
of the bellcrank support.
Tighten pivot nut ahd check for smooth and free
operation. Maximum spring scale drag of 2 lb is ac-
ceptable to move the bellcrank. Torque to 100
in-lb plus drag torque if acceptable.
If a force in excess of 2 lbs. is required to move
the bellcrank, see Section 8.600 for A139-1 bearing
reaming and spotface procedure.
b) Temporarily attach the A315-l and A317-l into air-
craft to check for proper push-pull tube rigging
length. Insert rigging pin thru the cabin assembly
into the A317-l bellcrank for rigging. Temporarily
attach Al21-9, 11 and 13 push-pull tubes to the A317.
Place the left and right pedals together at the mid
(neutral) travel position. Place a 2.90 inch spacer
between each inside pedal and stop. Adjust the rod
ends on the Al21-9 and Al21-11 push-pull tubes as
required to insert a bolt through the rod end and
the A317-1 bellcrank. Check push-pull tube rod end
and the A317-l bellcrank. Check push-pull tube rod
end witness holes for engagement.
8.522 A317-l Lower Bellcrank Installation (cont'd)
c) After adjusting pedal travel, remove the rigging pin

and apply full left pedal and adjust Al21-13 push-
pull tube to obtain .06" minimum clearance of the
A013-3 bellcrank and the vertical firewall. Adjust
push-pull tube as required.
NOTE
It is permissible for the bell-

crank arm to touch and deflect
acoustical foam, as long as it
does not interfere with free
movement and full travel of the
controls.
d) With the A315 support and A317 bellcrank attachment,

disconnected from the keel panels (A121-9 and -11
push-pull tubes disconnected) slide bellcrank forward.
NOTE
The A121-13 push-pull tube at-

tach bolt must be installed with
bolthead to the right side for
clearance in vertical tunnel.
NOTE
On installation to the A317 bell-

crank, an AN960-416 washer is in-
stalled to fill gap between rod
end and the left plate of the
A317 bellcrank (washer on left
side of rod end).
e) Attach A315 bellcrank support to keel panels.
f) Attach the Al21-9 and -11 push-pull tubes to the

A317 bellcrank.
g) Torque all attaching NAS1304 bolts to 100 in.-lb plus

nut drag. Install palnuts and torque stripe fast-
eners.
h) Check for smoothness and ease of operation. Move

pedals full travel. Check for any interference
between tubes, wires and structures.

8.522 C317-2 Lower Forward Bell Crank Installation (cont'd)
i) If required, check complete Tail Rotor rigging if changes to A 121-9, -11, or -13
push-pull lengths have been made.
j) Verify all attach bolts and jamnuts torqued per Fastener Torques Section 1 .300.
k) Install panels.
8.530 A013-3 Upper Bellcrank
8.531 Bellcrank Removal
1. Remove A 121-15 push-pull tube.
2. Remove belly inspection panel.
3. Disconnect A 121-9 and -11 at A317 bellcrank.
4. Disconnect A315 and A317 bellcrank with A317 bellcrank attached.
5. Slide A315 and A317 bellcranks with A 121-13 push-pull tube attached up to
disconnect -13 push-pull tube at upper bellcrank.
NOTE
Upper bellcrank needs to be rotated as far aft as possible to

remove A 121-13 push-pull tube attach bolt.
6. Remove upper bellcrank attach bolt. Catch all A214-2 and A 141-3 washers
installed as bolt is remove.
7. Remove upper bellcrank from structure.
8.532 Bellcrank Installation
1. Install A 130-12 spacer and two A 105-3 journals inside A013-3 bellcrank. Ream
A 139 bearing with 0.375/0.376 inch dead sharp reamer if required for
journal's smooth installation.
2. Install bellcrank with A141-3 washers bellcrank with A141-3 washers next to
blue Turcite A139-1 bearings. If gap exists between A141-3 washers and
outboard support, fill either with A214-3 or A 141-3 washers.
3. Torque attach bolt per Section 1 .320. Install palnut.

8.532 A013-3 Upper Bell crank Installation (cont' d)
4. Check for smoothness and ease of operation.
5. Attach A 121-9, -11 and -13 push-pull tubes along with A31 5 and A317
bellcrank assemblies, following procedure in Section 8.522.
CAUTION
A 1 21-1 3 push-pull tube to AO 1 3-3 upper bellcrank attach bolt

head must point to right side of helicopter for clearance.
6. Install the A 121-15 push-pull tube.
7. Check rigging if necessary.
8. Torque all attaching bolts and jamnuts per Section 1 .300.
9. Check for smoothness and ease of operation. Move pedal full travel, check for
any interference between tubes, wires and structures.
1 O.lnstall panels.
8.540 A331-1 Intermediate Bellcrank
8.541 A331-1 Intermediate Bellcrank Removal
1 . Disconnect A 1 21-1 5 and -1 7 push-pull tubes from A331-1 bellcrank.
2. Disconnect A331-1 attach bolt and remove bellcrank.
8.542 A331-1 Intermediate Bellcrank Installation
Install two A 1 05-3 journals into bellcrank bearings. An A 141-3 washer is required
on each side of bellcrank to A 139-1 bearings. (Ream A 139-1 bearing with
0.375/0.376 inch dead sharp ream if required for journal's smooth installation).
NOTE
If required for A 1 21-1 7 attach bolt clearance with the scroll two
AN960-416 washers may be installed between the bell crank and
the frame to raise the bellcrank. This will require use of
NAS 1304-40 bolt, to attach bellcrank to frame.

8.542 A331-1 Intermediate Be1lcrank Installation (cont'd)
a) Torque to 100 in-lb plus nut drag. Install palnuts.
b) Check for smoothness and ease of operation.
c) Connect A121-15 and -17 push-pull tubes. A214-3

safety washers are required under the boltheads.
d) Re-rig if push-pull tube lengths were altered.
e) Move pedals full travel, check for any interference

between tubes, wires, components or structures.
8.550 Al20-1 Aft Bellcrank
8.551 A120-1 Aft Bellcrank Removal
a) Disconnect A121-17 push-pull tube from A120 aft bell-

crank.
b) Disconnect bellcrank pivot from attach bolt connected

to tail rotor gearbox:
c) Remove nut holding bellcrank to the pitch control.

Remove bellcrank and reinstall nut and shims found
between bellcrank and pitch control for bellcrank
installation.
8.552 A120-1 Aft Bellcrank Installation
See A031 Pitch Control Installation (See Section 8.562).
8.560 A031 Pitch Control
8.561 Pitch Control Removal
a) Remove tail rotor hub and blade assembly. Mark

corresponding tail rotor blade grips, tail rotor
pitch change to each of the pitch control ears,
for later reinstallation so re-rigging is not required.
b) Disconnect and remove aft bellcrank per Section 8.551.
c) Remove pitch control from tail rotor output shaft.
8.562 Pitch Control Installation
a) Slide A031-1 pitch control assembly onto output shaft.
b) Position A120-1 bellcrank assembly on the tail rotor

gearbox and install NAS1304-25 bolt, one AN960-416
washer under bolt head, two MS20002-4 washers, one
one each side of the bearing and NAS679-A4 nut.

8.562 Pitch Control Installation (cont'd)
b) Measure the gap existing between the A120-l bell-

crank ear and the flats on the A125-1 pitch control
stud. Install sufficient A117-20, -21 and -22
washers between bellcrank and stud to completely
fill the gap but not apply any axial preload on
the spherical bearing after all the nuts are tightened.
The clearance tolerance is plus or minus .003".
Install one AN960-416L washer and NAS679-A4 nut on
protruding end of stud. Torque nut to 70 in.-lbs
plus nut drag while holding stud from rotating.
Install palnut.
c) Torque nut on A120-l bellcrank pivot to 100 in.-lbs

plus nut drag. Install palnut.
d) Attach aft end of Al21-17 push-pull tube to the Al20

-1 bellcrank and A214-3 safety washer under nut next
to rod end. Torque nut to lOOin.-lb. plus nut drag.
Install palnut.
e) Install pitch control links per Section 8.572.
f) Install tail rotor hub and blade assembly (See Section

9.212).
g) Ensure all bolts, jamnut and palnuts torques per

Fastener torques, Section 1.300.
8.570 Tail Rotor Pitch Links
8.571 Tail Rotor Pitch Link Removal
NOTE
To ensure proper rigging upon re-

installation of pitch links, mark
pitch links to corresponding
blade grip and pitch control ear.
a) Disconnect the two attach bolts on either rod end of

the pitch link.
b) Remove pitch link.
8.572 Tail Rotor Pitch Link Installation
l WARNING I
A214-3 safety washers are to be
installed next to rod end.

8.572 Tail Rotor Pitch Link Installation (cont'd)
WARNING
Both pitch links must be same part number (same type and
material). Mixing one-piece with adjustable-length pitch links
is prohibited. Mixing steel one-piece with aluminum one-piece
pitch links is prohibited.
Refer to Figure 9-11 .
1. If installing one-piece pitch link(s); connect pitch link to pitch link control arm
and blade pitch horn.
2. If installing new, adjustable-length pitch link(s) based on old pitch link length:
a. Match pitch link to proper blade pitch horn and pitch control arm and connect
pitch link. Torque attach bolts per Section 1 .320. Install palnuts, torque per
Section 1 .320, and torque stripe per Figure 2-1. Repeat for opposite blade.
b. Torque attach bolts per Section 1.320. Verify proper rod end centering and
adjust as required. Install palnut, torque per Section 1.320, and torque stripe
per Figure 2-1. Repeat for opposite blade.
c. Check tail rotor control rigging per Section 10.140.
3. If installing new, adjustable-length pitch links (nominal length setting):
a. Assemble male rod end, with jam nut and palnut installed, into female rod end.
Adjust rod ends until a dimension of 2.360 inches, measured between rod end
bearing centers.
b. Attach pitch link female rod end to outboard side of pitch control arm. Torque
bolt per Section 1 .320. Install palnut, torque per Section 1.320, and torque
c. Connect pitch link male rod end to blade pitch horn. AN960-416, AN960-
416L, or A 141-14 washers may be under nut for chordwise balance. Torque
bolt per Section 1.320. Install palnut, torque per Section 1 .320, and torque
d. Torque pitch link jam nut and palnut per Section 1 .320 and torque stripe per
Figure 2-1. Repeat steps a. thru d. for opposite blade.
e. Check tail rotor control rigging per Section 10.240.
Change 25: JUN 2006 8.59

8.572 Tail Rotor Pitch Link Installation (cont'd)
4. Operate the tail rotor controls thru their entire operating range an verify no
binding or abnormality exists.
5. Dynamically balance tail rotor per Section 10.240.
8.600 A203 YOKE AND A205 FORK ASSEMBLY (Figure 8-1 0)
Three different bearing types have been used in A203 yoke and A205 fork assemblies:
A 139-1 blue-plastic Turcite journal bearings, B 115-1 spherical bearings, and C648-2 Teflon-
lined journal bearings. More than one type bearing may be used in an installation, but each
pivot axis must have same type bearings.
8.610 Bearing Removal
Care must be taken not to damage yoke or fork assemblies during bearing removal.
A 139-1 Turcite bearings may be removed from A203 yoke or A205 fork assemblies
with a broken-screw extractor or by pressing or tapping them out with a small brass or
aluminum drift.
B 115-1 Spherical bearings and C648-2 journal bearings may be removed with a press.
Press from inner side of bearings while supporting outboard side of yoke or fork. Use
a socket or other suitable pressing tool to apply the force.
8.615 C648-2 Bearing Installation (0.5625/0.5630 inch diameter bearing bores)
1 . Clean mating surfaces of A205 fork or A203 yoke where C648 bearing is
installed. Deburr any sharp edges that may damage bearings during installation.
2. Coat yoke or fork bearing bores with zinc chromate or epoxy primer. While
primer is still wet, press in C648 bearing while supporting backside of fork or
yoke.
8.620 A 139-1 Bearing Installation (0.499/0.501 inch diameter bearing bores)
a) Clean mating surfaces of A205 fork or A203 yoke where A 139 bearing is installed.
Deburr any sharp edges that may damage bearings during pressing operation.
b) Coat yoke or fork bearing bores with zinc chromate or epoxy primer. While primer
is still wet, press in A 139 bearing.
c) With both A 139 bearings installed, ream inner bearing bores with a 0.375 inch dead
sharp reamer. Using A 1 05-11 journals as a gauge, continue to ream bores until a
very light drag fit is achieved. It may be necessary to use a 0.376 or 0.377 inch
reamer to obtain correct fit.
d) Place one A 141-3 washer and one A 105-11 journal on NAS6604 bolt. Insert bolt
into A204-1 arm. Place second A 105-11 journal and second A 141-3 washer on bolt.
8.60 Change 25 JUN 2006

NOTE
ENSURE THAT JOURNALS FREELY
MOVE THROUGH BEARING WITH A
MAXIMUM OF A VERY LIGHT DRAG.
FIGURE 8-13A BEARING REAMING
SHAVE OFF FACE OF NEW BEARING

WITH COUNTERBORE TO LOWER FRIC-
TION OF LARGE WASHER TO BEARING
FACE.
FIGURE 8-13B BEARING FACING
A139-1
FIGURE 8-13C BEARING FACING

~X-.005 in.~
WIDTH MEASUREMENT
I
NAS6604-30
NAS1~~4-30 '-.. I - x- l
BOLT ', \l.ii
A141-3
WASHER
~
AlOS-11
7 \~
A105-11
A141-3
WASHER
JOURNAL JOURNAL
I-A204-1
FIGURE 8-13 BEARING REAMING, FACING, ARM
&WIDTH MEASUREMENT

8.620 A139-1 Bearing Installation (cont'd)

e) Measure the distance between the A141-3 washers with
the washers held tightly against the journals. Using
a one-inch spotface tool with a 0.25 inch pilot, light-
ly shave the face of each bearing until the measurement
across the bearing faces is 0.005 inch less than the
measurement between the A141-3 washers. When this di-
mension is achieved, do not shave any more material off
the bearing faces (See Figure 8-13C).
f) Reassemble the yoke or fork assembly and torque the
NAS6604 (or NAS1304) bolt to 100 in.-1b plus nut drag.
ChecK for freedom of movement with no play or drag.
8.630 B115-1 Bearing Installation
The B115-1 Bearing may be either interference-fit or Loc-
tite®-secured slip-fit in the A203 yoke or A205 fork, depending
on the diameter of the bearing bores.
8. 631 Interference-Fit Bearings ( 0. 6239 I 0. 6244 inch diameter
bearing bores)
a) Clean the bearing bores of the yoke or fork assembly.
Deburr any sharp edges and inspect and remove any met-
al shavings in the bearing bores.
b) Heat the yoke or fork assembly to approximately 180
degrees Fahrenheit.
c) Coat one bearing bore with zinc chromate primer. wnile
the primer is still wet, press in the B115-1 bearing to
the bottom of the bore.
d) Coat the other bearing bore with a graphite solution
(Lubri-Kote Type A or equivalent). Press in the B115-1
bearing until it is 0.010 to 0.020 inch above the top
of the bearing bore.
8.632 Loctite®-secured Slip-Fit Bearings (0.6255/0.6260 inch

diameter bearing bores)
a) Clean the yoke or fork assembly bearing bores of old
Loctite®.
b) Measure the bearing bores; maximum allowable diameter
is 0.6260 inch.
c) Lightly coat the B115-1 bearing outer races with Loc-
tite® 271 compound and install the B115-1 bearings in-
to the bearing bores. Wipe off excess Loctite®. Do
not allow Loctite® to enter the B115-1 bearing.
Page 8.62 Change 12: 22 JAN 93

LOCTITE® IS A REGISTERED TRADEMARK OF
LOCTITE CORP. NEWINGTON, CT 06111
8.630 8115-1 Bearing Installation (cont'd)
d) While the sealant is still wet, assemble yoke or fork assembly per Section 8.640.
Wait until sealant has been allowed to cure per manufacturer's instructions prior
to checking bearing pivot force.
8.640 Yoke and Fork Assembly Installation
1. Assemble fork or yoke assembly. Torque NAS6604 (or NAS1304) bolt per Section
1.320.
2. Place a torque wrench on bolt head at fork or yoke pivot point. The force required to
pivot assembly must be 5 in-lbs or less.
3. To reduce pivot force for A 139-1 bearings:
a. Disassemble fork or yoke assembly.
b. Ream inner bores of A 139-1 bearings; a very slight oversized bore may be
required.
c. Reassemble yoke or fork assembly. Recheck pivot force.
4. To reduce pivot force for interference-fit 8115-1 bearings:
CAUTION
Do not rotate bearing with a drill motor to reduce pre-load as this

may damage Teflon® liner and cause premature failure.
a. Place a 7/16 inch socket against outer race of the bearing installed with graphite
solution. Tap bearing lightly to relieve axial preload caused by torquing bolt. The
pivot force should drop with this slight movement of bearing race. If outer bearing
race is moved too far inward, bearing will be preloaded in opposite direction and
pivot assembly will have to be disassembled so that bearing can be pressed back
into its original position. The pivot assembly will have to be reassembled and
retorqued as described above.
b. If pivot force is still too high, replace interference-fit bearing yoke or fork assembly
with a adhesive-secured slip-fit bearing yoke or fork assembly.
c. Reassemble yoke or fork assembly per Figure 8-10. Recheck pivot force.

NAS6604-28
or
NAS1304-28
NAS6604-28
or
NAS1304-28
BOLT
A203-5
YOKE ASSY.
8330-13
PAL NUT
MS21042L4
NUT
FIGURE 8-14 8115-1 BEARING INSTALLATION

CHAPTER 9
ROTOR SYSTEMS
Section Title Page
9.000 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1

9.100 Main Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1
9.200 Tail Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.26C
9.210 Tail Rotor Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.26C
9.212 Tail Rotor Installation with Spherical Teeter Bearings . . . . . . . . . . . . . 9.27
9.213 Tail Rotor Installation with Elastomeric Teeter Bearings . . . . . . . . . . . . 9.30
9.214 Tail Rotor Hub Spherical Bearing Replacement . . . . . . . . . . . . . . . . . . 9.32A
9.215 Tail Rotor Hub Elastomeric Bearing Replacement . . . . . . . . . . . . . . . . 9.32B
9.220 Inspection and Repair of Tail Rotor Blades . . . . . . . . . . . . . . . . . . . . . . . 9.33
OCT 2018 Chapter 9 Rotor Systems Page 9.i

Intentionally Blank
Page 9.ii Chapter 9 Rotor Systems OCT 2018

CHAPTER 9
ROTOR SYSTEMS
9.000 Description
Refer to Chapter 26 for main rotor description.
The tail rotor has two all-metal blades and a teetering hub with a fixed coning angle. The
pitch change bearings have self-lubricated liners. The teeter hinge bearings are elastomeric
or have self-lubricated liners. The tail rotor blades are constructed with aluminum skins
and root fittings. Maintaining the paint finish will reduce corrosion and erosion.
9.100 Main Rotor

This section has been moved to Chapter 26 Main Rotor.
OCT 2018 Chapter 9 Rotor Systems Page 9.1

Intentionally Blank
Page 9.2 Chapter 9 Rotor Systems OCT 2018

9.200 Tail Rotor
9.210 Tail Rotor Assembly Removal
1. Mark or tag each pitch link and corresponding blade for reinstallation. Remove hardware
securing pitch links to tail rotor blades, noting hardware removed.
NOTE
Tail rotor pitch link-to-blade attach bolts may be different lengths

and/or have different washers installed under nut for balancing.
2. Remove nut and A141-14 washer securing A119-1 bumper to tail rotor gearbox output
shaft.
3. Remove teeter hinge bolt, then slide tail rotor assembly and bumper, and A130-1
spacers (A030-1 hub assembly only), off of shaft.
OCT 2014 Chapter 9 Rotor Systems Page 9.26C

FIGURE 9-11 TAIL ROTOR ASSEMBLY INSTALLATION (A008-4 ASSEMBLY SHOWN)
Page 9.26D Chapter 9 Rotor Systems OCT 2014

9.212 Tail Rotor Installation with Spherical Teeter Bearings

(see Section 9.213 if tail rotor has elastomeric teeter bearings)
1. Before hub installation, inspect:
a. A 130-1 Spacers: Worn faces or deep indentations from bearing ball are
cause for replacement.
b. Tail rotor gearbox output shaft: Shaft worn at flats for A 130-1 spacer
or elongated bolt hole requires output shaft replacement. A021-1 tail
rotor gearbox output shafts may be replaced by an RHC-authorized
component overhaul facility. B021-1 tail rotor gearboxes must be
returned to RHC for output shaft replacement.
c. Teeter bearings in hub: If inner ball is tight, move ball in bearing to work-
in and reduce stiffness.
2. Align tail rotor bla9es with same pitch change link from which removed.
3. Place A 130-1 spacers inside hub and install hub assembly on tail rotor
gearbox output shaft per Figure 9-12.
WARNING
Ensure blades are installed in proper direction of rotation,

and large A 137-2 spacers installed per Figure 9-11.
NOTE
Tail rotor hub teeter bearings may have to be pressed back

slightly to allow installation on tail rotor gearbox output
shaft. Place two small sockets inside hub against bearing
outer races, insert screwdriver between sockets, and I
carefully spread bearings apart for reinstallation.
4. Install tail rotor teeter (delta) hinge bolt and nut. Torque nut per Section
1 .330. Install palnut, torque per Section 1.320, and torque stripe.
NOTE
No washers are installed under teeter hinge nut or bolthead

on hubs using spherical teeter hinge bearings.
WARNING
Failure to check tail rotor for proper installation per step 5

can result in failure of teeter hinge bolt and loss of tail
rotor.

9.212 Tail Rotor Hub Installation with Spherical Teeter Bearings (cont'd)
5. After torquing teeter bolt, check tail rotor hub bearings, bolt as follows:
a. Place a line on exposed portion of each bearing ball using a felt pen or
grease pencil.
b. Teeter tail rotor assembly while observing marked lines relative to output
shaft of tail rotor gearbox.
c. Teeter bolt, nut, bearing inner balls, and spacers must remain rigid
(stationary) to output shaft when teetering tail rotor.
d. Teeter bearing outer races are press fit in hub and must not move relative
to hub.
NOTE
If bearing ball, bolthead, and/or nut are moving with hub

and blade assembly, insufficient clamp-up is indicated.
Possible causes and corrective action for insufficient clamp-
up are:
1. Worn A 130-1 spacers - replace spacers.

11. Hub teeter bearing stiff- manually work-in bearing
by moving ball.
111. Output shaft flats worn at bolt hole - return
gearbox to RHC for repair.
iv. Metal at bottom of hub bore is preventing bearing
outer races seating- remove bearings, clean bore
and reinstall bearings.
v. Force required to teeter tail rotor assembly not to
exceed 3 lb, measured at blade tip, before first
forward flight. After 6 hours of forward flight,
teeter forces must not exceed 1 lb.
6. Install bumper, A 141-14 washer, and nut on output shaft. Torque nut per
Section 1.320, install palnut, and torque stripe.
7. Connect pitch links blades. Torque fasteners per Section 1 .320 and torque
stripe.

¢ A/C FWD
---®--
~/--=--=- _, __,
TIP CAP
r--..--:--...,r--.....,
A r-l
BALANCE WEIGHTS l I
I
I
A029-l BLADE ASSY. ~ I
I
I
I
I
I I VIEW AA
I I
'\ I!
'\ I-- J
'-~---.../
I I
I
...__ Al29-2
HUB PLATE I
I
1
~A030-l
\ HUB ASSY
Al30-l SPACER
Al28-l HUB
--~~r--~--- NOTE:
NO WASHER
-UNDER BOLT
HEAD OR UN-
DER NUT.
VIEW AA
FIGURE 9-12 TAIL ROTOR ASSEMBLY (SPHERICAL TEETER BEARINGS)
Change 25: JUN 2006 9.29

9.213 Tail Rotor Installation with Elastomeric Teeter Bearings

(see Section 9.212 if tail rotor has spherical teeter bearings)
1. Align tail rotor blades with same pitch link from which removed. Install tail
rotor on tail rotor gearbox output shaft, and verify counterclockwise direction
of rotation (when viewed from left side of aircraft).
2. See Figure 9-11. Verify blades cone toward tail rotor gearbox.
3. Install tail rotor teeter hinge bolt, washers, and nut. Tighten nut until elastomeric
bearing metal spacers contact output shaft (See Figure 9-1 2).
4. Connect pitch links to blades and torque fasteners per Section 1 .320.
5. See Figure 10-7. With tail rotor horizontal, tape a tracking stick to tailcone at
blade tip.
NOTE
A tracking stick can be made from sheet metal approximately

1 inch wide x 12 inches long with a 90 degree bend 2 inches
from one end.
6. Rotate drive train at clutch shaft. Mark tracking stick where forward drain hole
of each blade tip passes.
7. Reposition (teeter) tail rotor on output shaft until both blade tips pass the
same point on the tracking stick ± 0.125 inch.
8. Torque teeter hinge bolt per Section 1 .330. Recheck track per step 6 and
adjust per step 7, if required, and retorque teeter hinge bolt.
9. When track is satisfactory, install pal nut on teeter hinge bolt, torque per
Section 1 .330, and torque stripe per Figure 2-1.
10. Remove tracking stick.
11. Teeter tail rotor back and forth. Verify teeter hinge bolt, bearing metal spacers,
washers, and nuts remain stationary when tail rotor is teetered.
WARNING
Movement of teeter hinge bolt, washer(s), spacer(s), or nut(s)

indicate insufficient clamp-up, which can result in Joss of tail
rotor.
12.1nstall urethane bumper, washer, and nut. Torque nut per Section 1.330, and
9.30 Change 25: JUN 2006

ROBINSON MAINTENANCE MANUAl. MOOELR22
TAIL ROTOR HUB
REFERENCE
MARKS
;
,
FIGURE 9-13 TAIL ROTOR HUB REMOVAL FOR BEARING REPLACEMENT
Change 17: 31 DEC 98 Page 9.31

LONG "SCRAP" NAS6604 OR AN4

TAP ON BOLT HEAD TO BOLT. GRIND OFF BOLT HEAD
REMOVE OPPOSITE BEARING. CORNERS AND PAINT YELLOW TO
INDICATE "TOOL STATUS.
11
AN315 OR AN316 NUT. GRIND

OFF CORNERS SO MAX DIAMETER SPHERICAL BEARING
OF NUT IS LESS THAN MINIMUM
DIAMETER OF TAIL ROTOR HUB
BORE.
ENSURE THREADED PORTION

- - - - O F BOLT PROTRUDES THROUGH
MODIFIED NUT TO ACT AS A
"PILOT (TO CENTER BOLT
11
IN BEARING BALL AND PRE-

VENT HUB BORE DAMAGE).
SPHERICAL BEARING
FIGURE 9-13A TAIL ROTOR HUB
SPHERICAL BEARING REMOVAL
MT201 BEARING PRESSING

FIXTURE
FIGURE 9-13B TAIL ROTOR HUB

SPHERICAL BEARING REPLACEMENT
Page 9.32 Change 17: 31 DEC 98
9.214 Tail Rotor Hub Spherical Bearing Replacement
NOTE
Some early-model tail rotors have one hub bearing swaged

into hub. This bearing is nonreplacable and, if worn, hub
assembly must be replaced.
1. Remove tail rotor per Section 9.210.
2. Mark hub per Figure 9-13.
3. Loosen four blade retaining bolts. Remove two center bolts securing hub
between hub plates and remove hub (see Figure 9-13).
4. See Figure 9-13A. Press out worn bearing(s).
5. Clean hub bore, removing old primer or metal shavings which might prevent
bearings from seating at bottom of bores.
CAUTION
Bearings are a slight press fit in hub bores. Inspect bores

for fretting. If fretting is found, tail rotor hub assembly is
UNAIRWORTHY.
6. See Figure 9-13B. Using special tool MT201, install bearings into hub as
follows:
NOTE
Hub may be heated to 170°F maximum to ease bearing

insertion and help prevent installation damage.
Apply Section 1.450-approved primer to original primed bore. Bearing

is to be installed to bottom of hub bore. Apply primer or A257-7
lubricant to remaining bore and install bearing flush with top of hub. If
bearing is installed too far, spacers and hub will not fit over gearbox
output shaft.
NOTE
Install tail rotor without delay if using primer in both bearing

bores.
7. Reinstall hub between hub plates per reference mark (see Figure 9-13).
Torque two center hub and four blade retaining bolts per Section 1.320,
install palnuts, and torque stripe.
8. Install tail rotor per Section 9.212.
Change 21: JUN 2000 Page 9.32A

9.215 Tail Rotor Hub Elastomeric Bearing Replacement
2. Remove four blade retaining bolts and remove blades.
3. See Figure 9-13C. Using special tool MT556, press out worn bearing.
4. Clean hub bore, removing old primer or metal shavings which might prevent
bearing from seating at bottom of bore.
CAUTION
Bearings are a slight press fit in hub bores. Inspect bores

for fretting. If fretting is found, tail rotor hub assembly is
UNAIRWORTHY.
5. Coat bottom of bearing bore with Section 1 .450-approved primer. While

primer is still wet, press bearing fully into hub using special tool MT556 per
Figure 9-130.
6. Repeat steps 1 thru 5 to replace opposite bearing, if required.
7. Seal between circumference of each bearing and hub with primer as required
in two places.
8. Assemble blades to hub. Verify counterclockwise direction of rotation.

Verify correct orientation of bolts and correct location/orientation of A 137-1
& A 137-2 spacers per Figure 9-11. Torque bolts per Section 1 .320, install
palnuts, and torque stripe.
9. Install tail rotor per Section 9.213.
Page 9.32B Change 21: JUN 2000

R 0 BIN soN MAINTENANCE MANUAL MOCELR22
PRESS TO REMOVE OPPOSITE BEARING
' AN4-25A BOLT

(Supplied with tool)
A062-2
~ : MT556-6 CAP (Beveled side
HUB ASSEMBLY
1 1 , t/ facing bolt and
~/, :;~~~~~~;!~1
~
I
I
I
MT556-5
SUPPORT
FIGURE 9-13C ELASTOMERIC BEARING REMOVAL
Change 22: MAR 2004 Page 9.32C

PRESS TO INSTALL BEARING
~ MT556-2
~ MANDREL
8361-1 BEARING
!+~--~
it
I I
tiD
l-l-r
MT556-5 I I
SUPPORT~ I I
I I
I
r_lI
I
--~
FIGURE 9-130 ELASTOMERIC BEARING INSTALLATION
Page 9.320 Change 21 : JUN 2000

9.220 Inspection and Repair of Tail Rotor Blades
This procedure outlines the inspection and repair limits for

tail rotor blades. Repairs are limited to blending out mech-
anical scratches, dents, nicks, removing corrosion and refin-
ishing the blades.
IWARNING I
Any damaged tail rotor blade
that cannot be repaired within
the limits of this section must
be declared NON-AIRWORTHY and be
removed from serv1ce immediately.
Inspection:
a) Scratches and Corrosion: Blade skins may be polished

out with a .10 inch blend radius within the following
limits:
1. Outboard of 6 inches from the blade tip. The

maximum depth allowed is .008 inch.
2. Inboard of 6 inches from the blade tip. The

maximum depth is .004 inch for any corrosion
or scratches running in a direction more than
15° from the spanwise direction. The maximum
depth less than 15° is .006 inch.
b) Dents on Skins (See Figure 9-14): Smooth, round-bot-

tomed dents which have a .06 inch minimum radius and
occur from the leading edge to a point .75 inch aft of the
leading edge are limited to .010 inch. Aft of .75
inch from the leading edge dents are acceptable within
the following limits:
1. Outboard of 6 inches from the blade tip, ~ents

cannot exceed .06 inch.
2. Inboard of 6 inches from the blade tip dents

cannot exceed .02 inch.
3. Dents within .5 inch of the trailing edge or tip

cannot be repaired.
4. Dents over the skin-to-root-fitting bond joint

cannot be repaired.

9.220 Inspection and Repair of Tail Rotor Blades(cont'd)
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.
c) Nicks and Notches in Trailing Edge: Blend all nicks

and notches in the extreme trailing edge up to a maximum
of .05 inch. The blend must extend for 1.0 inch each
side of the nick or notch.
d) Erosion of the Leading Edge: Replace any blade where

erosion has caused deformation or ripples in the leading
edge.
e) Dents, Scratches, and Corrosion on the Root Fitting:

Damage on root fittings must be blended out using .10
inch radius within the following limits:
1. No repairs allowed within .5 inch diameter circle

from the center of the bearings.
2. Maximum depth of .040 inch all other areas.
f) Rework Process and Measurement of Material Removed:

See Main Rotor Blade Repair, Section 9.130.
g) Painting (See Figure 9-14) :
1. Clean with M.E.K. and wipe lint-free with a

tack rag.
2. Apply a 2 to 3-inch-wide strip of epoxy primer

along all exposed bond joints.
3. Apply two full coats of epoxy primer to all

exterior surfaces. Time limits are 10 minutes
minimum, 8 hours maximum between coats. If
8 hours is exceeded, scuff with 600 grit,·
M.E.K. wipe and mist primer before applying
next coat.
4. Spray finish coat flat black.
5. Spray trim stripes.

16"---j
Max. depth 0.004" I
I Max. depth
~pt::;cr I o.ooa" SCRATCHES
Max. depth in this

area 0.010"
f"- -l__[
6
"
I
0.75"
I-Max.
- +T
Max. depth 0.020" I depth 1 DENTS
_I_.060" _I_ ! _
.1.
Dents in these
areas are not
repairable
I
'---- No repairs-----·
allovJed in
this area
,_ _ 2.00"
(Typical 7 places)
PAINT
FIGURE 9-14 INSPECTION/REPAIR OF TAIL ROTOR BLADES

CHAPTER 10
RIGGING, TRACK AND BALANCE

Section Title Page
10.000 Rigging, Track and Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1

10.001 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1
10.002 Rod End Adjustment Procedure for Rigging . . . . . . . . . . . . . . . . . . . . . . 10.1
10.100 Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2
10.110 Main Rotor Flight Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2
10.111 Cyclic Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2
10.112 Swashplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3
10.113 Collective Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3
10.120 Main Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3
10.121 Cyclic Travel Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8
10.122 Collective Travel Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.11
10.130 Tail Rotor Flight Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.12
10.131 Pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.12
10.132 A316 Bellcrank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.12
10.133 A331 Bellcrank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.12
10.134 A120-1 Bellcrank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.15
10.135 Tail Rotor Pitch Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.15
10.140 Tail Rotor Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.15
10.150 Throttle Correlation Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.19
10.200 Track and Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.21
10.210 Equipment Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.21
10.220 Equipment Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.21
10.221 Main Rotor Equipment Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 10.21
10.222 Tail Rotor Equipment Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.23
10.230 Main Rotor Track and Balance Procedure . . . . . . . . . . . . . . . . . . . . . . . 10.27
10.231 Main Rotor Balance Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.28
10.232 Main Rotor Pitch Link Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 10.28
10.233 Main Rotor Trim Tab Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.31
10.234 Main Rotor Track and Balance Trouble Shooting . . . . . . . . . . . . . . . . 10.33
10.240 Tail Rotor Balance Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.35
10.250 Autorotational RPM Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.38
OCT 2018 Chapter 10 Rigging, Track and Balance Page 10.i

Intentionally Blank
Page 10.ii Chapter 10 Rigging, Track and Balance OCT 2018

CHAPTER 10
RIGGING, TRACK AND BALANCE
10.000 Rigging, Track and Balance
10.001 Introduction
This section contains the procedures necessary to rig the main rotor flight controls,
tail rotor flight controls and throttle correlation. The track and balance procedures in
this section are to be used in conjunction with Chadwick-Helmuth balancing equipment
instructions.
10.002 Rod End Adjustment Procedures For Rigging
The following procedure is a standard for the adjustment of rod ends on the R22 helicopter.
1. Loosen the palnut and jamnut on the rod end.
2. Screw the rod end in or out of the push-pull tube or pitch link as required to obtain the
proper rigging adjustment.
3. After adjustment of the rod end, check the witness hole in the push-pull tube or pitch
link to ensure the rod end is installed far enough to cover the hole. This should be
checked using a piece of .020” safety wire. The safety wire must not pass through
the witness hole into the push-pull tube or pitch link.
4. Align the rod ends on both ends of the push-pull tube or pitch link so they will have
maximum misalignment clearance with the bellcrank clevis or arm (both rod ends
must move “stop to stop”). Collective rigging settings are made by readjusting the
total length of the pitch links. Adjustments (turns on the upper rod end or hex portion
of the pitch link) to each pitch link will be the same. The pitch link length may be
adjusted in three ranges; coarse, medium and fine. Adjustments are made as follows:
a. Coarse length adjustments to the length are made by rotating the coarse-threaded
section of the hex portion of the pitch link (the upper rod end is disconnected, the
lower rod end remains connected). Loosen the jamnut on the coarse threads only.
Increase blade angle by unscrewing the hex from the lower pitch link. Decrease
the angle by screwing the hex portion into the barrel. One full turn changes the
blade angle by approximately .72 degrees.
b. Medium length adjustments are made by rotating the upper rod end only. Disconnect
the rod end from the blade and loosen the rod end jamnuts. Increase blade angle
by unscrewing the rod end from the hex portion of the pitch link. Decrease the
angle by screwing the rod end into the hex. One full rod end turn changes the
blade by approximately .48 degrees.
c. The fine length adjustments are made by rotating only the hexagonal portion of the
pitch link. The upper and lower rod ends remain connected. Loosen the jamnuts
above the hex. Increase blade angle by screwing the hex out of the lower barrel.
Decrease blade angle by screwing the hex into the lower barrel. One full turn of
the hex portion changes the blade angle approximately .24 degrees.
5. Torque rod end jamnuts and palnuts per § 1.300.
OCT 2014 Chapter 10 Rigging, Track and Balance Page 10.1

10.100 Rigging
10.110 Main Rotor Flight Controls
10.111 Cyclic Controls
The cyclic control travel is non-adjustable and is controlled by A211-1 stop plate
attached to the cyclic box assembly.
NOTE
If the A121-1 push-pull tube length has been changed or the

length of the A205 fork was changed, they must be readjusted
to the dimensions shown in Figure 8-3.
a. Place the cyclic stick against the aft stop and the collective control full down.
b. Adjust the A121-3 push-pull tube to obtain a clearance of .130 inch between the
aft arm of the jack shaft and the main rotor gearbox upper cap flange.
Page 10.2 Chapter 10 Rigging, Track and Balance OCT 2014

10.111 Cyclic controls (cont'd)

c) Check for clearance between the forward jackshaft
arm and the Al21-7 push-pull tube guide with col-
lective stick full up and cyclic stick full for-
ward. Minimum clearance is .125 inch.
d) Place the cyclic control in the neutral position.
This point is 8.3 inches to 'the right of full
left travel and at the mid-point of the total fore
and aft travel. (See Figure 10-1). Place the
collective control full down.
e) Apply full cyclic and collective friction.
NOTE
Care must be taken not to move
the cyclic control from the
neutral position.
10.112 Swashplate
a) With the cyclic and collective controls locked in
position per Section 10.111, adjust the Al21-7 and
Al21-5 push-pull tubes to obtain a constant clear-
ance from the A281-l flange.
The minimum clearance from the flange is 5/8 inches.
(See Figure 10-2) Nominal settin~ is 3/4 inches.
10.113 Collective Control
Since the collective slider stop is non-adjustable, this
check is to ensure full control travel is obtained and does
not interfere with the swashplate travel.
a) Lift the swashplate boot so the uniball and slider
tube may be observed.
b) Pull the collective control full up. The uniball must
not extend past the top of the slider tube more than
.060 inch. If this occurs, adjust the Al21-5 and
Al21-7 push pull tubes as follows:
1. Turn the upper rod ends of the Al21-5 and
Al21-7 push-pull tubes in equally to lower
the swashplate.
2. Recheck the uniball-slider tube clearance
per Step b above.
10.120 Main Rotor
The main rotor is rigged by determining the average blade
angle. Blade angle measurements are taken at the .75 radius
of the main rotor (or 37.75 inches in from the blade tip).

8.3 INCHES
VIEW LOOKING FWD

r·-..
,lf·--:...- CYCLIC CONTROL LATERAL
[j ·- NEUTRAL POSITION
I
FULL LEFT_/\\ NEUTRAL
I '
TOTAL TRAVEL
MID POINT OF--+----;

TOTAL TRAVEL \ ,.
fl;
CYCLIC CONTROL
\'~f0, I Jn,,
. LONGITUDINAL
d:. _ _
~ NEUTRAL POSITION
~,\
1
FULL FORWARD FULL AFT
\ f'-NEUTRAL
\I
FIGURE 10-1 CYCLIC CONTROL STICK NEUTRAL POSITION

Max travel for up collective,

flush to 0.06 inch above top
of sleeve.
l
MIN. DOWN
!
0.625 CLEARANCE
COLLECTIVE
u_ ____ ------l----
t
FIGURE 10-2 LOWER SWASHPLA TE CLEARANCE
3. 70 inches tor upper, rotating fork

3.50 inches for lower, non-rotating fork
FIGURE 10-3 A205 FORK DIMENSIONS
Change 24: APR 2005 10.5

10.120 Main Rotor
The main rotor is rigged by determining average blade angle. Blade angle measurements
are taken at 0. 75 radius of main rotor at 37.75 inches in from blade tip.
Main rotor blade angles are measured using MT050-1 rigging fixture and a Keii-Strom
KS 11 3 propeller protractor or a comparable protractor (see Figure 1 0-4). Use following
procedure to set up for rigging:
1. Verify A205 forks at swashplate are set to proper length per Figure 10-3. Measuring
to bolt bore center lines, lower fork assembly should be 3.50 ± 0.03 inches and
upper fork assembly should be 3. 70 ± 0.03 inches.
2. Level rotorcraft per Section 1 .220 Method 2, Main Rotor Hub.
3. Place a tracking stick at end of one rotor blade and mark height of blade tip. Rotate
rotor 180° and mark height of opposite blade tip. Teeter main rotor as necessary
to obtain a main rotor track of ± 1 inch.
4. Zero propeller protractor to main rotor hub at location marked "Level Here". The
protractor must be placed parallel to teeter hinge bolt.
NOTE
When zeroing protractor, face or dial must always face one rotor
blade to avoid doubling of instrument error. Mark this blade
with a piece of tape. When making blade angle readings, face
or dial of protractor should always face marked blade.
5. Measure in from tip of each main rotor blade 37.75 inches and place masking tape
chord wise across each blade with center of tape over 37.75 inch mark.
WARNING
Use a grease pencil or soft marker to mark rotor blades. Ball

point pens or other sharp instruments can scratch blade skins~
causing cracks and fatigue failure of blade.
Mark each rotor blade with a different color designation, such as red or blue, to be
used in recording blade angles.
10.6 Change 26: APR 2007

MT050-1
MAIN ROTOR
RIGGING FIXTURE MAIN ROTOR BLADE
DISTANCE FROM END

OF MAIN ROTOR BLADE
USE PIECE OF CARDBOARD

OR TAPE TO IDENTIFY WHICH
BLADE PROTRACTOR WAS
FACING WHEN SET TO ZERO.

10.121 Cyclic Travel Rigging
NOTE
Adjust collective travel rigging before cyclic travel rigging.
1. Place collective control full down. Place cyclic control in the neutral pos1t1on
laterally (8.3 inches to the right of full left travel) and hold against forward stop.
NOTE
Sand bags may be used to secure the cyclic control against the
forward stop to ensure it will not move.
2. Rotate blades so the pitch links are aligned with the longitudinal axis of the
helicopter. Place the tracking stick at one of the blade tips for reference when
rotating the rotor.
3. Forward longitudinal cyclic:
a. Measure blade angles and record below. Rotate rotor 180° and record blade
angles below.
Blue Blade Position Cyclic Full Forward

0
Pitch horn aft ---------------- 0 nose up
Pitch horn fwd + nose down
----------------
0-;-2= ---------- 0
R22, R22HP 8.3/8.8 degrees required
R22 Alpha, Beta 10.5/11.0 degrees required
Red Blade Position Cyclic Full Forward

Pitch horn aft ---------------- 0
0
nose up
Pitch horn fwd + nose down
________________ o -;- 2= __________ o
R22, R22HP 8.3/8.8 degrees required

R22 Alpha, Beta 10.5/11.0 degrees required
b. Adjust aft swash plate push-pull tube as required (one full turn = 0.42 °)
to obtain blade angle averages between 8.3 ° and 8.8 °. Additional coarse
adjustment is available by simultaneously adjusting the two forward push-pull
tubes but they both must be adjusted exactly the same amount.
4. Aft longitudinal cyclic:
a. Place cyclic control in the neutral position laterally and hold against aft stop.
b. Measure blade angles and record below. Rotate the rotor 180° and record
blade angles below.

10.121 Cyclic Travel Rigging (cont'd)
4. Aft longitudinal cyclic:
Blue Blade Position Cyclic Full Aft

0
Pitch horn aft nose down
0
Pitch horn fwd + nose up
0.;.2= 0
(8.5/9.0 deg. req d)
Red Blade Position Cyclic Full Aft

0
Pitch horn aft nose down
0
Pitch horn fwd + nose up
07-2= 0
(8.5/9.0 deg. req'd)
c) Adjust the aft swashplate push-pull tube as

required (one full turn = .42°) so
obtain
0
blade angle averages between 8.5 and 9.0 .
Additional coarse adjustment is available by
simultaneously adjusting the two forward push-
pull tubes but they both must be adjusted ex-
actly the same amount.
NOTE
If adjustment is required to ob-
tain aft cyclic control blade
angles, the forward cyclic must
be rechecked.
5. Left lateral cyclic:
a) Place the cyclic control in the neutral

position longitudinally (mid travel) and hold
the cyclic against the left stop.
b) Rotate the rotor until the pitch links are

aligned with the lateral axis of the heli-
copter. Place the tracking stick at the end
of one blade for reference.
c) Measure the blade aneles and record below.

Rotate the rotor 180 and record the blade
angles below.


Blue Blade Position Cyclic Full Left
0
Pitch horn on right - - - - - nose up
0
Pitch horn on left +- - - - nose down
0~2= 0
(=9~.0~/~9-.5 deg. req'd)
Red Blade Position Cyclic Full Left

0
Pitch horn on right nose up
Pitch horn on left +- - - -0 nose down
0.;.2= 0
~(~9~.0~/~9-.5 deg. req d)
d) Adjust either of the two forward push-pull

tubes as required (one full turn = .6 deg.6
to obtain blade angle averages between 9.0
and 9.5 0 .
6. Right lateral cyclic:
a) Place the cyclic control in the neutral
position longitudinally (mid travel) and hold
against the right stop.
b) Measure the blade angles and record below.
Rotate the rotor and record the blade angles
below.
Blue Blade Position Cyclic Full Right
0
Pitch horn on right nose down
0
Pitch horn on left + nose up
-----
0.;.2= 0
(=5~.5~/~6-.~0 deg. req'd)
Red Blade Position Cyclic Full Right

0
Pitch horn on right nose down
0
Pitch horn on left +- - - - - nose up
0.!.2= 0
----.
(5. 516, 0 deg. req' d)

c) Adjust either of the two forward push-pull

tubes as required (one full turn = .6 deg.6
to obtabn blade angle averages between 5.5
and 6.0 .
NOTE
tain right cyclic control blade
angles, the left cyclic must be
rechecked.
10.122 Collective Travel Rigging
1. Place the cyclic control in the neutral position

(See Figure 10-1). Place the collective control
full down. Apply full cyclic and collective fric-
tion.
2. Rotate the main rotor to align the pitch links with

the longitudinal axis of the rotorcraft. Place the
tracking stick at the end of one blade to be used
as a reference point when turning the rotor.
3. Measure the blade angles using the MT050-1 rigging

fixture and propeller protractor.
NOTE
The MT050-1 fixture is placed on
top of the blade so it straddles
the tape at the 37.75 inch sta-
tion. The fixture must be held
tightly against the leading edge
to ensure accurate readings. The
face of the protractor must face
the marked blade when taking
readings. (See Section 10.120,
Step 2).
Record blade angles, then rotate rotor 180° and

again record angles. Adjust the pitch link of
each blade until the two blade angles are within
0.2 degrees of each other when the blade pitch link
is in the forward position. Check the blade angles
with each blade pitch link aft. These angles must
be within 0.2 degrees also.

10.122 Collective Travel Rigging (cont'd)
COLLECTIVE FULL DOWN
Blue Blade Red Blade
0
(PHF) Pitch Horn Fwd. nose up (PHF) - - -0 nose up
---
(PHA) Pitch Horn Aft.
0
nose up (PHA)+___ 0 nose up
0 0
- - -0-:-2=- - - 0-i-2=
4. Pull the collective control to the full up position.

Apply full collective friction. Measure the blade
angles per Step 3 above and record in the chart
below.
0 0
Blue Blade nose up Red Blade nose up
(Low pitch setting 2°) (11°/12° above low )
nose up. pitch setting.
10.130 Tail Rotor Flight Controls
10.131 Pedals (See Figure 10-5)
Pedal rigging is accomplished as follows:
1. Insert a 3/16-inch diameter rigging pin through the

hole in the right-hand keel panel and the rigging
pin holes in the A317-1 bellcrank.
2. Adjust the Al21-9 and -11 push-pull tubes as re-

quired to obtain a dimension of 2.90 inches from
each pedal to the stops located on each side of
the forward console.
10.132 A316 Bellcrank (See Figure 10-5)
Remove the rigging pin and place the left pedal against its
stop. Adjust the A121-13 push-pull tube to obtain a minimum
of .060 inches between the A316-1 bellcrank arm and the
vertical firewall control tunnel.
10.133 A331 Bellcrank
Place the right pedal against its stop. Adjust the A121-15
push-pull tube to obtain a minimum clearance of .100 inches
between the A331-l bellcrank and the actuator gearbox housing
(See Figure 10-6).

Al21-15 P/P TUBE

A316-l BELLCRANK
A121-13 P/P TUBE
PEDAL STOPS
3/16 IN. DIAM.

RIGGING PIN,
NEUTRAL POSITION
A121-ll P/P TUBE ______ _j

Issued 5/22/87 FIGURE 10-5 PEDAL CONTROL INSTALLATION
Page 10.13
>- -----------
FUSELAGE
\ ROD END OTHER SIDE

\
Al21-15 P/P TUBE A331-l BELLCRANK
\
,
,, \
\
Al21-17 P/P TUBE I )
\ I
\ I
TAIL CONE
VIEW LOOKING DOWN
FIGURE 10-6 A331 BELLCRANK INSTALLATION

10.133 A 120-3 Bellcrank (cont'd)
NOTE
Actuator must be disengaged when adjusting A331 bellcrank

to check closest point.
Place left pedal against its stop and check for clearance between A331-1 bellcrank
and tailcone.
10.134 A 120-1 Bellcrank
With tail rotor pedals in neutral position, adjust A 121-17 push-pull tube as required
to obtain a nominal dimension of 4.85 inches between bellcrank arm center line
and machined face of tailcone casting (see Figure 1 0-7).
10.135 Tail Rotor Pitch Links
If applicable, adjust pitch links to a dimension of 2.360 inches between rod end
centers (See Section 8.570).
10.140 Tail Rotor Rigging
WARNING
Both pitch links must be same part number (same type and
material). Mixing one-piece with adjustable-length pitch links
is prohibited. Mixing steel one-piece with aluminum one-piece
pitch links is prohibited.
1. Set up:
a. Ensure removable pedals are installed.
b. Level rotorcraft per Section 1 .220 Method 2, Main Rotor Hub.
c. Rotate tail rotor until forward blade is parallel to tailcone.
d. Tape a tracking stick to tailcone at tip of forward blade.
NOTE
A tracking stick can be made using a 1 inch by 12 inch strip of

aluminum with a 90° bend 2 inches from one end.
e. Place left pedal against its stop. Using a tip drain hole as a reference, first
mark tracking stick where blade tip passes stick.
f. Using clutch shaft so teeter angle is not disturbed, rotate tail rotor 180° until
opposite blade tip drain hole is aligned with tracking stick. Mark stick.
Change 26: APR 2007 10.15

10.140 Tail Rotor Rigging (cont'd)
g. Adjust teeter of tail rotor to position blade tip mid point between marks. This
will be the left-pedal tacking mark. Rotate tail rotor and check that the blades
track. Repeat above procedure as necessary to track tail rotor within 0.125
inch.
2. Measure tail rotor blade angles as follows:
a. Using a soft marker or grease pencil mark each blade as red or blue.
b. Measure in from each blade tip 5.25 inches (0. 75 radius) and place a mark
chord wise on each blade at this point (soft marker or grease pencil).
c. Have some one hold forward blade tip at left pedal track mark.
d. Place MT050-2 rigging fixture on aft blade inboard side.
NOTE
The MT050-2 fixture must be centered on 0. 75 radius mark.
e. Using a propeller protractor measure blade angle and record below. Rotate tail
rotor 180° and record opposite blade angle.
Pedals Full Left
Blue Blade 0 nose right

- - -
Red Blade + ___ 0nose right

0
0
-+-2
(19.0°/19.5° required)
10.16 Change 26: APR 2007

AFT MACHINED FACE

Al48-1 TAILCONE
CLOSURE BULKHEAD
j;
PROPELLER
Al21-17 P/P TUBE PROTRACTOR
.
t (·.::· ·:
' ··--r---~
0 ~
TAIL ROTOR ASSEMBLY~ _,C -.l
ru·rr 1.
MT050-2
~;;;~~~
--- __r-- - L__ . - ----, y
'----~~~--. -- -~:-~}:::.J
r5.25"-1
~TRACKING STICK DISTANCE FROM THE
END OF THE TAIL
ROTOR BLADE
DISTANCE FR0~1 -~-- 5.25"--1

THE END OF THE
TAIL ROTOR BLADE .!..---~
~
MT050-2 RIGGING FIXURE
FIGURE 10-7 A120-1 BELLCRANK INSTALLATION

I CAUTION l
For acceptable track, differences
between Blue and Red blade angles
must not exceed .4 degrees. If
the blade angles cannot be ad-
justed to within .4 degrees of
each other using the pitch links
they should be replaced.
NOTE
Pitch link jamnuts must be tight

to ensure accurate blade angle
measurements.
f) Adjustment of the blade angles is made using the

rod ends of the A121-17 push-pull tube. One
full turn of the rod end will change the blade
angles .42 degrees. Adjust the rod end as ne-
cessary to obtain 19.0 to 19.5 degrees.
g) Place the right pedal against its stop. Measure

the blade angles and record below.
NOTE
When pedal is placed against the

right stop, a new tracking mark
must be placed on the track stick
as the tip path will change due
to blade angle change.
Pedals Full Right
Blue Blade 0 nose left
0
Red Blade + nose left
07-2= 0
(9.6/10.6 deg. req'd)
h) Adjust the A121-17 push-pull tube as necessary

to obtain blade angles of 9.6 to 10.6 degrees.
NOTE

tain right pedal blade angles,
the left pedal angles must be
rechecked.

i) If the blade angle range, for left and right
pedal settings, cannot be obtained using the
above procedure, this indicates the pedal travel
is either too great or too small. Use the
following procedure to check and adjust pedal
travel:
1) Add the right and left pedal angles together.
If the total is less than 28.6° the pedal
total travel is too amall. If the total
is greater than 30.1 the total travel is
too great.
2) To increase the total travel, lengthen the
Al21-9 and -11 push-pull tubes attached to
the tail rotor pedals.
3) To decrease the total travel, shorten the
A121-9 and -11 push-pull tubes.
NOTE
These changes should be made in
1/2 turn increments of the push-
pull tube rod ends.
4) Recheck the tail rotor blade angles per steps
e through h above.
j) Ensure all rod ends are installed properly by
checking the push-pull tube witness holes. Tight-
en all rod end palnuts and jamnuts. Torque stripe
all jamnuts.
10.150 Throttle Correlation Rigging (See Figure 10-8)
a) For inservice check and adjustment, perform the
following:
1) Rotate the throttle in "off" direction
through the overtravel spring to the
positive stop.
2) Holding the throttle tight against the stop,
raise collective to full up stop while ob-
serving throttle bellcrank on carburetor.
Throttle bellcrank should just barely start
to move when the collective up stop is
reached.

Adjust A327-1 Overtravel Spring Assembly

to fit following geometry with no spring
compression: Collective full up, throttle
twist grip rotated full closed, A609-2 Arm
at dimension shown. Then, adjust A336 or
B364 Push-Pull Tube to fit with carburetor
arm just off idle stop (0.02-0.05 inch
movement at rod end bolt) (push-pull tube
must be readjusted whenever idle stop is
adjusted). Select A336-1 or -2 push-pull
tube, or install A 130-54 spacer(s), as
required to obtain proper adjustment.
OVERTRAVEL
SPRING
A336-1 or -2 PUSH-PULL TUBE (0-320 engine)

8364-1 PUSH-PULL TU~E (0-360 engine)
.
~---
?? ;r~--
Connect
to middle
0 hole
CARBURETOR BORE
CENTERLINE
IDLE RPM
ADJUSTMENT
SCREW
Throttle lever to be
58±7 .5 degrees at full
open (set to nearest
tooth)
FIGURE 10-8 THROTTLE CORRELATION RIGGING

10.150 Throttle Correlation Rigging (continued)
NOTE
Before adjusting throttle connecting rod, ensure idle RPM and
engine shimming are correctly adjusted per §§ 2.210 and 6.130.
3. See Figure 10-8. If required, adjust length of throttle connecting rod for 0.020–0.050
inch gap between carburetor butterfly bellcrank and idle RPM adjustment screw when
performing step 2.
4. Tighten jamnut(s), check witness holes, and safety wire rod end, as required. (Note:
If A933-3 rod end is installed, B330-7 palnut is required.)
10.200 Track and Balance
10.210 Equipment Requirements
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.
10.220 Equipment Installation
10.221 Main Rotor Equipment Installation
NOTE
Use the following track & balance procedures in conjunction with
approved equipment manufacturer’s balancing instructions.
CAUTION
Cable security is critical; helicopter will be flown at VNE.
a. Refer to Figure 10-9A. Using appropriate hardware, attach brackets to vibration

transducer and attach assembly A359-1 panel as shown. Remove removable controls.
b. Install magnetic pickup bracket onto swashplate if not previously installed.

Intentionally Blank

10.221 Main Rotor Equipment Installation (cont'd)
IWARNING I
Ensure attachment bolts are
torqued to 100 in.-lbs plus nut
drag. The PT121 bracket will re-
main installed for inflight track
and balance.
c) Install the 3030 magnetic pickup onto the PT121

bracket. Set the interrupter pickup gap to
.030" ± .010".
d) Attach the 3319-1 cable to the magnetic pickup.
Pull collective stick full up and cyclic stick
full left. Secure the cable to the mast fairing
with duct tape. Route the cable to the lower
front of the left door frame. Secure the cable
every 12" with duct tape.
I CAUTION I
Security of the cable is essen-
tial as the helicopter will be
flown at Vne.
e) Attach the 4296-1 cable to the accelerometer

mounted on the console. Secure with duct tape.
I CAUTION I
Ensure the cable cannot become
tangled with tail rotor pedals.
f) Attach the cables to the balancer and secure ex-

cess cable to the bracket in front of the left
seat.
g) Apply the 4270 target tapes to the main rotor

blades per Figure 10-9.
10.222 Tail Rotor Equipment Installation (See Figure 10-9C)
a) Install the 4177 accelerometer under the top forward

tail rotor gearbox output cartridge attachment bolt.
Connector end of accelerometer must point up.
b) Connect the 4296-2 cable to the accelerometer. Wrap

cable around the tailcone several times towards the
forward end. Secure with duct tape.

TARGET WIDTH
w
Dl
U1
........
3:
z
c:::(
Cl...
U1
r--
t CHORDWISE TARGET
j
t LENGTH
I
4270 M.R. TARGET PATCH LOCATION _ ____.
FIGURE 10-9 MAIN ROTOR TARGET PATCH LOCATION

DUCT
TAPE
PT121
BRACKET
FIGURE 10-9A MAIN ROTOR EQUIPMENT INSTALLATION

CHORD (COUNTER)
WEIGHTS
DOUBLE INTERRUPTER
INSTALLED HERE
FIGURE 10-9B
DOUBLE INTERRUPTER
INSTALLATION
If the interrupters are installed as shown above the Main

Rotor Balancing Chart will be out of phase.
Using a model 135M-10 Strobex with the interrupters
installed per above drawing and using Doubler Interrupter
Logic on the Balance Box, the Forward Blade must be relabeled
as Aft. The Aft Blade must be relabeled Forward. Adding and
subtracting chord weights and rotor head shifts would also
be out of phase.
To use the Main Rotor Track and Balance Chart without
correcting it, you must reverse the interrupters. The
double interrupter must be on the opposite side of the
driveshaft as the Chord (counter) weights.
Page 10.25A Change 6: 28 JUL 89

Change 6: 28 JUL 89 Page 10.2SB

DUCT ,...., A
TAPE ~
~b--£5~
i·
~·, t
BALANCER
.....--sTROBEX
~e~
4296-2
CABLE 4177
ACCELEROMETER
~
/\
FIGURE 10-9C TAIL ROTOR EQUIPMENT INSTALLATION

10.222 Tail Rotor Equipment Installation (cont'd)
TARGET
TAPE
WARNING
Tail rotor balancing equipment must be removed for flight.
FIGURE 1 0-9C TAIL ROTOR BALANCING EQUIPMENT INSTALLATION
Change 25: JUN 2006 10.26A

f\ ____ ,.,..,1
I \ I
\~ j PHOTOCELL
(PIVOT PHOTOCELL MOUNTING
(~ \ \ ~ 1~,
BRACKET SO PHOTOCELL BEAM
ALIGNS WITH TARGET TAPE
WHEN TAPE IS AT 12 O'CLOCK
POSITION.)
I I
(VIEW LOOKING FORWARD)
WARNING
Tail rotor balancing equipment must be removed for flight.
FIGURE 10-90 TAIL ROTOR PHOTOCELL INSTALLATION
1 0.26B Change 25: JUN 2006

c) Place a target tape on tail rotor hub inboard surface approximately 1 inch in
from on blade's outboard attach bolt.
CAUTION
Ensure cables cannot become entangled in tail rotor.
d) Refer to Figures 10-9C and 10-90. Install and secure photocell and mounting
bracket to velocimeter bracket as shown. Connect extension cable to photocell
and wrap cable several times around tailcone and secure with duct tape.
e) Connect cables to balancer.
10.230 Main Rotor Track and Balance Procedure
NOTE
Prior to installing balancing equipment, verify blades are clean

and smooth, rod ends & spherical bearings & scissors play are
within limits, correct upper (rotating) scissors friction, correct
swashplate tilting friction, and correct teeter and coning hinge
frictions. Verify Interrupter is opposite chord arm.
In-flight track and balance is accomplished using the following testing and adjustment
sequence:
1. Check main rotor track in a hover. When using Vibrex 177- or 8350- series
equipment, place Function knob in track position, RPM (flash rate) on Strobex to
424. Adjust track by shortening high blade pitch link per Section 10.232 to bring
track within 0.25 inch.
2. Check main rotor balance in a hover. For Vibrex 177- or 8350- series equipment,
place Function knob in "A" position, RPM on Phazor to 530. Adjust balance as
indicated by main rotor balance chart 0.2 IPS.
3. Fly the helicopter at 50, 60, 70, 80, 90, and 100 knots. Check track at each
airspeed and record.
WARNING
Do not exceed Vne of helicopter when checking in-flight track.
4. Make slight tab adjustment to correct for a climbing blade by bending trim tab down
per Section 10.233.
5. Repeat Steps 3 & 4 as required until track is within 3/8 inch at all airspeeds.
6. Readjust main rotor balance in an hover to no greater than 0.2 IPS.
7. Check autorotational RPM per Section 10.250. Adjust as required.
8. Evaluate collective trim, longitudinal cyclic trim, and lateral cyclic trim. Adjust as
required.
9. Check main rotor balance in an hover. Verify no greater than 0.2 IPS. Adjust as
required.
Change 25: JUN 2006 10.27
10.231 Main Rotor Balance Adjustments
Spanwise balance adjustments are made by adding or subtracting weight as

indicated by the balance chart. Weight is changed by removing the blade tip cover
and changing A298 tip weights. Fine adjustments may be made with AN960-1 0
or AN960-1 OL washers and also by trimming washers.
Coarse adjustment of chordwise balance is accomplished by shifting rotor hub

(see Section 9.124) as indicated on balance chart. Fine adjustment of chordwise
balance is accomplished by adding or subtracting A255-1 or -2 chord weights or
AN970-4 washers as indicated by balance chart. A maximum of two A255-2
weights (two A255-2 weights equal six A255-1 weights) may be installed.
Three A255-1 weights = One A255-2 weight
Eight AN970-4 washers = One A255-1 weight
10.232 Main Rotor Pitch Link Adjustment
Two adjustments can be made to change main rotor pitch link length. Coarse
adjustments are made by loosening the upper rod end jam nut, disconnecting the
rod end from the blade pitch horn, and turning the rod end up or down (one-half
turn of rod end changes track approximately 0.25 inch).
Fine adjustments are made by leaving the upper rod end connected to the pitch link
and loosening the rod end jam nut, loosening the barrel jam nut, and then screwing
the barrel up or down. One barrel revolution is equivalent to one-half turn of rod
end. Partial turns of the barrel can be made by counting the number of hex flats
rotated (see Figure 10-11) or by noting degrees of barrel rotation.
CAUTION
Check witness holes in pitch links after making an adjustment;
a piece of 0.020-inch diameter safety wire must not pass
through.
10.28 Change 22: MAR 2004

ADD TO
MAIN ROTOR TRACK AND BALANCE CHART AFT
SHIP S/N (10) AN960-10L WASHERS BLADE"'-
Page of Page - -
'
MOUNT ACCELEROMETER
ON LEFT SIDE OF SUBTRACT
CONSOLE POINTED DOWN ~ ADD TO
SPANWISE FWD
BLADE
( 5) AN960-10L
CHORD ARM WASHERS (lO)
WEIGHTS AN960-10L
{A255-1) 0 WASHERS
FORWARD
BLADE
AFT
BLADE BALANCE TRACK (At Percent of RPM or KNOTS)
CLOCK IPS HOVER CLIMB 50 70 80 90 100 104
I I I I I I I I
I I I I I J I I
CHANGE MADE:r---~r-----,--~-,----,----,----,,----.-----.----~--~
I ~
CHANGE MADE:
,~~~,~~~~~~~~
CHANGE MADE:r-----r----,r----.-----.----.-----.----,-----.----~~~
I II
Change 1 6: 19 SEP 97 FIGURE 10-10 Page 10.29
WITNESS HOLES BARREL

UPPER ROD END
FIGURE 10-11 MAIN ROTOR PITCH LINK

Intentionally Blank

FIGURE 10-12 MAIN ROTOR BLADE TRIM TAB ADJUSTMENT

10.233 Main Rotor Blade Trim Tab Adjustment
NOTE
To correct for a "climbing" blade condition (blade spread that

exceeds 3/8 inch with forward airspeed), bend high blade trim
tab down.
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.
CAUTION
Tighten MT526-1 or MT526-8 trim tab bending tool bolt to

bend tab; do not use tool as a lever.
CAUTION
Bend tab upward only when absolutely necessary; bending tab

upward can increase rotor vibration.
CAUTION
MT526-1 trim tab bending tool (for A016-4 [stainless steel

skin] blades) and MT526-8 trim tab bending tool (for A016-6
[aluminum skin] blades) are not interchangeable. Use of wrong
bending tool can result in blade damage. MT090-1 trim tab
bending tool (for earlier blades) is obsolete.
1. Using felt tip marker, ink mark main rotor blade trim tab per Figure 10-12. Mark
line with a measuring point in the center of the tab (approximate).
2. Position MT352-1 gage chordwise across blade upper surface and tab trailing edge.
Zero dial indicator on measuring point.
3. Position MT526-1 (trim tab bending tool (for A016-4 [stainless steel skin] blades)
or MT526-8 trim tab bending tool (for A016-6 [aluminum skin] blades) on tab per
Figure 10-12. Slide tool completely over tab until tool stops contact blade trailing
edge. Double-rib side of tool should contact tab upper surface to bend tab down.
Double-rib side of tool should contact tab bottom surface to bend tab up.
4. Tighten MT526 bending tool bolt to bend tab. Make slight bends and re-measure
tab with MT352-1 gage. Bend trim tab 0.015 inch (down) to effect dynamic
movement of main rotor blade tip approximately 0.2 inch (downward).
OCT 2014 Chapter 10 Rigging, Track and Balance Page 10.32A

Intentionally Blank
Page 10.32B Chapter 10 Rigging, Track and Balance OCT 2014

10.234 Main Rotor Track and Balance Troubleshooting
The following are some of the symptoms and corrections which

occur in the Track and Balance O?erations of the helicopter. Decide
on the various causes of a given trouble and then eliminate causes
one by one, beginning with the most probable.
Symptom Probable Cause Correction
1. Excessive Cyclic Main Rotor Out of Track Track and Balance with
Stick Shake or Balance Chad"li<7ick-Helmuth Balanc-
ing Equipment
Rough or Binding A205-3 Replace or refer to
Fork Assy (Upper Swash- Section 8.6 of Mainte-
plate) nance Manual
Brinelled Spindle RHC replacement of
Bearings (rough Spindle Bearings
movement)
Blade surface rough Feather in rough edges
(chipped) paint or repaint
Rough or Binding Replace nitch link rod
Pitch Links ends for smooth operation
M.R. Blade Boot Replace boot or realign.
Misaligned Boot should show
deformation as cyclic
and collective are moved
through their normal arc
or travel.
M.R. Hub Teeter or RHC replacement or rework
Coning Hinge Binding for smooth operation
M.R. Blade Trim Tabs Bend Trim Tabs down
Bent Upward evenly
Blade Match RHC reulacement of
blade(s)
2. Excessive Ship Main Rotor out of Track and Balance with

Vibration Track and Balance Chadwick-Helmuth Balanc-
ing Equipment
M.R. Hub Teeter or Refer to Section 9.123
Coning Hinge Friction of Maintenance Manual
Improperly Adjusted
Sticky Coning Hinge RHC replacement or refer
Bearings in M.R. Hub to Section 9.123

10.234 Main Rotor Track and Balance Troubleshooting (cont'd)
Symptom Probable Cause Correction
2. Excessive Ship Brinelled Spindle RHC replacement of

Vibration Bearings (rough Spindle Bearing
(cont'd) movement)
Worn Teeter Bearing RHC replacement of M.R.
in M.R. Hub Hub Bearings
3. Excessive Cyclic Brinelled Spindle RHC replacement of

Stick Forces Bearings (rough Spindle Bearings
movement)
M.R. Blade Trim Tabs Bend Trim Tabs down
Bent Upward evenly
4. Intermittent M.R. Hub Teeter or Refer to Section 9.123

Blade Track Coning Hinge Friction
Picture Improperly Adjusted
Sticky Coning Hinge RHC replacement or refer
Bearings in M.R. Hub to Section 9.123
Teeter Hinge not Adjust track to minimize
Broken-In error
Brinelled Snindle RHC replacement of
movement)
5. Radical Changes Worn Teeter Hinge RHC replacement of M.R.

to Cylic Trim Bearings in M.R. Hub Hub Bearings
Brinelled Spindle RHC replacement of
movement)
6. Lateral Inter- Engine misfiring due to Refer to Lycoming

mittent Aircraft malfunction in snark- Maintenance Instructions
Vibration plugs, ignition ieads,
magneto or engine not
broken-in

10.240 Tail Rotor Balance Procedure

1
Refer to specific manufacturer S installation instructions when using balancing equipment
other than Chadwick-Helmuth 177- or 8350- series Vibrex system.
Install Chadwick-Helmuth equipment per Section 10.222. Set Function Knob on Balancer
to appropriate channel. Set balancer RPM Range knob to X1 0 and set RPM to 340. With
helicopter running/ with governor ON/ view tail rotor assembly with Strobex. Tune
Balancer while viewing target tape and adjusting RPM dial on Balancer. Record clock
angle and IPS on tail rotor balance chart. Adjust as required until balance is less than 0.2
IPS.
WARNING
Both tail rotor blades must be same part number
Spanwise balance adjustments for A029-1 square-tip blades made by adding/ subtracting,
or exchanging weights under the removable tip cover. Use A 134-1 or -2 tip weights or
AN960~8 or -8L washers. -8L washers may be trimmed as a very fine adjustment.
Span wise balance for A029-2 round-tip blades are made by exchanging different diameter
washers under nut securing blade's outboard retaining bolt. The bolt has sufficient
length to allow necessary span wise weight changes; verify 2-4 threads protruding past
nut after torquing per Section 1.320.
Chord wise balance is adjusted by adding, subtracting, or exchanging A 141-14/ A214-3,

AN960-416 or -416L washers under nut securing blade's pitch link attaching bolt.
Change pitch link, attaching bolt length as required for proper thread engagement (see
Section 1.300, refer to IPC for allowable lengths).

A008-2 TAll ROTOR SHIP S/N _ __

(WITH A029-1 SQUARE-TIP BLADES) DATE - - - - -
TRACK AND BALANCE CHART HOURMETER - - -
----- TARGET
BLADE
REFLECTIVE
~TARGET ADD TO
2 BLANK
REFLECTIVE TARGET
AN960-8L
MOUNTED OPPOSITE WASHERS S
p
ANY CHORD WEIGHT
PREVIOUSLY INSTALLED A
N
0
~---BLANK
w
BLADE I
s
ADD TO
2 TARGET E
AN960-8L
------ __ WASHERS
3
CHORDWISE WEIGHTS SPANWISE WEIGHTS

(2)AN960-416L WASHERS = (l)AN960-416 WASHER (2)AN960-8L WASHERS = (l)AN960-8 WASHER
(3.5)AN960-416L WASHERS = (l)A214-3 WASHER (8)AN960-8L WASHERS = (l)Al34-l WEIGHT
(5)AN960-416L WASHERS = (l)Al41-14 WASHER
RUN CLOCK IPS CHANGE MADE BEFORE NEXT RUN
FIGURE 10-14

A008-4TAIL ROTOR SHIP S/N - - - -

(WITH A029-2 ROUND-TIP BLADES) DATE - - - - -
TRACK AND BALANCE CHART HOURMETER - - - -
~\.-ry...~·:{.. 'f.
ry.._\)'0 "'\)\)~ "ry...~\:}~~s~s

1(~\)~ ~ ~~
~\)~s x-<:J(),':J?.: 1\
~s '\(),~
~ry...s'\ 't
-TARGET
BLADE
REFLECTIVE
TARGET
~LECTIVE TARGET
MOUNTED OPPOSITE
ANY CHORD WEIGHT
PREVIOUSLY INSTALLED 0 N
w
--BLANK SUBSTITUTE
BLADE AT TARGET S
NAS1149F0463P E
MOUNT ACCELEROMETER
2 (STEEL)
ON GEARBOX WITH CON- FOR
NECTOR POINTED UP. 3 NAS1149F0463K
WEIGHTS (ALUMINUM)
(2)NAS1149F0432P WASHERS = (l)NAS1149F0463P WASHER

(3.5)NAS1149F0432P WASHERS = (l)A214-3 WASHER
(3)NAS1149F0463P WASHERS = (l)Al41-14 WASHER
(6.5)NAS1149F0463P WASHERS = (l)AN970-4 WASHER
*A MINIMUM OF ONE NAS1149F0432P WASHER MUST BE INSTALLED
IN CHORDWISE LOCATION ON EACH BLADE.
RUN CLOCK IPS CHANGE MADE BEFORE NEXT RUN
FIGURE 10-14A

10.250 Autorotational RPM Adjustment
Use the following procedure for checking and adjusting autorotational RPM:
WARNING
Failure to properly adjust autorotational RPM (RPM too low) may

prevent the rotorcraft from achieving proper RPM at low gross
weights.
1. Perform autorotation RPM check at minimum practical weight. Calculate the takeoff
gross weight of the helicopter. Record the time on the hour meter.
Take-Off gross weight
Take-Off hourmeter reading
2. Set the altimeter to 29.92" Hg ( 1013.2 millibars) prior to performing the

autorotation. Autorotate with the collective control firmly held against the down
stop with an airspeed of 50 KIAS.
WARNING
Do not allow the rotor to overspeed when performing

autorotation checks. Progressively lengthen both main rotor
pitch link rod ends until full down collective can be obtained
without over-speeding the rotor.
Take at least 3 RPM readings at 500 to 1000 foot altitude intervals.
Record the following in-flight data:
Hourmeter Pressure Test

Test# OAT
Reading Altitude %RPM

10.250 Autorotational RPM Adjustment (cont'd)
3. After each flight, refer to figure 10-15 and determine the following:
Elapsed Time
Test Gross
(in-flight Pounds of RPM
Weight
hourmeter Fuel Test% RPM Correction
Test (take-off gross Chart%
reading minus Consumed (from in-flight (chart% RPM
# weight RPM
data)
take-off (elapsed time minus Test%
minus fuel
hourmeter x 45 lbs/hr) RPM)
consumed
reading)
4. Adjust the pitch links based on the average RPM correction required. Lengthen both
pitch links to decrease RPM if the test RPM is greater than the chart RPM
(lengthening the pitch links one full rod end turn will reduce RPM 3%). Shorten
both pitch links to increase RPM. Be sure to adjust both pitch links exactly the
same so track will not be affected.
5. Repeat steps (a) through (d) as required until the RPM correction is ± 1% of chart
RPM. Determine chart RPM as follows:
a. Start at outside air temperature, and draw a vertical line up to the pressure
altitude.
b. Draw a horizontal line from the pressure altitude to the rotorcraft gross
weight at time of autorotation.
c. Draw a vertical line down from the gross weight to the required autorotation
RPM.
d. Make adjustment to the main rotor pitch links as required to obtain test
autorotation RPM within ± 1 % of chart RPM (see Figure 1 0-1 5).

""0
cu
co IJ
CD
...... 0
0
.j:::..
0 -mz
UJ
20 AUTOROTATION RP_;;cM'-----
0
!\7""~ T v,\cov 7 ~ v v\
1 \~}t7 1---y1. ,J/ v / 7 /l z
COLLECTIVE ruLL DOWN
8 . v U'lo_7 r-t-,..\G "' ,.., _/
/ 1\><>~ y ,.., I/ /, ~
/ 0~ 0 / //I// / ~\~<J'9 50 KIAS s:
f-< 6 / v i/v ~vi //\f /7f l/v /7\J?-1> ~"-\.> (One full turn of rod ends = 3% RPM) ~
N 7 i/ 7J\ [7T .7; 1- ,..--( /V )-,sS (One full turn of rod end = two turns of the barrel)
z-t
N 14 V :-z ;;-\ / -T/' <?~
/
~
,..,·
Vi , / / A ~~ m
g v V ' aa\J :-::::: 1 _ z
0 \\J' j/ /
12
/v ,......(' /v ,/1__
., 7 )>
.. / Y V\v v 1/ //
X \ / / / -1
IJ.c:i'~c:/1~1
G) z
w 10 / / ,..,...- / ,...... '0/ / :: ~~ '
-c n
::xl a V /1 7/V~V VI/ /Y 1/ ~· m
m 8 i/ [/( v /\ / // 1:// / / 7 ;,-s~
~ s:
/7 /7 // /7 7 / / // / / '\-"v'0
t~ y
\)' 7-7
0I 1 )>
~ < v v v l/\ v v b,/ / ,.., / I/ v 1/ +"y'S'0-~
(J1
~ 6 / // / 7 17 I/ \ / / / / ./ 7 / / t7-7l "''?<::::> c;:,
z
/ 7 / / /\/ / / v / / / 7 !7-~ ~
4 v ,..r \ 7 :;::-1- 7 r
~~l [7 l7 7-l-71-~
/ / / /1 / / 8r--·;,.r---------71C / v /
0
/ / // ,......(' /v /v ):::7 J-.V v-'- 17 ; 1/ / V / 7
2 / / v / 7\_7 :./·?·:/- v Y I/ 7 / / v-17
0 l/ /71/7 /7 / I/ \ / : // I/ / : / / / / /
l/ [v1 l/ / )V / / f\ ~ - 7 :{ V V 1/ 1/
()
:::J" ~z /"/ v( / / V I / '\ A: / / :ol/ / / V -l-1-r-
cu ~40 -30 -20 -10 0 10 20 30 40 98 100 102 104 106 108 110 112
::J
co TEMPEI\ATURE, DEGREES c' % RPM
CD I I I I
I I I I I I I I I I I I I II I I I ; I I II I I I I I I I I I I I I I I II s:
N -40 -20 0 20 40 60 BO 100 (Example: OAT=23°C, llp=2000', W=1050 1bs, RPM= 99.5%.) 0
w TEMPEnATUT\E, DEGREES F c
'--
m
r
}:>
z D
N IU
0 N
0
01
CHAPTER 11
ENVIRONMENT CONTROL
Section Title Page
11-00 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1

11-10 Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.3
11-11 Nose Vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.3
11-20 Cabin Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.5
11-21 Heater Shroud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.5
11-22 Blower Assembly (Earlier Helicopters) . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.6
OCT 2018 Chapter 11 Environment Control Page 11.i

Intentionally Blank
Page 11.ii Chapter 11 Environment Control OCT 2018

CHAPTER 11
ENVIRONMENT CONTROL
11-00 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. On earlier aircraft, pushing in on the knob will
seal and lock the door vents closed. On later aircraft, a rotating knob is provided to lock
the vents. For maximum ventilation, open door vents wide during hover but only one inch
or less during cruise. The rotating knob can be used to hold vents partially open.
The fresh air inlet in the nose is opened by pulling the cabin air knob on the console face.
Air from the nose inlet is directed along inside surface of the windshield for defogging as
well as for ventilation.
A cabin heater is optional. It consists of an air outlet mounted on the left side of the engine
cooling fan scroll, a muffler heat shroud, a control valve at the firewall, an outlet grille
forward of the pilot’s seat or forward of the tail rotor pedals, and interconnecting ducting.
Earlier heaters used an electric blower, located on the left side of the engine compartment,
and a blower switch, located on the ledge forward of the pilot’s seat, for air. A push-pull
control, located on the ledge forward of the pilot’s seat, actuates a valve which directs
heat either into the cabin or out an overboard discharge on the cabin underside.
NOTE
For earlier heaters that use an electric blower for air, the heater
shroud may be removed during warm seasons (when heater is
not in use) to prolong muffler life. Current production heaters
provide constant cooling air to muffler via the cooling fan scroll
and are designed to remain installed.
OCT 2018 Chapter 11 Environment Control Page 11.1

FIGURE 11-1 NOSE VENT
Page 11.2 Chapter 11 Environment Control OCT 2018

11-10 Ventilation
11-11 Nose Vent

A. Removal
1. Refer to Figure 11-1. Remove Aspen PFD per § 13-61, if installed. Remove
screws securing upper console to lower console and tilt upper console aft. Protect
instrument face with foam support or equivalent.
2. Remove battery per § 33-10 as required.
3. Remove and discard cotter pin securing clevis pin and A522-1 (air vent) control
inner wire to vent box flap assembly. Remove and retain clevis pin.
4. Remove hardware securing AN742-3 clamps and control housing to lower console
assembly.
5. Remove jam nut and lockwasher securing control (at knob) to lower console
assembly; remove clamps and grommet as required and remove control.
B. Installation
1. Refer to Figure 11-1. Position A522-1 (air vent) control in lower console, install
lockwasher and jam nut on control, and tighten nut against console support
assembly. Verify security.
2. Install MS35489-4 grommet in vent box flap assembly.
3. Secure control inner wire to vent box flap assembly using clevis pin and (new)
cotter pin. Verify security.
4. Install hardware securing AN742-3 clamps and control housing to lower console
assembly. Verify security.
5. Actuate vent and adjust clamp position as required for proper vent operation.
Verify control housing does not slip through clamp when opening and closing
vent. Verify clearance under knob is 0.03–0.10 inch with knob fully depressed
(closed).
6. Install battery per § 33-10 if removed.
7. Tilt console forward and install screws securing upper console to lower console.
Verify security. Install Aspen PFD per § 13-61, if removed.

FIGURE 11-2 CABIN HEATER

11-20 Cabin Heater
11-21 Heater Shroud

A. Removal
1. Loosen clamps and disconnect hoses from heater shroud. Temporarily cover
open hoses to protect system from contamination.
2. Remove exhaust system per § 6.510.
3. Remove screws securing shroud to muffler and remove shroud.
B. Installation
1. Install shroud on muffler and install screws. Verify security.
2. Install exhaust system per § 6.520.
3. Remove temporary covers and connect hoses to shroud. Tighten clamps and
verify security.
C. Configuration for Flight with Heater Shroud Removed (Earlier Helicopters):
NOTE
For earlier heaters that use an electric blower for air, the heater
shroud may be removed during warm seasons (when heater is
not in use) to prolong muffler life. Current production heaters
provide constant cooling air to muffler via the cooling fan scroll
and are designed to remain installed.
1. Remove electric blower per § 11-22 Part A.

2. Remove heater shroud per Part A.
3. Remove hoses and attaching hardware from inside engine compartment.
4. Pull out HEATER circuit breaker (10 amp) at panel, and placard as required.

11-22 Electric Blower (Earlier Helicopters)
A. Removal
1. Remove hardware securing screen, spacer, and inlet to LH engine side skirt and
blower assembly, and remove screen, spacer, and inlet. Remove LH engine side
skirt.
2. Turn battery switch off and pull out HEATER circuit breaker (10 amp) at panel.
Disconnect blower assembly wiring from airframe electrical harness at connectors.
3. Loosen clamp securing hose to blower assembly and disconnect hose. Temporarily
cover open hose to protect system from contamination.
4. Remove hardware securing blower assembly and ground wire to frame and remove
blower assembly.
B. Installation
1. Install hardware securing blower assembly and ground wire to frame, but do not
torque.
2. Remove temporary cover and connect hose to blower assembly. Tighten clamp
and verify security.
3. Turn battery switch off and pull out HEATER circuit breaker (10 amp) at panel.
Connect blower assembly wiring to airframe electrical harness at connectors;
verify security.
4. Install LH engine side skirt; install hardware securing screen, spacer, and inlet
to LH engine side skirt and blower assembly (adjusting position of blower as
required). Verify security. Standard torque hardware securing blower assembly
and ground wire to frame, and torque stripe per Figure 2-1.

CHAPTER 12
FUEL SYSTEM
Section Title Page
12.000 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.1

12.100 Fuel Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.3
12.110 Main Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.3
12.120 Auxiliary Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.7
12.130 Fuel Cap(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.9B
12.200 Fuel Vents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.11
12.210 (Vent Line) Rollover Valve Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . 12.11
12.300 Drain Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.11
12.400 Fuel Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.13
12.410 Fuel Quantity Senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.13
12.420 Fuel Quantity Indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.14
12.430 Low-Fuel Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.15
12.500 Gascolator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.16
12.600 Minimum Fuel Flow Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.17
OCT 2018 Chapter 12 Fuel System Page 12.i

Intentionally Blank
Page 12.ii Chapter 12 Fuel System OCT 2018

CHAPTER 12
FUEL SYSTEM
12.000 Description
Fuel system maintenance is specific to either bladder or all-aluminum tank installations (current
production aircraft have flexible bladders in aluminum enclosures while earlier aircraft use
all-aluminum tanks). Mechanics are advised to identify fuel tank installation type, and to
follow the appropriate maintenance procedures. Maintenance procedures for the carburetor or
engine fuel system accessories may be found in the appropriate manufacturer’s technical data.
The fuel system is gravity-flow (no fuel pumps) and includes a main tank, an auxiliary tank
(optional for all-aluminum tanks), a shut-off valve control located behind the left seat, and
a strainer (gascolator). Fuel tank air vents are located inside the mast fairing.
Plunger-style drain valves are provided for the gascolator and for each fuel tank sump. The
gascolator is located on the lower left side of the firewall. The drain valves for the auxiliary
tank and bladder-style main tank are located inside the cowl door below the auxiliary tank.
Plastic tubes attached to the valves allow fuel to be drained overboard.
Fuel samples are taken by pushing on the plunger(s). For all-aluminum main tanks, the
drain is located on the left side of the fuselage and is opened by pushing in on the plastic
tube. On newer helicopters, a glass tube stowed inside the upper, aft cowl door is provided
which may be used to catch the fuel samples. Fuel should be sampled from all three
locations prior to the first flight of the day and after refueling to verify no contamination
and correct grade.
The fuel gages are electrically operated by float-type transmitters in the tanks. When the
gages read E the tanks are empty except for a small quantity of unusable fuel. The low
fuel caution light is actuated by a separate electric sender located on the bottom of the
main tank.
The auxiliary tank is interconnected with the main tank and is located somewhat higher so
it will become empty first while fuel still remains in the main tank. The fuel shutoff valve
controls flow from both tanks to the engine.
OCT 2018 Chapter 12 Fuel System Page 12.1

FIGURE 12-1 FUEL SYSTEM (BLADDER TANK INSTALLATION SHOWN)
Page 12.2 Chapter 12 Fuel System OCT 2018

12.100 Fuel Tanks
CAUTION
Flexible hoses kink easily; handle with care.

CAUTION
Temporarily cap fuel fittings when opened.

WARNING
Fuel vapors are explosive. Do not use electric tools in vicinity

of an opened fuel system.
12.110 Main Tank

A. Removal
1. Defuel helicopter per § 1.150.
2. Remove mast fairing. Open access doors, disconnect ELT antenna and ground
wire at connectors if ELT is installed, and remove tailcone fairing. Remove B423-1
channel assembly and B429 skins (cowling between tanks).
3. Remove left backrest assembly.
4. Loosen clamps, or cut and discard safety wire, securing vent tubes to main tank
assembly and pull tubes off of tank. Remove hardware securing A713-1 strap to
tank.
5. Cut and discard ty-raps as required and disconnect fuel quantity sender and low-
fuel switch assembly wiring from airframe harness at connectors. Remove nuts
securing wiring to fuel quantity sender if connectors are not installed.
6. a. Bladder Tank: Disconnect D205-32 (tank-to-fuel shut-off valve) hose assembly

from valve and D205-33 (tank interconnect) hose assembly from aux tank. Cut
and discard ty-raps attaching D205-34 (drain) hose assembly and D205-33
hose assembly to support, then disconnect hose from drain valve connector.
(Hose assemblies remain attached to main tank during tank removal.)
b. All-Aluminum Tank: Disconnect A726-2 (tank-to-fuel valve) and B141-1 (tank

interconnect; aux tank option) line assemblies and remove line assemblies.
7. Remove hardware securing tank's A028-7 frame (panel) to B428-1 frame (panel)
and A020-2 (steel tube) upper frame. Remove hardware securing tank outboard
corners to horizontal firewall vertical flange. Remove hardware securing tank forward
channel to underside of horizontal firewall (access from engine compartment).
8. Carefully remove tank assembly.

12.110 Main Tank (continued)
B. Installation
NOTE
When positioning main tank in helicopter, verify vertical strip

attached to horizontal firewall is between tank’s D249-4 angle
(attached to stiffener on bottom of tank) and tank’s exterior skin.
NOTE
Electrically verify proper function of low-fuel warning switch

and fuel quantity sender prior to main tank installation. Perform
fuel quantity sender check per § 12.410 as required.
1. Bladder Tank: If not previously accomplished, connect D205-32 (tank-to-fuel

shut-off valve) hose assembly to main tank strainer assembly, D205-33 (tank
interconnect) hose assembly to main tank AN815-6D union, and D205-34 (drain)
hose assembly to main tank AN815-4D union. Special torque hose nuts per §
1.330 and torque stripe per Figure 2-1.
2. Position main tank assembly in helicopter, carefully routing attached hose assemblies
(bladder tanks) to appropriate locations.
3. Install hardware securing tank outboard corners to horizontal firewall vertical flange.
Install hardware securing A713-1 strap to tank. Install hardware securing A028-7
frame (panel) to B428-1 frame (panel) and A020-2 (steel tube) upper frame. Install
hardware securing tank forward channel to underside of horizontal firewall (access
from engine compartment). Standard torque hardware per § 1.320 and torque
4. a. Bladder Tank: Connect D205-32 hose assembly to fuel valve elbow. Connect
D205-33 hose assembly to aux tank strainer assembly. Connect D205-34
hose to drain valve connector. Special torque hose nuts per § 1.330 and
torque stripe per Figure 2-1. Install two MS3367-5-9 ty-raps around D205-33
and D205-34 hose assemblies to stand-off ty-rap hoses to support, but do not
tighten. Maintain 0.25 in. minimum clearance for D205-33 hose with frame
assembly and firewall, and for D205-34 hose with firewall and support. Cinch
ty-raps until snug without over-tightening, and trim tips flush with heads.
b. All-Aluminum Tank: Connect A726-2 (tank-to-fuel shut-off valve) line assembly

to tank elbow or tee (aux tank option) and fuel valve elbow. Connect B141-1
line assembly (aux tank option) to aux tank nipple and tank tee. Special torque
line nuts per § 1.330 and torque stripe per Figure 2-1.
5. Connect fuel quantity sender and low-fuel switch assembly wiring to airframe
harness at connectors. Install nuts securing wiring to fuel quantity sender if
connectors are not installed; special torque nuts per § 1.330 and torque stripe per
Figure 2-1. Install ty-raps as required.
6. Connect vent tubes to tank and tighten clamps until snug, or wrap two turns
0.032-in. dia. lockwire and safety tubes tight to tank. Verify security.

B. Installation (continued)
7. Check fuel quantity indication per § 12.420. Verify no leaks.
8. Inspect fuel cap alignment stripes per R22 Service Bulletin SB-107. Verify proper
installation and legibility of D682-44 decals.
9. Install left backrest assembly.
10. Install B423-1 channel assembly, B429 skins (cowlings between tanks), and A706-
1 tailcone fairing. Install mast fairing. Connect ELT antenna & ground wire at
connectors if ELT is installed. Secure access doors.
11. Perform pitot-static leak check if system was disturbed.
C. Bladder Replacement
NOTE
During disassembly, progressively tape bladder openings to

protect interior from foreign object contamination. During
assembly, progressively remove protective tape.
CAUTION
B028-1 bladder assembly temperature should be above 65°F

before removing, installing, or flexing bladder.
1. Remove main fuel tank per Part A.
2. Remove fuel quantity sender per § 12.410.
3. Remove screws securing D250-6 cover assembly to B028-1 bladder assembly and
tank. Carefully remove cover, with low-fuel switch assembly attached. Remove
o-ring, and discard if condition warrants.
4. At vents, remove screw securing bladder to tank.
5. At fuel filler neck, remove fuel cap and screws securing bladder to tank.
6. At forward inboard corner, remove B254-3 strainer assembly, AN815-4D union, &
AN815-6D union and discard o-rings. Remove screws securing bladder to tank.
7. Remove hardware securing B578-1 bulkhead assembly, B575-4 channel, and

B575-5 stiffener to tank. Detach hook-and-loop tape and remove bulkhead.
8. Detach hook and loop tape and carefully remove bladder.

9. Carefully insert new B028-1 bladder assembly inside main tank assembly. Align
bladder and tank fastener holes and press hook-and-loop tape together.
10. Install hardware securing B578-1 bulkhead assembly, B575-4 channel, and B575-5
stiffener to tank. Verify security.

C. Bladder Replacement (continued)
11. At forward inboard corner, apply A257-9 anti-seize to screw threads and install
screws securing bladder to tank. Lubricate new o-rings with A257-6 grease and
install o-rings on B254-3 strainer assembly, AN815-4D union, and AN815-6D
union. Install strainer and unions; special torque per § 1.330 and torque stripe per
Figure 2-1.
12. At fuel filler neck, apply A257-9 anti-seize to screw threads and install screws
securing bladder to tank. Install fuel cap.
13. At vents, apply A257-9 anti-seize to screw threads and install screw securing
bladder to tank.
14. On bottom, lubricate (new) o-ring with A257-6 grease and install o-ring in bladder
ring groove. Carefully insert D250-6 cover into bladder, with attached low-fuel
switch assembly. Apply A257-9 anti-seize to threads and install screws securing
cover to bladder and tank.
15. Install fuel quantity sender per § 12.410.
16. Pressure check assembled fuel tank by plugging vents and fittings and pressurizing
bladder to no more than 1 psi. Check for leaks with a mild soap and water solution
applied to all seams.
17. Install main fuel tank per Part B.

12.120 Auxiliary Tank
A. Removal
1. Defuel helicopter per § 1.150.
2. Open right side of mast fairing. Open access doors, disconnect ELT antenna &
ground wire at connectors if ELT is installed, and remove tailcone fairing. Remove
B423-1 channel assembly and B429 skins. Remove B430 door and skin.
3. Remove right backrest assembly.
4. Loosen clamps, or cut & discard safety wire, securing vent tubes to aux tank
assembly and pull tubes off tank. Remove hardware securing pitot-static line
clamp to tank channel.
5. Cut & discard ty-raps as required and disconnect fuel quantity sender wiring
from airframe harness at connectors. Remove nuts securing wiring to sender if
connectors are not installed.
6. Remove hardware securing rotor brake cable assembly to B112-1 lever. Cut &
discard heat shrink and disconnect bead chain from cable at connector.
7. Cut & discard ty-rap securing drain tube to angle (bladder tank), or remove hardware
securing drain tube clamp to firewall clip.
8. Disconnect hose or line assembly from tank fitting.
9. Bladder Tank: Above right seat, gently lift foam from bulkhead and remove fasteners
securing tank to bulkhead.
10. Remove screws securing tank channel to frames.
11. Remove perimeter screws securing tank to bulkhead. Remove tank.

12.120 Auxiliary Tank (continued)
B. Installation
1. Position aux tank assembly in helicopter. Install perimeter screws securing tank to
bulkhead.
2. Install screws securing tank channel to frames.
3. Bladder Tank: Above right seat, gently lift foam from bulkhead and install fasteners
securing tank to bulkhead.
4. a. Bladder Tank: Connect D205-33 hose assembly to aux tank fitting, special
torque hose nut per § 1.330, and torque stripe per Figure 2-1. Verify 0.25 in.
minimum clearance with frame assembly and firewall (reposition hose assembly
angle as required).
b. All-Aluminum Tank: Connect B141-1 line assembly to aux tank fitting, special
torque line nut per § 1.330, and torque stripe per Figure 2-1.
5. a. Bladder Tank: Install MS3367-5-9 ty-rap securing drain tube to angle. Cinch
ty-rap until snug without over-tightening, and trim tip flush with head.
b. All-Aluminum Tank: Install hardware securing drain tube clamp to firewall clip.
6. Install hardware securing rotor brake cable assembly to B112-1 lever. Slip length
of B158-6 heat shrink over rotor brake chain, connect chain and cable, and activate
heat shrink over connector. Verify security.
7. Connect fuel quantity sender wiring at connectors. Install nuts securing wiring to
fuel quantity sender if connectors are not installed. Install ty-raps as required.
8. a. Bladder Tank: Connect vent tubes to tank and tighten clamps until snug. Verify
security.
b. All-Aluminum Tank: Connect vent tubes to tank, wrap two turns 0.032-in. dia.
lockwire and safety tubes tight to tank. Verify security.
9. Install hardware securing pitot-static line clamp to tank channel.
11. Inspect fuel cap alignment stripes per R22 Service Bulletin SB-107. Verify proper
installation and legibility of D682-44 decals.
12. Install right backrest assembly.
13. Install B430 door and skin. Install B423-1 channel assembly and B429 skins.
Install tailcone fairing, connect ELT antenna ground wire at connector if ELT is
installed, and close access doors. Close right side of mast fairing.

12.120 Auxiliary Tank (continued)
C. Bladder Replacement
NOTE
During disassembly, progressively tape bladder openings to
protect interior from foreign object contamination. During
assembly, progressively remove protective tape.
CAUTION
B028-2 bladder assembly temperature should be above 65°F
before removing, installing, or flexing bladder.
1. Remove aux fuel tank per Part A.

2. Remove fuel quantity sender per § 12.410.
3. Remove screws securing D250-8 cover assembly to B028-2 bladder assembly
and tank. Carefully remove cover, with strainer, siphon, and union attached.
Remove and discard o-ring.
4. At vents, remove screw securing bladder to tank.
5. At fuel filler neck, remove fuel cap and screws securing bladder to tank.
6. Remove hardware securing B579-1 bulkhead assembly and B577-2 stiffener to
tank. Detach hook-and-loop tape and remove bulkhead.
7. Detach hook-and-loop tape and carefully remove bladder.
8. Carefully insert new B028-2 bladder assembly inside aux tank assembly. Align
bladder and tank fastener holes and press hook and loop tape together.
9. Install hardware securing B579-1 bulkhead assembly and B577-2 stiffener to
tank. Verify security.
10. At fuel filler neck, apply A257-9 anti-seize to screw threads and install screws
securing bladder to tank. Install fuel cap.
11. At vents, apply A257-9 anti-seize to screw threads and install screw securing
bladder to tank.
12. Lubricate new o-ring with A257-6 grease and install o-ring in bladder ring groove.
Carefully insert cover into bladder, with strainer, siphon, and union attached. Apply
A257-9 anti-seize to threads and install screws securing cover to bladder and tank.
13. Install fuel quantity sender per § 12.410.
14. Pressure check assembled fuel tank by plugging vents and fittings and pressurizing
bladder to no more than 1 psi. Check for leaks with a mild soap and water
solution applied to all seams.
15. Install aux fuel tank per Part B.

FIGURE 12-1A FUEL CAP ALIGNMENT STRIPES
Page 12.9A Chapter 12 Fuel System OCT 2018

12.130 Fuel Cap(s)
WARNING
Fuel cap alignment stripes are required by regulation and
necessary for the pilot to verify fuel caps are properly secured.
An improperly secured cap may come off in flight.
1. Refer to Figure 12-1A. Paint fuel cap stripes (in two places 180º apart) and A250 neck
if stripes have deteriorated (in one place facing outboard) per the following:
a. Clean surfaces to be painted using a lint-free, clean cloth dampened with acetone.
Allow surfaces to dry.
b. Apply D257-7 black (Imron AF400/AF700) for light-colored ships or D257‑5 white
(Imron AF400/AF700) for dark-colored ships, mixed in accordance with paint
manufacturer’s recommendations, to surfaces.
2. Attach D682-44 decal to A689 fuel cap as shown.
OCT 2018 Chapter 12 Fuel System Page 12.9B

FIGURE 12-2 FUEL VENTS

12.200 Fuel Vents
12.210 (Vent Line) Rollover Valve Assemblies
R22 rollover valves contain one brass ball. In normal conditions, air flows around the vent
ball from the bladder expansion spaces. In the event of inadvertent over-filling or in-flight
fuel sloshing, the ball will float and seal the vent. If the aircraft is inverted, the ball seals
the vent to minimize fuel spillage. There are no internal packings.
A. Removal
1. Open right side of mast fairing.
2. Above lower rib, remove D277-6 (spring) clamp securing A729-61 tube to D251-1
rollover valve assembly and pull tube off of valve. Pull valve downward, through
rib grommet.
3. Loosen B277-4 (worm gear) clamp securing A729-48 or A729-62 tube to rollover
valve and pull tube off of valve.
B. Installation
1. Observe orientation markings and push A729-48 or A729-62 tube onto D251-
1 rollover valve assembly and tighten B277-4 (worm gear) clamp. Push valve
upward, through lower rib grommet.
2. Above rib, push A729-61 tube onto rollover valve and install D277-6 (spring)
clamp. Verify security.
3. Perform vent system check per Part C.
C. Vent System Check
1. Open right side of mast fairing. Verify main and aux fuel tank caps are installed.
2. Attach temporary hose to one A731-4 (vent) tube.
3. Blow into the temporary hose (do not use compressed air) and verify air blows out
the other vent tube. If air does not blow out the other vent, remove obstruction(s)
and repeat check.
4. Close mast fairing.
12.300 Drain Valves
A. Removal
1. Defuel helicopter per § 1.150. Remove engine right cowling, as required.
2. Cut & discard safety wire securing A729 tube to A761-1 drain valve, if installed, and
pull tube off of valve.
3. Remove valve from connector, tank, or gascolator assembly. Tape fuel system opening.
4. Actuate valve to expose stem, then remove & discard o-ring.

D252-3 FUEL QUANTITY SENDER D252-4 FUEL QUANTITY SENDER
Main Tank (Bladder Tank) Aux Tank (Bladder Tank)
A550-1 FUEL QUANTITY SENDER B122-1 FUEL QUANTITY SENDER

Main Tank (All-Aluminum Tank) Aux Tank (All-Aluminum Tank)
FIGURE 12-3 FUEL QUANTITY SENDER CHECK

12.300 Drain Valves (continued)
B. Installation
1. Actuate A761-1 drain valve to expose stem, and install new o-ring in stem seat.
2. Lightly coat valve threads using B270-6 sealant. Remove tape and install valve in
connector, tank, or gascolator assembly. Standard torque valve per § 23-32 and
3. Push A729 tube onto valve. Wrap tube with two turns 0.032-inch diameter
lockwire and safety tube to valve, as required.
4. Fuel helicopter per R22 Pilot’s Operating Handbook Section 2 and inspect fuel
system for leaks. Install engine right cowling, if removed.
12.400 Fuel Quantity
12.410 Fuel Quantity Senders
CAUTION
Rotation of fuel sender center stud or base nut is not permitted.
WARNING
Do NOT apply system voltage to installed fuel quantity senders.
A. Removal
1. a. Bladder Tanks: If removing D252-3 fuel quantity sender, remove main fuel
tank per § 12.110. If removing D252-4 fuel quantity sender, defuel helicopter
per § 22-52.
b. All-Aluminum Tanks: Defuel helicopter per § 22-52 until level is below
fuel quantity sender mounting hole. Cut & discard ty-raps as required and
disconnect sender wiring from airframe harness at connectors. Remove nuts
securing wiring to sender if connectors are not installed.
2. Remove hardware securing fuel quantity sender to cover assembly or tank.
Carefully pull sender lever through opening, then tape opening.
B. Installation
1. Perform fuel quantity sender check per Part C.
2. Inspect condition of sender gasket and replace as required. Remove tape from
opening, position gasket on sender, and carefully insert sender lever through
opening. Install hardware, special torque bolts in criss-cross pattern per § 23-33,
and torque stripe per Figure 2-1.
3. Bladder Tanks: If removed, install main fuel tank per § 12.110.
4. Connect sender wiring to airframe harness at connectors. Install nuts securing
wiring to sender if connectors are not installed. Install ty-raps as required.

12.410 Fuel Quantity Senders (continued)
C. Check
1. Remove fuel quantity sender per Part A.
2. Simulate mounting position of appropriate sender per Figure 12-3. Position float
arm as shown and measure the resistance with a multimeter. Verify resistance
is within tolerance in the four positions given.
3. If resistance is out of tolerance at any of the four positions given, bend the float
arm up for a sender with excessive resistance, or bend the float arm down for a
sender with too little resistance. Repeat steps until sender resistance is within
tolerance.
4. Install fuel quantity sender per Part B.
12.420 Fuel Quantity Indication

1. Defuel helicopter per § 22-52. Turn fuel shut-off valve off.
2. Fuel main tank with exactly 6.2 gallons (if equipped with main and aux bladder tanks),
5.6 gallons (if equipped with main bladder tank only), 6.3 gallons (if equipped with
main and aux all-aluminum tanks), or 5.4 gallons (if equipped with main all-aluminum
tank only) of fuel per R22 Pilot’s Operating Handbook Section 2. Wait five minutes
for fuel levels to equalize. Inspect for leaks.
3. Turn battery switch on and read fuel quantity gage. Verify fuel gage indicates one half
to one and one half needle-widths below a quarter of a tank, as shown in Figure 12-4.
4. If indication is beyond allowable limit, perform fuel quantity sender check per § 12.410.
If sender resistance is within tolerance, adjust fuel gage per § 14.440, or replace fuel
gage as required and repeat check.
Main Tank Gage Main Tank Gage
MINIMUM ALLOWABLE INDICATION MAXIMUM ALLOWABLE INDICATION

1½ Needle-widths below ¼ of a tank ½ Needle-width below ¼ of a tank
FIGURE 12-4 FUEL QUANTITY INDICATION CHECK

12.430 Low-Fuel Switch Assembly
CAUTION
Avoid contaminating fuel bladder or tank interior. Cover arms

with sleeves and use lint-free gloves when working inside interior.
A. Removal
1. Remove main fuel tank per § 12.110.
2. Remove A521 low-fuel switch assembly wiring pins from connector housing.
3. Remove fuel cap. Carefully capture switch assembly body with clean mechanical
fingers (avoid capturing movable float). Remove AN924-5D nut securing switch
assembly to cover or tank.
4. Carefully pull switch assembly through fuel cap opening, avoiding fuel quantity
sender. Install fuel cap, and tape fuel bladder or tank opening.
B. Installation
1. Lubricate new o-ring with A257-6 grease, and install o-ring over A521 low-fuel
switch assembly threads.
2. Tape switch assembly wiring to 30-inch length of lockwire.
3. Remove fuel cap and tape. Position tank upside down. Thread lockwire through
fuel cap opening and switch assembly mounting hole. Pull switch assembly wires
and threads through mounting plate and retaining nut.
4. Apply light coat B270-1 sealant to mating face of AN924-5D nut and install nut
securing switch assembly to cover or tank. Special torque nut per § 1.330 and
5. Install main fuel tank per § 12.110.
6. Perform operation check per Part C.
C. Operation Check
1. Turn battery switch on. Fuel helicopter per R22 Pilot’s Operating Handbook Section
2 as required and inspect fuel system for leaks.
2. With a clean wooden dowel, gently depress low-fuel switch assembly float and
verify low fuel warning light illuminates after approximately 1 second delay.
3. If warning light does not illuminate when float is depressed, but does illuminate
when activating push-to-test switch, replace switch assembly.

12.500 Gascolator Assembly
A. Cleaning Sediment Bowl
1. Turn battery switch off. Turn fuel shut-off valve off. Remove left side skirts. Electrically
ground helicopter. Drain fuel into an approved, electrically-grounded container using
A666-1 gascolator assembly drain valve.
2. Cut & discard safety wire securing gascolator collar to outlet fitting. Unscrew collar,
and remove collar, ring, and sediment bowl.
3. Remove gasket and screen from gascolator top. Inspect, then clean, sediment bowl
and screen.
4. Install screen and gasket in gascolator top. Apply light coat A257-6 grease to collar
threads and collar inner flange. Verify large diameter of ring contacts collar inner
flange. Slide ring and collar over bottom of sediment bowl so small diameter of ring
engages groove in bowl flange. Position sediment bowl drain valve thru hole in belly
panel, and hand-tighten collar, ring, and bowl onto gascolator top until snug. Verify
no threads exposed in gascolator top. Safety collar to outlet adapter using 0.032-inch
diameter lockwire.
5. Turn fuel shut-off valve on. Perform ground check and run up per §§ 2.205 & 2.210.
Verify no leaks; repair as required. Install left side skirts.

12.600 Minimum Fuel Flow Check
1. Turn battery switch off. Turn fuel shut-off valve off. Electrically ground helicopter.
Remove right side skirts. Verify fuel tank cap(s) are installed.
2. Fuel main tank with exactly 3.0 gallons (bladder tanks) or 1.7 gallons (all-aluminum tanks)
fuel per R22 Pilot's Operating Handbook Section 2.
3. Disconnect B283 hose assembly from carburetor, turn battery switch and fuel shut-off
valve on, and defuel helicopter into an approved, electrically-grounded container until low
fuel light illuminates. Turn battery switch and fuel shut-off valve off.
4. Place electrically-grounded, calibrated container beneath hose, turn fuel shut-off valve on,
and record time required to fill container. Verify filling time does not exceed maximum
time listed below:
ALLOWABLE FUEL FLOW RATE
QUANTITY MAXIMUM TIME
1 U.S. Gallon 2 minutes 25 seconds

4 Liters 2 minutes 33 seconds
1 Imperial Gallon 2 minutes 54 seconds
5. If filling time is exceeded, perform vent system check per § 12.210. Inspect fuel tank
outlet strainer, line assembly, and hose assemblies for obstructions. Remove obstructions
and repeat check.
6. Connect B283 hose assembly to carburetor, special torque nut per § 1.330, and torque
7. Perform ground check and run up per §§ 2.205 & 2.210. Verify no leaks. Install right
side skirts.

Intentionally Blank

CHAPTER 13
INSTRUMENT SYSTEM
Section Title Page
13-00 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.1

13-10 Pitot-Static System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.3
13-20 Primary Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.4
13-21 Vertical Speed Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.4
13-22 Airspeed Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.6
13-23 Dual Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.7
13-24 Altimeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.9
13-25 Manifold Pressure Gage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.10
13-26 Magnetic Compass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.11
13-30 Engine Gages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.12
13-31 Ammeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.12
13-32 Engine Oil Pressure Gage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.13
13-33 Engine Oil Temperature Gage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.14
13-34 Cylinder Head Temperature Gage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.14
13-35 Fuel Quantity Gages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.15
13-36 Carburetor Air Temperature Gage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.15
13-40 Additional Standard Indicating Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . 13.16
13-41 Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.16
13-42 Outside Air Temperature (OAT) Gage/Voltmeter . . . . . . . . . . . . . . . . . . . . 13.17
13-43 Hourmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.18
13-50 Instrument Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.18
13-60 Electronic Flight Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.21
13-61 Aspen PFD Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.21
OCT 2018 Chapter 13 Instrument System Page 13.i

Intentionally Blank
Page 13.ii Chapter 13 Instrument System OCT 2018

CHAPTER 13
INSTRUMENT SYSTEM
13-00 Description
Standard primary instruments include an airspeed indicator, engine and rotor dual
tachometer, altimeter, manifold pressure gage, and magnetic compass. Engine gages
include an ammeter, oil pressure, oil temperature, cylinder head temperature, and fuel
quantity for main and aux (if installed) tanks. Also standard are a clock, a carburetor air
temperature gage, and a digital outside air temperature gage. An hourmeter is located on
the ledge just forward of the pilot’s seat.
For instrument panels with electronic flight displays, a P/N D327 light filter may be used to
reduce reflections in the windshield at night. The light filter is installed by clipping it to the
front of the display. Filter use is at pilot discretion.
The pitot-static system supplies air pressure to operate the airspeed indicator, altimeter,
and vertical speed indicator. The pitot tube is located on the front edge of the mast fairing.
The static source is located inside the aft cowling inboard of the cowl door hinge.
Water can be drained from pitot-static lines by removing the plastic drain plugs which are
accessible through the inspection panel on the underside of the cabin. Draining lines should
only be required if the airspeed indicator or altimeter appears erratic.
Pitot and static sources should be inspected frequently for bugs or other obstructions.
OCT 2018 Chapter 13 Instrument System Page 13.1

FIGURE 13-1 PITOT-STATIC SYSTEM
Page 13.2 Chapter 13 Instrument System OCT 2018

13-10 Pitot-Static System
CAUTION
Do not apply suction to pitot system or pressure to static system.
A. Pitot System Leak Test

1. Open mast fairing.
2. Refer to Figure 13-1. Seal drain hole in elbow aft of pitot tube with pressure-
sensitive tape. Connect a medical syringe, with plunger withdrawn, to pitot tube
via flexible tubing.
3. Slowly apply pressure to pitot line by depressing syringe plunger until airspeed
indicator reads 70 knots (plunger will remain in place).
4. Gently tap airspeed indicator glass to remove friction effects.
5. If airspeed indication drops more than 10 knots in one minute, an unacceptable
leak is indicated. Slowly release pressure. Locate and repair any leak(s). Retest
after any repairs.
6. Remove tape from pitot tube drain hole and verify airspeed indicator has returned
to zero.
7. Remove test equipment. Close mast fairing.
B. Static System Leak Test
CAUTION
Airspeed indicator, altimeter, and vertical speed indicator may
be damaged if suction to static line is applied or removed rapidly.
1. Refer to Figure 13-1. Set altimeter to location elevation.

2. Connect a medical syringe, with plunger depressed, to static port tube via flexible
tubing.
3. Slowly apply suction to static port by withdrawing syringe plunger until altimeter
indicates 500 feet greater than location elevation (plunger will remain in place).
4. If altimeter indication drops more than 100 feet in one minute, an unacceptable
leak is indicated. Slowly release suction. Locate and repair leak(s). Retest after
any repairs.
5. Remove test equipment.

13-20 Primary Instruments
13-21 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. Diagram
Refer to Figure 13-1 for pitot-static system diagram.
C. Removal
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 perimeter screws securing face to console and pull face aft.
3. Remove screws securing instrument to face.
4. Disconnect wiring as applicable.
5. Disconnect pitot/static lines and cap & plug instrument and system fittings, as
applicable.
6. Remove instrument and place on foam padding.
D. Installation
CAUTION
2. Remove caps and plugs and connect pitot/static lines. Verify security.
3. Connect wiring as applicable. Verify security.
4. Install screws securing instrument to face. Verify security.
5. Install perimeter screws securing face to console. Verify security.
6. Perform pitot-static system checks as required per § 13-10.
7. Perform appropriate function checks per § 2.200.

13-21 Vertical Speed Indicator (continued)
E. Scheduled Maintenance and Inspections
Refer to § 2.400 100-Hour/Annual Inspection.
F. Special Maintenance and Inspections
1. If vertical speed indicator displays climb indication but does not return to zero in
level flight, or if indication is erratic:
a. Inspect static system for water or obstructions, and remove water or
obstructions if found.
b. Perform pitot-static system checks as required per § 13-10.
2. Perform appropriate function checks per § 2.200. If vertical speed indicator still
displays erratic indication, or displays no indication, remove indicator per Part C,
and return to RHC for inspection.
3. Install airworthy indicator per Part D.

13-22 Airspeed Indicator
A. Description
The airspeed indicator displays airspeed in knots and miles or kilometers per hour.
The airspeed indicator operates properly in forward flight only; backward or lateral
flight will not indicate correct airspeed. The airspeed indicator will indicate airspeeds
up to a maximum of 102 knots (red line).
B. Diagram
C. Removal
Remove airspeed indicator per § 13-21 Part C.
D. Installation
Install airspeed indicator per § 13-21 Part D.
1. If airspeed indicator displays no indication:
a. Inspect pitot tube for obstructions and remove obstructions if found.
b. Inspect pitot tube connection, and tighten connection if loose.
c. Open upper console and inspect pitot line for kinks or bends.
d. Perform pitot-static system checks as required per § 13-10.
e. Perform appropriate function checks per § 2.200. If indicator still displays
no indication, remove indicator per Part C, and return to RHC for inspection.
f. Install airworthy indicator per Part D.
2. If airspeed indicator displays erratic indication:
a. Inspect pitot-static system connection(s), and tighten connection(s) if loose.
b. Inspect pitot-static system lines and verify no lines are cracked or broken.
c. Inspect pitot-static system for water, and remove water if found.
d. Open upper console and inspect pitot lines for kinks or bends.
e. Perform pitot-static system checks as required per § 13-10.
f. Perform appropriate function checks per § 2.200. If indicator still displays
erratic indication, remove indicator per Part C, and return to RHC for inspection.
g. Install airworthy indicator per Part D.

13-23 Dual Tachometer
A. Description
CAUTION
Installation of electrical devices can affect accuracy and
reliability of electronic tachometers.
An electronic engine and rotor dual tachometer is standard. Engine tachometer

signal is provided by magneto breaker points. Rotor tachometer signal is provided
by two magnetic senders at the main gearbox drive yoke. Each tachometer is on a
separate circuit with its own circuit breaker. With battery and alternator switches
off, the tachometers continue to receive power from the battery through a bypass
circuit as long as the clutch actuator switch is in the engage position.
NOTE
Do not stow helicopter with clutch switch engaged. The
tachometers are powered with the clutch engaged and will
discharge the battery.
NOTE
Do not use magnetized tools.
CAUTION
B. Removal
1. Turn battery switch off and pull out TACHS E (2 amp) and R (2 amp) circuit
breakers at panel.
2. Remove perimeter screws securing instrument face to console and pull face aft.
3. Remove screws securing console harness connector to A792 dual tachometer
and unplug connector.
4. Supporting instrument, remove screws securing tachometer to face, and remove
tachometer.

13-23 Dual Tachometer (continued)
C. Installation
1. Turn battery switch off and pull out TACHS E (2 amp) and R (2 amp) circuit
breakers at panel.
2. Install screws securing A792 dual tachometer to instrument face. Verify security.
3. Plug in console harness connector to tachometer and install connector screws.
Verify security.
4. Install perimeter screws securing face to console. Verify security.
5. Perform accuracy check and needle synchronization per Part D.
D. Adjustment
NOTE
Adjust rotor tachometer if engine and rotor tachometer needles
are not within 1% of each other at 104% RPM.
1. Remove screws securing instrument face panel to upper console and carefully pull
panel aft.
2. Run-up helicopter per R22 Pilot’s Operating Handbook (POH) Section 6 at 104%
engine tachometer indication.
3. Turn adjustment screw on back of tachometer (apply 1/8 turns) clockwise to
increase and counterclockwise to decrease rotor tachometer indication. Adjust
rotor tachometer to indicate 104%.
4. Shutdown helicopter per POH Section 6. Tighten screws securing instrument panel
to upper console.
Refer to § 1.102 for additional component maintenance.
1. Perform adjustment as required per Part D.
2. If tachometer cannot be adjusted, remove tachometer per Part B, and return to
RHC for inspection.
3. Install airworthy tachometer per Part C.

13-24 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; they must agree within 70 feet.
B. Diagram
C. Removal
Remove altimeter per § 13-21 Part C.
D. Installation
Install altimeter per § 13-21 Part D.
1. If altimeter displays no indication:
a. Inspect static lines for obstructions and remove obstructions if found.
c. Perform appropriate function checks per § 2.200. If altimeter still displays
no indication, remove altimeter per Part C, and return to RHC for inspection.
d. Install airworthy altimeter per Part D.
2. If altimeter displays erratic indication:
a. Inspect static system for water, and remove water if found.
c. Perform appropriate function checks per § 2.200. If altimeter still displays
erratic indication, remove altimeter per Part C, and return to RHC for inspection.
d. Install airworthy altimeter per Part D.

13-25 Manifold Pressure Gage
A. Description
The manifold pressure gage provides an indicator of absolute air pressure in the
engine intake manifold. The red line on the gage indicates the maximum manifold
pressure that the rotorcraft is type certificated for at 104% rotor RPM. The manifold
pressure gage should indicate within 0.3 inches Hg of ambient barometric pressure
when engine is not running.
B. Removal
Remove manifold pressure gage per § 13-21 Part C.
C. Installation
Install manifold pressure gage per § 13-21 Part D.
D. Scheduled Maintenance and Inspections

E. Special Maintenance and Inspections

Manifold Pressure System Leak Check
1. Disconnect A740-1 line assembly from engine fitting.
2. Connect a medical syringe, with plunger depressed, to line assembly fitting via
flexible tubing.
3. Slowly apply suction to system by withdrawing syringe plunger until manifold
pressure gage indicates 10 inches Hg (plunger will remain in place).
4. If manifold pressure gage indication rises more than one inch in one minute,
an unacceptable leak is indicated. Slowly release suction. Locate and repair
leak(s). Retest after any repairs.
5. Remove test equipment.

13-26 Magnetic Compass
NOTE
United States operators may refer to FAA AC 43-215 for
additional information.
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 14-39A for electrical schematic.
C. Removal
1. Remove hardware securing compass mount to windshield bow.
2. Remove hardware securing compass assembly to mount.
3. Remove heat shrink as required and disconnect light bar wires from airframe
harness. Remove compass.
D. Installation
1. Install heat shrinks over wires and connect compass assembly’s light bar wires to
airframe harness. Verify security. Activate heat shrinks.
2. Install hardware securing compass to mount. Verify security.
3. Install hardware securing mount to windshield bow. Verify security.
4. At governed RPM, using the airport compass rose, align the helicopter skids on
the rose lines, and record the indicated compass headings at 30° increments.
Adjust compass compensator magnets as required until the maximum error at
any heading is 5° or less with all avionics operating, all exterior lights on, and
dimmer full bright. Record the final readings on the aircraft compass card. Re-
check 4 cardinal headings with lights off and all avionics off except COM radio 1
and transponder. Verify maximum error remains 5° or less.
1. Perform compass deviation check per Part D step 4.
2. If compass cannot be adjusted to limits specified, remove compass per Part C,
and install airworthy compass per Part D.

13-30 Engine Gages
13-31 Ammeter
A. Description
The ammeter indicates electrical system loads. System load is measured at the shunt
located on the lower-left side of the vertical firewall in the engine compartment.
B. Schematic
C. Instrument Cluster Removal
2. Remove Aspen PFD per § 13-61 if installed.
3. Remove screws securing upper console to lower console and tilt upper console aft.
4. Remove nuts securing console wiring to B144 instrument cluster and remove wiring.
5. Remove screws securing instrument cluster to shell assembly’s face plate and
remove instrument cluster.
D. Instrument Cluster Installation
2. Position B144 instrument cluster on shell assembly’s face plate and install screws.
Verify security.
3. Install nuts securing console wiring to instrument cluster studs. Verify security.
Verify security.
5. Install Aspen PFD per § 13-61 if removed.
1. Check continuity across two 3-amp fuses in B304-18 fuse assembly (at the
ammeter shunt) and replace fuse assembly as required.
2. Inspect wiring for loose, chafed, frayed, or broken wires. Verify no damaged
connectors. Verify wiring neatness, proper routing and installation, and security.
3. If ammeter is still inoperative, remove ammeter per Part C, and install airworthy
ammeter per Part D.

13-32 Engine Oil Pressure Gage
A. Description
The engine oil pressure gage indicates engine oil pressure and receives its signal
from a variable-resistor-type sender located in left-hand forward corner of engine
compartment next to hourmeter pressure switch.
B. Schematic
C. Removal
Remove instrument cluster per § 13-31 Part C.
D. Installation
Install instrument cluster per § 13-31 Part D.
2. Perform appropriate function checks per § 2.200. If accuracy of engine gage is
suspected, remove instrument cluster per § 13-31 Part C, and return to RHC for
inspection.
3. Install airworthy instrument cluster per § 13-31 Part D.

13-33 Engine Oil Temperature Gage
A. Description
The engine oil temperature gage indicates engine oil temperature and receives its signal
from a probe mounted in the engine oil pressure screen housing or oil filter adapter.
B. Schematic
C. Removal
D. Installation
Perform special maintenance and inspections per § 13-32 Part F.
13-34 Cylinder Head Temperature Gage
A. Description
The cylinder head temperature gage indicates the temperature of the #4 cylinder and
receives its signal from a thermocouple installed in the #4 cylinder head.
B. Schematic
C. Removal
D. Installation

13-35 Fuel Quantity Gages
A. Description
The fuel quantity gages indicate the fuel level of main and aux (if installed) fuel tanks
and receive signals from variable resistance type senders mounted on the bottom of
each tank.
B. Schematic
C. Removal
D. Installation
13-36 Carburetor Air Temperature Gage
A. Description
The carburetor air temperature gage is used to determine when carburetor heat is
required during possible carburetor icing conditions, such as high humidity. Apply
heat as required to keep needle out of yellow band. The carburetor air temperature
gage should read approximately the same as the OAT gage when engine is cold.
B. Schematic
C. Removal
D. Installation

13-40 Additional Standard Indicating Equipment
13-41 Clock
A. Description
A manually set electric analog clock is standard equipment; a digital clock is optional.
B. Schematic
C. Removal
1. Turn battery switch off.
2. a. Remove perimeter screws securing face to console and pull face aft, or
b. Remove Aspen PFD per § 13-61 if installed, and remove screws securing
upper console to lower console and tilt upper console aft.
3. Remove screws securing clock to face.
4. Disconnect console wiring from clock wiring at connectors, and remove clock.
D. Installation
2. Connect console wiring to clock wiring at connectors. Verify security.
3. Install screws securing clock to face. Verify security.
4. a. Install perimeter screws securing face to console and verify security, or
b. Tilt console forward and install screws securing upper console to lower console
and verify security; install Aspen PFD per § 13-61 if removed.
1. Check AGC-3 (3 amp) fuse at firewall for evidence of melting and replace fuse as
required.
3. If clock is still inoperative, remove clock per Part C, and install airworthy clock per
Part D.

13-42 Outside Air Temperature (OAT) Gage/Voltmeter
A. Description
NOTE
No cutting or splicing of OAT probe wires is permitted.
The outside air temperature indicator has a stainless steel probe protruding from chin
of rotorcraft and is connected to gage by a calibrated length of cable.
B. Schematic
C. Removal
2. Remove Aspen PFD per § 13-61 if installed.
3. Remove screws securing upper console to lower console and tilt upper console aft.
4. Remove screws securing OAT gage to face.
5. Disconnect console wiring from OAT gage wiring at connectors, and remove
gage.
D. Installation
2. Connect console wiring to OAT gage wiring at connectors. Verify security.
3. Install screws securing OAT gage to face. Verify security.
Verify security.
5. Install Aspen PFD per § 13-61 if removed.
2. If OAT gage is still inoperative, remove OAT gage per Part C, and install airworthy
OAT gage per Part D.

13-43 Hourmeter
A. Description
An hourmeter actuated by engine oil pressure is located on the ledge just forward of
the pilot’s seat.
B. Schematic
C. Removal
1. Remove screws securing D830-1 hourmeter to ledge just forward of the pilot’s seat.
2. Disconnect airframe wiring from hourmeter and remove hourmeter.
D. Installation
1. Connect airframe wiring to hourmeter (A859-42 to positive terminal). Verify security.
2. Install screws securing D830-1 hourmeter to ledge just forward of the pilot’s
seat. Verify security.
2. If hourmeter is still inoperative, remove hourmeter per Part C, and install airworthy
hourmeter per Part D. Make appropriate maintenance record entries.
13-50 Instrument Markings

See R22 Pilot’s Operating Handbook (POH) Section 2 for instrument markings.

Intentionally Blank

FIGURE 13-2 SIX-INSTRUMENT CONSOLE WITH ASPEN PFD – TYPICAL
FIGURE 13-3 ASPEN PFD PITOT-STATIC SCHEMATIC

13-60 Electronic Flight Displays
13-61 Aspen PFD Installation

A. Description
The Aspen PFD (Primary Flight Display) is an LCD unit with displays for attitude,
altitude, airspeed, heading, and optional NAV (HSI/CDI). The Aspen PFD is a
situational awareness aid, to be used in conjunction with required VFR instruments
(altimeter, airspeed indicator, and magnetic compass).
The standard Aspen PFD installation configures the lower half of the display as a
directional gyro. An optional installation configures the lower half of the display to
a Horizontal Situation Indicator (HSI).
B. Schematic
Refer to Figure 14-42 for C800-1 Aspen PFD electrical schematic.
C. Removal
1. Turn battery switch off and pull-out EFIS circuit breaker (7.5 amp) at panel.
2. Gently depress blue tab at top of Aspen PFD to release display from mounting
bracket.
3. Disconnect pitot and static lines from display using quick-disconnect couplers.
Temporarily cap pitot and static line fittings at display and in aircraft to prevent
contamination.
4. Loosen screws securing airframe wiring harness connector to display, unplug
connector, and remove display.
D. Installation
2. Plug airframe wiring harness connector into Aspen PFD display and tighten
screws. Verify security.
3. Remove temporary fitting caps and connect pitot and static lines to display using
quick-disconnect couplers.
4. Insert display into mounting bracket until blue tab snaps into place. Verify
security.
5. Push-in EFIS circuit breaker (7.5 amp) at panel. Turn battery & avionics switches
on.
6. Perform appropriate functional checks per Aspen EFD1000H PFD Pilot's Guide.
Turn battery and avionics switches off.
7. Perform pitot-static leak check.

13-61 Aspen PFD Installation (continued)
E. Antenna
Refer to § 16-80 for antenna locations & R22 Illustrated Parts Catalog (IPC) Chapter 6.
NOTE
Do not use magnetized tools.
Removal
2. Using plastic scraper, remove B270-1 sealant from around EFIS antenna at
corners where it attaches to tailcone.
3. Cut and discard ty-raps as required and disconnect antenna cable at connectors
(secured to frame). Remove screws securing antenna and antenna ground
wire to tailcone and remove antenna.
Installation
2. Remove paint and primer from antenna and antenna ground wire mating
surfaces to ensure electrical ground.
3. Install screws securing antenna and antenna ground wire to tailcone. Verify
security.
4. Apply small bead B270-1 sealant (0.1 inch max in height) around antenna at
corners where it attaches to tailcone and allow to dry.
5. Connect antenna cable to antenna at connectors; secure to frame using ty-
raps. Verify security.
6. Perform ground checks per Part D steps 5 and 6.
F. Scheduled Maintenance and Inspections
Maintenance is on condition. Contact Aspen Avionics at www.aspenavionics.com
for instructions for continued airworthiness.
NOTE
Refer to § 34-60 for avionics software information.

13-61 Aspen PFD Installation (continued)
G. Special Maintenance and Inspections
1. Turn battery and avionics switches off. Open circuit breaker panel and upper
console.
2. Inspect condition of and verify no obvious damage to Aspen displays, pitot-static
lines, metal braiding, copper bus bars, circuit breaker, and wiring. Verify no
loose, chafed, or broken wires or terminals. Verify no evidence of arcing. Verify
equipment security.
3. Secure circuit breaker panel and upper console. Perform ground checks per Part
D steps 5 and 6.

Intentionally Blank

CHAPTER 14
ELECTRICAL AND AVIONICS SYSTEMS
Section Title Page
14.000 Electrical and Avionics Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.1

14.600 Electrical Systems Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.12
14.800 Avionics Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.25
14.900 Upper Console Harness Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.41
14.1000 IFR Trainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.43
14.1010 IFR Trainer Component Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.43
14.1020 IFR Trainer Console Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.45
14.1030 IFR Trainer Component Location . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.46
14.1040 IFR Trainer Avionics Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.47
14.1100 R22 Mariner Avionics Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.60
OCT 2018 Chapter 14 Electrical and Avionics Systems Page 14.i

Intentionally Blank
Page 14.ii Chapter 14 Electrical and Avionics Systems OCT 2018

CHAPTER 14
ELECTRICAL AND AVIONICS SYSTEMS
14.000 Electrical and Avionics Systems
Electrical System information has been moved to Chapter 33.
Avionics System information has been moved to Chapter 34.
[Pages 14.3 thru 14.11A have been deleted, are no longer effective, and should be discarded.]
OCT 2018 Chapter 14 Electrical and Avionics Systems Page 14.1

Intentionally Blank
Page 14.2 Chapter 14 Electrical and Avionics Systems OCT 2018

Intentionally Blank
OCT 2018 Chapter 14 Electrical and Avionics Systems Page 14.11B

FIGURE 14-1 ELECTRICAL SYSTEM SCHEMATIC (S/N 0001 thru 0077)
(Impulse coupling ignition; 9/21/79 thru 12/1/80)

(V)
.-t
..:t
.-t
N ().)
N bO
[[ Cd
_, VOLTAGf P-I
REGULATOR
w 66 A700-1
. I. I F .I I
0
0 Al5A I2 V :-::1 25 OVER VOLT AGE
24
~
90
TO CLUTCH
T~Y BATTERY DI I flATT[RY =
1 A 780 -2
R£1. AY
In~
Fl
I ACTUATOR CIRCUI JO SWITCH ODE I
~
LNDG =if 33
LT. BATTERY RELAY
WIRING ------. .. ] _r / ----&.2. IB 22
TO 48 50 165 "
I7 19
CLUTCH
SWITCH AlTERNATOR SWITCII
26 A617 INSTRUM.
~ CLUSTER
AM11EHR
_, I
138
Sill! NT iAMMETER
ENGINE ·12j
STARTER
~ 102
J 32 114
z
~
~
129 120
w
u A448-3 11448-3
ZI Hf/>1"1'A.
~ 40 41 60
z 4
...w
-z
1-
:x:
8
~ -'
n.
~ ..:
:0::
z
N
~
I
MAIN BOX
N CIIIP
I
..: DETECTOR
on
~
.LOW FUH
D N
::!;
I
OUTSIDE
AIR
CARB
AIR
FUEL
QTY.
SENDER
ENG.
OIL
[IIG
OIL
CYL.
II.D.
TEMP. 61
SWITCII
UJ <t: TEMP TEMP.
PRESS. TEMP. PROBE
-mz
V1
SEriOER SEIIDER SEriDER
w
!;;
0::
'-"
SENDER
* LOW FUEL TEST SWITCII 42
135 ('-..
00
..........
D ELECTRICAL SYSTEM SCHEMATIC (S/N 078 THRU 324)(12/9/80 THRU 1/10/83)
(IGNITION VIBRATOR) *These changes added to some
N
N
..........
II FIGURE 14-2 A/C Ser.# in this series 1.1")
See Page 14.15 Schematic ""d
<I)
;j
{f)
{f)
H
,....._
co
.........
tU N
tU N
a .........
1.{")
.J
w '"t:l
D 6 11780-1 (!)
;:j
0 III 12 v:-1 AL lERNA TOR (/)
~
(/)
_::..::~~ "I
90 H
I > __ .
TO CLUTCH
ACTUATOR CIRCUITRY .I JO
""'"
5111 TCH 6.~5
,/'__
"'
OD£
BAITEI!Y :=:
£11780 -2
AlTERNATOR
LNDG.
LT.
WIRING
TO
j L
50
165 T
11 1
CLUTCH
SWITCH
I-
TACH POII(R
RElAY
.J
c{
J 102
z
c{
~
w 129 120 32
u 11448-3 1\448-3
ZI HEATER
c{ 60 47 I 144 ~
z
~
36 140 41
TAll
w OUTS Ill£
AIR
CARB r·
AIR : I:HIP
WARNING
z1- 5:
TEMP
IND.
m
ffi
w
TEMP .
INO.
I
I. 5 liGHT
Ci "'
-'
IX
''-" A655-l
TIME
~
0..
~ DElAY ....,
~ Hill" B OX~- TAll BOX
z ,.....,
'1j
N
<C'
'
FUEL CYL.
CHIP
:x:
"' 58
CIIIP
DETECTOR
DEHCTOR;J LOll fllH EffGIN£ HR.
0 -w "'
N
:!
lllJTSIO£
AIR
CIIRB
AIR OTY. ENG.
ENG
Oil H.D.
TEMP. 61
Sill TCH METER
m ' TEMP. SENDER Oil
<C HMP. T[HP.
~ S[NUER PRESS. PROO£
Vl
..... SEN!JFR 51.NO£R
z 0 :>: SENDER
-
CJ ;:;: lOll FUH TEST SWITCH 42
.........
"' 135
m .
0
0
0 \0
ELECTRICAL SYSTEM SCHEMATIC (S/N 324 THRU 363)(1/10/83 THRU 8/23/83)
a ...::t
rl (IGNITION VIBRATOR)
FIGURE 14-2A
...::t
rl
...::t
rl
(!)
bD
ctl
P-1
If)
rl
--:t
rl
01
I
().)
bO
Cll
.J ~
w A780- I
D 6 -----;
0 12 v. AL lERNA TOR
~I 90 AVIONICS/
FLIGHT I NST.
llATHRY
Al5Al
DIODE
RAt TERY
.r
:=:
A780 -2
l
30 SWI~W
~ 65 64
- AI TERNATOR
l N[l(; ACliiATOH CIRCUITRY
Ll. " j BATH RY RFlAY
WIRING 176 165
TO 17
9JllQI MASTER 20
SWITCII
RADIO
.J
1- RFI.AY
c( TO llUAl
TAOI INSTt 29
:J 102
z
c(
~ ....___,___.
w 129 128
u 32 NIGHT liGHTS
z.
c(
Hf/Wl
A448-3 A440-3
z 0
w
140 141 153 60 47
TAIL
44
...w
MAIN BOX
OUTS l!l£ "'ex: OVER CHIP
.1 ~~AIR ~ti'l
43. TEMP . WARNING
z ~
t-
I " .
TEMP
HIO.
WARNING lT
7
5 tiGHT
Ci •. J
69
~
2
~
0.
,...""
N
N '
'
"ij'" 51:
l MAIN BOXJl~
CHIP
I
:>: 58
TAll BOX
CHIP
DETECTOR
m j
DETECTOR
""
"' run
0
~
N OIITSIO£ CIIRB L..'...'.J ENG CYL. LOW FUEL ENGINE IIR.
;'!; AIR AIR QTV. ENG. H.O. SWITCH METER
Oil
·~ ' TEMP. TEMP. SFNIJER OIL
T£Mr.
TEMP. 61
PRESS. PROOf
,..,
Vl
SENOfR SfNilfR
SENilER ~FNOfR
2
-
m 0
0
"'
;;:
'"
ELECTRICAL SYSTEM SCHEMATIC (S/N 350,351,357-361,& 364 THRU 411)
·~
LOW fUEl TEST SWITCH 42
~
00
.........
N
0 \0,
(IGNITION VIBRATOR) R22 ALPHA
N
.........
II --:t
rl, FIGURE 14-28 {8/4/83 THRU 5/18/84)
If)
'"0
(J)
;::.1
rJJ
rJJ
H
0
"'
01
TO CLUTCH ACTUATOR CIRCUITRY
~
~
I_, CLUTCH CAUTION
LIGHT
ELEC.CLOCK
134
N
r1
,......
w
D (!)
0 00
~
~
22
Ctl
...c:
18& u
29
50
_, MASTER
RADIO
RELAY
c(
:J
z
c(
~I
AVIONICS/
FLIGHT INST.
BUS
u
z
c(
TO DUAL
TACH INSTl.
z
w
1-
z ~
..
:J
Ci ;
~ ~
'-:.
I
2 .
"'
N
OUTSIDE
AIR
CARD
AIR
p
ENG ENGINE HR .
~ TEMP. OIL METER
0 "'
SENDER
TEMP.
SENDER
PRESS
SENDER
m I 135
LOW FUEL TEST SWITCH 42

2
-m ELECTRICAL SYSTEM SCHEMATIC (S/N 412 thru 443)
o
II I ~
0 (IGNITION VIBRATOR) (5/18/84 thru 10/1/84)
FIGURE 14-2C
\.0
....-i
-.::t
-.::t ....-i
....-i
(!)
00
Ctl
P-<
(")
:::r
. - - - - - - - , A78Q-7 BATTERY CADLE
~
O'Q
CD .:::;. NOSE BA TTEAY ( 12 VI
-1 (OPTIONAL!
-....j ";" A78Q-2 BATTERY CABLE
D
1-'
0
N
TO ClUTCH ACTUATOR CIRCUITRY l_A78Q-1 BATTERY CABLE
y -m
~ 7 STANDARD BATTERY I12V) 2
~ ALTERNATOR
CLUTCH CAUTION ELEC. CLOCK -}7B0-2 BATTERY CABLE
liGHT
1.0 134 ~ ,.-----, w•ltu,.. 4
m
0 0
_2!._
A+ -:-
2
_]STARTER 22
,] RELAY ~
118
!:!
~NGINE
~!"ARTER
32 ...z
m
ENGir-E z
RIGHT MAG
29 A617 INSTRUM. )>
CLUSTER
50 AI lERNA TOR
SWITCH
z
MASTER
0
RAOIO m
RELAY
~
)>
z
LIGHTING
BUS
c)>
AVIONICS/
FliGHT INST. r
BUS
TO DUAL
TACHINSf\..
~
:I
~
ll
N
0 ~
N
0
.,.. p
0
N
OUTS roE CARD
t-el AIR OTY. ENG ENGINE ttR 0
:':0 AIR
P> . TEMP. TEMP . SENDER OIL METER m
(TQ Ill SENDER SENDER PRESS
w SENDER r
CD :1
LOW FUEL TEST SWITCtt 42
~ :0
1-' 135 IU
-1>
IU
1-' FIGURE 14-20 ELECTRICAL SYSTEM SCHEMATIC - DUAL BATTERY PROVISION
()"\
;p (IGNITION VIBRATOR) (5/18/34 thru 10/1/84)
0
66 ~ 0'\
~
01
01 CLUTCH CAUTION ELEC. CLOCK
..,~
a: LIGHT
r-0---1.134 • <'J
rl
.J
w
black
I
)AGC-1
FUSE ~
D 26
~
2
r--..
0 94
i
OfiM(tl
5 Q)
~
wllitt 6
bO
91 ~
C'\1
66
,..c:
32 18~1199 u
4";5
LOW VOLTAGE
WARNING LIGHT
h·•l)
29 A617 INSTRUM.
I so I CLUSTER
MASTER
RADIO
RELAY
.J
c( 49
'if
:J DIODE ASSY.
z
c(
AVIONICS!
~ FLIGHT INST.
BUS
w I
~------------~"-~l_________ j 42
u TO DUAL 4 '------------"12'::,--------------------,
z
c(
TACHINSTl, ~~~~·~8~------~
32 ...
OUTSIDE CIIRB LOW OIL
zw AIR
TEMP
IND.
AIR
TEMP
IND.
1 PRESSURE
- WARN. LT.
1-
z
Ci 1-
:t
~
£!
...
a.
<(
:1!
2 "I
<(
OUTSIDE
AIR
C.lRB
AIR
196 LOW FUEL
~ SWITCH
0 .""' TEMP
SENDER
TEMP
SENDER LOW FUEL
197
61
m "D
-.w
I
<(
on
*
TEST SWITCH v
2
- ~ w 506
:1!
0 it
u "
m '--''
FIGURE 14-2F ELECTRICAL SYSTEM SCHEMATIC
(IGNITION VIBRATOR) (S/N 444 thru 655, 10/2/84 thru 6/10/87)
r:Q
\()
rl
0 0
0
\() ...:j"
II ...:j" *If installed .
rl
Q)
rl
bO
C'\1
p..
~1180-1 BATTERY CABLE
----. -=NOSE BATTERY(12 VI

0 ~BATTERY (OPTIOilAll
::r ~LnELAY -1 A780-2 BATTERY CABLE
Pl l' 1-'
::J 141 1142
(Jq .+:--
(1) 11 0> ]J
TO CLUTCH ACTUATOR CIRCUITRY r-'"'~(&-------------------'"'--f--i -:!780-1 BAnEAY CADLE 0
....._,
~ ~ER'f' ti~ 0
V SWITCH ,.;;. STANDARD BATTERYC12VI 0
-lf ALTERNATOR ...--.
CLUTCH CAUTION
1-' LIGHT ELEC. CLOCK .l_A780-2 BATTERY CABLE ()
N ~ ,-----., ,.uo... •m , 0
y ::J -m
~ltn rt z
~ .
_.._._ _ _3
~ p. UJ
(l!•ug• 2 ..........
-1.1-.J.+.-l----l---/
\0 whll• e
0 L...,_
---. 0
eo 116 ALTERNATOR
CONTROL UNIT
(AQ42-31 11 IT
z
I , 101 ~
LOW VOLTAGE
WARNING LIGHT ~
© tyel)
2t A6111NST-.
CLUSTER r-
z
-t
I so I m
MASTER z
RADIO ,.
RELAY
••
z
n
DIOOE ASSY. m
A045·2
LIGHTING ~
BUS
AVIONICS/ ~l7l
FLIGHT INST.
BUS
,.z
111
TOOUAL I 4
TACH INSTl. r.J!'-..::4&,__ _ _----,
32 44
,.cr-
OUTSIDE CARD LOW OIL
AIR AIR ~ PRESSURE
TEMP TEMP • WARN. LT.
IND. IND •
.
%
:::;
". I!"
oo(
:IE
"'I
oo(
on
;~ ~~Ey~ ENGINE
t/1·€
EN~LNE .::EvALD
"... OUTSIDE CARD
AIR AIR SENDER p.?~~S TEMP TEMP
I
oo(
TEMP TEMP SENDER SENDER PROBE ~
II)
SENDER SENDER 0
w
!
a: D
42
t-cJ " 506 'f-
m
Pl r-
(Jq
(1)
D
FIGURE 14-2F ELECTRICAL SYSTEM SCHEMATIC - DUAL BATTERY PROVISION ro
1-' (IGNITION VIBRATOR) (S/N 444 thru 655, 10/2/84 thru 6/10/87) ro
+:--
1-'
....._,
*If installed .
0
0'\
...,~
66 A780·7 BATTERY CABLE
t\1
t\1
±
a: ~
12V.
BATTERY-=.
r 780·2 BATTERY CABLE
N
.J CLUTCH CAUTION ELEC. CLOCK
ALTERNATOR
rl
w LIGHT
r-0---1134 ~~
..!.
A •
BATTERY
D ~ SWITCH ~
~ 33 r---
0 AGC-1 139 ~
M~OS
~
~
FUSE Q)
:.
~ 00
26 2
ora"g•
---5 1=1
'' wh1te 6 Cll
!' ..G
90 191 166
u
29 lffi
so 137
MASTER
RADIO ENGAGE
RELAY
49
.J
<1:
::J
z
<1:
~
w
u
z
<1:
z OUTSIDE
36
w AIR
CARB
AIR
1
32
44
iJ -
TEMP TEMP
t- IND. IND.
-- @ MAINBOX
OVERTEMP
LOW OIL
z ...
/'""'"', WARN LT.
@PRESSURE
<i :r:
!2
Q
504 12 581
~ ....
:1
37
' 52 MAINBOX1yft
OVERTEMP
... TEST 69
z .'
"'......
39
f'") rJ ~
u ~
SWITCH _ i
• I
1
I MAINBOX
I OVERTEMP
I SENDER
I-----''
0 .,.'
OUTSIDE
AIR
CARR
AIR
FUEL
OTY.
AUX
FUEL
ENGINE
OIL ENGINE
CYL.
HEAD r - - - - j LOW FUEL
~I
TEMP TEMP SENDER OIL
UJ "':1
SENDER SENDER
OTY.
SENDER
TEMP
SENDER PRESS
TEMP
PROBE
569
L~KW F~:~WITCH
-z
SENDER
0:
0 " 42 TEST SWITCH ""'
u
m ......- 508
<ti
r---
0 0
0
rl
a: 1.0
--:;t
FIGURE 14-2G ELECTRICAL SYSTEM SCHEMATIC
(IGNITION VIBRATOR) (S/N 656 THRU 1084 EXCEPT S/Ns
--.."'t
rl
rl
1052, 1056, 1067, & 1071 AND OVERHAULED SHIPS Q)
00
6/10/87 AND ON) Cll
~
0 J_A780-1 BATIEAY CABLE
::r' -=NOSE BATTERY (12 Vl
Ill BIITTERY
_-1 (OPTIONAL}
!j RELAY
-,A780-2 BATTERY CABLE .......
OQ
ro 141 ..1>
{)'\ ]J
-...J
66
"" .-2L/--f!r""-'
fclL J_A780-7 BATTERY CABLE
0
0 0
....... ~ j_ BATTERY _..._,
7 SWITCH ..;:::. STANDARD BATTERY ( 12 Vl
N -- ALTERNATOR ()
CLUTCH CAUTION ELEC. CLOCK 0
y LIGHT
134 ,........-----,~
!j
rt
~ ~
-zm
BLUE 1
0..
- UJ
\0
A•
..__,
0 0
94
166
'U: z
29 ~
50
r------;===='_]199 ~
o-1-......---...,137
MASTER ~
z
-1
RADIO
RELAY 11617 INSTRUM. m
ALTERNATOR CLUSTER
49 SWITCH z
'!' 198~R )>
176
... tJ19
2
1
z
0
26 $l -~ .i£
164 m
15 16 AMMETER f"_- .
SHUNT ! 1 4 -
TO HEATER :!;= ~
~,LOW RPM + 67 102 )>
LIGHTING
-- . 2}"' HORN/LIGHT 1~ ALTERNATOR S
BUS
D. GYRO/ ADF NAV/COM (101 ~ ,'\"-, z
HORlZ. ~o NIGHT liGHTS c
198
46
...)>
OUTSIDE CARB
AIR AIR
TEMP TEMP MAINBOX
IND. IND. OVERTEMP
WARN LT•
. 5111
X
0 16
:::;
...c
,.. ,... ,.. _[. ~- 1 ,-·nisi-· ~s.:-'j-1, _
::t
_____,..J.., swrrCH J~: I -T"'J 1 MAINO'
..
0 '" 1 'ovERTEMP I ~ -·c·ii;;--
U ~ Diit:.i\v 1 U cHIP
c I SENDER I DETECTOR • I DETECTOR
[-'") U:
N t ___ _, ._ ___ J ~sa L___ J
OUTSIDE CARB FUEL AUX ENGINE CYL.
"'... rJ * u iJ
0 AIR AIR OTY. FUEL OIL ENGINE HEAD ~
c TEMP TEMP SENDER OTY. TEMP OIL TEMP S69
PRESS 196 lOW FUEL 0
SENDER SENDER SENDER SENDER PROBE
w
"' SENDER 197SWITCH ENGINE =
::t HOUR T
D
""0 0: LOW METER
0
Ill
. . DFU~1 TEST SWITCH •
9"
OQ ...m
ro S08
D
....... FIGURE 14-2H ELECTRICAL SYSTEM SCHEMATIC - DUAL BATTERY PROVISION IU
.<> IU
f-1
(IGNITION VIBRATOR) (S/N 656 THRU 1084 EXCEPT S/Ns
-...J 1052, 1056, 1067, & 1071 AND OVERHAULED SHIPS
tJj
6/10/87 AND ON)
0
0"\
585 z
584 ~
lU A780-1"
OR
1---)
01 TO CLUTCH ACTUATOR CIRCUITRY + A78D-7 BATTERY CABLE
a: ~ -
---.:1'+--------~...t-----------1
12V. =
A 1 SA BATTERY-I-A78D-2 BATTERY CABLE
DIODE --
N
rl
..1
w 585 CLUTCH CAUTION ELEC. CLOCK
~
ALTERNATOR
........
f
LIGHT
D ~134 ~
-~
j_ BATTERY BATTERY
583 -, SWITCH o RELAY
584
0 581
33 1 (])
bO
~
AGC-1
FUSE 587
or •
...
blue
~
23 ~
s:::
~
TARTER
(1j
sou~
582 01ange 2
5 ,..d
0
0
RELAY
L._j
wh•t•
--
e u
:!
~I .
90 ALTeRNATOR
ENGINE CONTROL UNIT
MASTER TARTER (ASI42-31
29 582 588
RADIO
~
RELAY L._
I J199
o-1-.,----, 137 LOW VOLTAGE
WARNING LIGHT
~ STARTING ENGINE
VIBRATOR RIGHT MAG 13 IY•I.)
(LE~~DE)
Ae 17 INSTRUM.
116 CLUSTER
AL~TOR
..1
t.~
SWITCH 1
c( 191
:J
z ' 19
c(
~ TO
LOW RPM
HEATER
~
15 18 D 560
m'0Sl
102
w ~HORN/LIGHT 10 ALTeRNATOR 5
u D. GYRO/
POR &. \;VM UH
ADF NAY/COM (101 585
z
c(
HORIZ. 111
4 198
S 20 NIGHT LIGHTS
L...__
48
zw 38
~
-
a
OUTSIDE CARS
~
1
AIR AIR 41
~ LT.~
TEMP TEMP STARTER MAINBOX TAl.. LOW 01..
IND. IND. WARN. OVERTEMP ~ CHP PRESSURE
I
. E~
\..})wARN LT • WARN. WARN.LT.
,_
Ci X
C) -
2
W5"" 12
589 LT.
~
:::;
rp
~~:-
OIL
a. MAINBOX 1 ? f r 0 5 PRESSURE
OVERTEMP
2"' .,.
z TEST 69. _ SWITCH
9
SWITCH I 1 MAINBOX
"
0
";' I 1 OVERTEMP TAILBOX
CHIP
1 I SENDER
"'on DETECTOR
D N
... OUTSIDE CARB FUEL AUX ENGINE CYL.
I_ _ _ _ ,.JI
~OW ~---J "T
.."' Alii AIR OTY. FUEL OIL ENGINE HEAD FUEL
UJ
0
TEMP TEMP SENDER OTY. TEMP OIL TEMP 569 ·-- SWITCH
z
-
w
2
~
SENDER SENDER SENDER SENDER PRESS
SENDER
PROBE
42
LOW FUEL t 1
TEST SWITCH ~
197 e:;~:J:tE
METER
m FIGURE 14-21 ELECTRICAL SYSTEM SCHEMATIC
u
........
D (IGNITION VIBRATOR) (S/N 1052, 1056, 1067, 1071, & 1085 AND ON.
rl
...::t
II *A780-1 and #587 wire rl
used with nose bat- (])
tery installation. bO
cU
p...
0
:::r
Ill 585
::.1
(JQ 584
rn TO CLUTCH ACTUATOR CIRCUITRY
D
'-.1
~ 0
585 CLUTCU CAUTION ELEC. CLOCK
f-J
LIGHT
N ~134
583
84
~
) AGC-1
-2m
FUSE ·m
~
\.() 94 ! 0
0
90 2
MASTER
29 582 66
RADIO L...-..
RELAY d IJm
~
LOW VOLTAGE
)wARNING LIGHl ~
(yell
DISENGAGE
!J z
Ati 17 INSTRUM.
CLUSTER -1
176
m
T GROUND
z)>
81 19
-·--
580
z
n
~ m
102
~
585 )>
~TLIGHTS L--- z
m 121
198
c
36
)>
OUTSIDE CARD 40
r
AIR AIR
TEMP TEMP STARTER MAINBO X LOW OIL
IND. IND. WARN. LT.~ OVERTEMP PRESSURE
~WARN LT. WARN. LT.
504
...X
-- -- I 12
569
TAt..~.?X
TEST SWITCH
£ 6
OIL
".::;
:1
"
1416 111 110 134 OVERTEMP
:oox~
~. . W
TEST li8.
r
A665-1
502
..,
a
r
_P
~
PRESSURE
SWITCH
SWITCH _ I I MAINBOX TIME TAILBOX
T I I OVERTEMP
"'
'
$~-
l ~3~ t I
L ___ j
I SENDER
DELAY
I
CHIP
DETECTOR
""' rJ ~) u rp_ • p T
FUEL AUX ENGINE _..J CYL.
"'
. OUTSIDE CARD
AIR AIR QTY. FUEL OIL ENGINE HEAD L---
OIL TEMP
TEMP TEMP SENDER OTY. TEMP
PRESS PROBE ••• ~NGINE9 ~
SENDER SENDER SENDER SENDER HOUR
SENDER METEH
.,.."'
!! 0
42 D
'-cJ "" m
Ill r
(JQ
rn FIGURE 14-J ELECTRICAL SYSTEM SCilEMATIC - DUAL BATTERY PROVISION D
f-J (IGNITION VIBRATOR) (S/N 1085 &ON) 1\l
.1> 1\l
f-J
'-.1
t:J
14.600 (cont'd)
12 V .D.C. BUS
128
A448-3
45 60 46
35 42
__ _, TAIL
CHIP FIGURE 14-2K
CYLHQ ~ WARN.
TEMP. LT.
IND.
M.R. GEARBOX OVERTEMP LIGHT
ON 2 AMP WARNING LIGHT BREAKER
MAINBOX MAINBOX TAIL BOX

CHIP OVERTEMP CHIP
DETECTOR SENDER DETECTOR
LOW FUEL
L
CYL.
HEAD SWITCH
TEMP.
PROBE
61
'?"
42
128
60 46 47 FIGURE 14-2L
TAIL
CHIP
~ WAAN. M.R. GEARBOX OVERTEMP LIGHT
LT.
ON 2 AMP WARNING LIGHT BREAKER
LOW VOLTAGE UNIT ON THE 2 AMP
WARNING LIGHT BREAKER
MAIN BOX MAINBOX TAILBOX
CHIP OVERTEMP CHIP
DETECTOR SENDER DETECTOR
CYL. LOW FUEL

HEAD SWITCH
TEMP. 61
PROBE
LOW FUEL
=
TEST SWITCH
42
12 V.O.C. BUS
172 LOW VOLT AGE UNIT

128
47
FIGURE 14-2M
TAll
u CHIP
~ WARN.
M.R. GEARBOX OVERTEMP LIGHT
LT. ON 2 AMP GAGES BREAKER
LOW VOLTAGE UNIT ON THE 2 AMP
WARNING LIGHT BREAKER
MAIN BOX
CHIP
DETECTOR
.
~ 58
TAIL BOX
CHIP
CYL. DETECTOR
HEAD
TEMP.
PROBE

A059-3 A059-2
~ :t:~;a L v
55
:::E~iLSY ~
14.600 ELECTRICAL SYSTEM SCHEMATICS (Cont'dl
/C~==l-""59:,:2'----II•·
11:: Y I
r--- WHITE
GREEN
r: f1 SO( ORANGE)
I L I I 81(\IHITE}
~~~
11
I 5 1
(Console)
CONSOLE
ELE~CAL C.£_N~CTDR
T
(Cabin)
L---':..::~:=--r~:"'~:'-;+-+--' ~~--EN-G:-iN-E:-~---:L_____________...=:::;
591
1.----'"'-'--------------------, GN~III~---....:r-r .----------1-+---~o;QSE/Il!.ll
:ra.uE~
7
+o-1.:.42~--,
CASE
A039 RICHT
1
POSIT lOll
LICHT
r,;;;,
UlJI
f.~
VERTICAl FIRE"'-ll/
WIN BULKHEAD
I
,r-------,H--t-.===~------f=~'--t33C-
: r----:6:;;73?,(:;Nt:;S~E;;;BA~TT~E:;:RY;;;;IN~ST!;-'~L!:=
BliTTERY INST'L
ss'itm OO.Il BATTERY INST\
):7":'---.
82
-' RELAY
~
e-: MOTOR lr~~E
). lI II [ ..
591 YELLOW J I 82(8LUE} 1t CZ-25 1'5 I A212-l
A~Z
TACII
REO
ORAilGE
j 8 I 71
I DI ! 72
I 80 J CZ-18
L _ _ __!8':._;.1.f,1 .j..sC2~·,!!164--~~f-,1f----------+----------,
J. 7 591
~====l~l===~j7r___ _ _
L.r.
ENGINE OIL~NO B
C
-J.t--fJ S~. u 591
'--'--'-1\ STARTER
.. --'\ ·tl A212-1
n
ASSY. BLUE HI j 83 l (IIHITE) 82 I I C2-17 I I 6 6 PRESS. NC
I I 71 - C2-10 :• .--258:?_5_ _ _ _.J.+--lf---FI-f::i-11 fp
- LOW OIL PRESSURE
BROliN
BLACK
A
Ej
I 491
1 '• II .89(BLUE)
83 X CZ-15 I
7Z r C2-ll I
I
m
so
IN4005' orooE
"
T
80(0it'.,GE) 1Tl RED
li
··~,
I 83
WARN. LT YELLD~/IIHITE : P: :"'
"RE• ~!,, 7807 I
I
L--------'B::9-,f'IH"C0!2"'-2"'4-r--+i,=t,----------+l+-----'a"'9---, BI(IIHITE)I2 I BLUEII sTE~coHER
587 ~~~~ " i 7 "1~====:::;---'~itt:~-r-:::-ii-r------------iti----....2!.-, BL~
~
82(BLUE) ll I
'--
~:
5
r , -- _---h A792 DUAl A569 GREEN 4 • v_ ' 2- 7 163
!) 85 • 85(0RANGE)rl, 1 REDn
..___.
TACHOMETER ~~~ ~ ~ I
A780•1 ·A~! LOW RPH ,..2L LOW RPM
IIARNING RED l'i-- e5 . !ORANGE)) 84 ' ' C2-19 II' II 633 ' l a~(IIHITE)II~: : BLUE I \oE~oRlAH
I I lA I~ l.t..:r : WARNING 76
UNIT YFllOII 12i I 81 IIHITE 83 '" B6(SLUE 'i tlK LANDING \ \
-=r=- rr· ~ Ll~/ 78 1 1
t~SL~U~E~~Jilr~s~62f~(~BL~u~El~====~~==~s6~~•~C2~-~21~==~~~~~~~;;,~lri~~~~~~~~~~~~~~~~~~~~~~~~~l!~;;~~;;;;;;tt~~~=:~~~~~s:==J
11
~
GE~
jlj,J,Jiij~ :.~4Zl "'; -

'\)
I· ':.'! A15A (E.!..L r ; STARTER BROIIII 4 632 C2-22 164 164 ~ STROBE
1.175 ' ;8 w1m
LOCKOUT GREY S I I Ell 633 Cl-35 16 LICHT
f - BLACK 161 1 I , 7o cz-9 _coL--LEC~TlvtrncH 1661

~
sa4 1 ~ 708 moeE EN~~;E~~rr 10
:h
I _ AI5A DIODE ,.---
LOW
RPII ~R·I~ R2 VIOLET
7 'l'
I--!0<!!R~AI~IG.!,_E-+-!+-JL.!•c!:•!...,_-+H-,
bl 1633 I
r -
STROBE lT ]
75 C2-ll
5~1TCII...-"'' -~~7tEPC~2~-1~4t=P~=F~u~~~!.-U.U-i-!!!!-_jl
ljT1
121
8049-10 HARNESS
(-7,-B;\60PT.) 80 IN lOB
POWER SUPPLY
OR ~to~uT~·-
(RICHT SIDE
HELICOPTER)
1'.!! JJ
RET.S~.
:::""""1.---11..
CASE z:o ~n
~-
t:: ~;:.
-
I HOSE BATTERY • NOSE BATTERY :
~~y~ ~:A~~ ""i:ci~I:G r\ ~. ~~: ~~:~ <II [=tl:l=j==~~\===~~I~~~=\~Ig=~==!=t:tl:t=~~1~L:I;~~·~~k:lt~~F=A~7~o~e-~J~c~•e~t~E~Ag5s~y===E::/:j~t~~~!'Q:•.:--.,::::=~A7~08~-~l~;:t~~l::~

9
8320 79 Cl ~
L--------, L J.J 1 r-'" " 107 C2-5 107 ~ ~1 ;:;lz :;! CLR 3 118 LICHT
TAIL
~ ~I
121
NOSE BATTERY
INSTALLATION ,___ r--;;c;l; 523
101 c2-2 107 ¥==r no 1 "f 109 rT, '' ·..,
r--~•'11 ~
109
(12 V)
694
':;'' I ~
NOA
57
I<AV LTS
SWITCII
I
1f
34 Cl-17 34 34 ··-
CYL HEAD
-~-S TEHP L_I I I ...
I['
II
'I II Cl-8
~"!~ ~
r--::.---,
11 CASE GrtO SENDER :
69~ 8280-4 RELAY II Dltt<U 10 Cl-7 I ~ bENG OIL • '
" ASSEMBLY IL RH~T 95 m Cl-22 ., I -:~ TEHP
Ag~~c~~ ~~:: :!~ •· ~g~l ~e &.: ~~ ~~:~~ ~~~~~ .__,s~Bi.2_._=~!-:i---.1 ~s c~¥:0-- g~~~~ ll TA~JA:~oTxoRJl
~ .--~1~41~---------------J
~
ENGAGE l tla l llB _.:: SENDER'
~ !J • C?-~~T-' ~~~!!lo~;l:::~~[II2 rl-1ff--A-99_9_MA_S_T_ER---lf41f+-l-l+...l.J~V

'I
fE - i·--_]~ I
694 J .-- 137 Ill .cLuTCil 94 C2-l2 LAND rusE tJ i'
swnOI I_- 'Tics
(j: d 695 44 AGC I 1)7
92
'ee
'"" --;,'
I SWITCII I 28 CZ-27
I 138 C2-35 .__...,
1 LICHTS
SWITCH 583
RADIO
RlLAY CASE
r - ll9'"lj"IRED@f
GEAR ":'
7" CHIP
~-~· ,:- ~ ~ •
'Gc:v "OfF"
T
II " I DISENGAGE _ GND IQO I 12 BLK{ HlTOR CASE DETECTOR
:~-rut'["~4 I•· 5~1 ~tu1~ HELICOPI~~)

90 97
IIARH. LT 1 5 4
L..._,
n
• 0RES 583 C2-6 66 2 r-- (LEFT SIDE OF r l •- GND
r:!!~-;:::===~,_!::-
41 6
~~~~R.<l~~~~~~6~~~~~~~~b~ffic~~-~E=~~~14~2 ~~~~ffijftffi~ ~~~~L: 71 ~~8~~CA~~
6 66 2 28
~/ 0 I~Ly,l,y..l
n]:1 I ~RETRACTION
r
47
(I=RI 5
10
A
617 8144
or CLUSTER sDClRE~. 67 2 29 5 103 r-
633 1
176 1 11~z r;...=
8
10 l 90 43-J.
I _lQLI "' ,_, ..·~BREAI:ER
,'" ""w"
INSTRUMENT 125 ZOO RES 'C - ".!.P LICHT ·•I 506 p 91 98 or liHIT SWITCII
T.R.G.S. CHIP
~-~+:.!LO!I!!CH!!T=J;l~24-41rlr-;-;'A~07~2~C~LO~C::.;Kh:..;--tt ~~Cil LT ·~p~ ~2...1:<, ·~~· 1 A" ~-
~AAN. LT
60 ~6
'·-
'OIL ___ I
PRESS. g· '~E-TE-.R- ,129
~n 'il
LIGHTING,,
TERM. BLK ....."l
• .J-1+1-1-l~l-hl
. ---
.
4
~
••• 168
L 15 GND 9
Cl 6
ri...:..:.";:_f---f,
.,..cl..SJ LIGHT I~
r~
T l~t~
l: -
r -
29
__r=;:::=
r~~
,. •
II
ENG OIL FRESS. SENDER "'D51
fsELT TENSION
L
4
v 99 SPRING
i' SWITCHES
,'
I c:=·- 5OJ
...._ E !HAL ~if Cl·ll 02 J' ~ L..!-~!!,ATOR I _ _ .
(I: RI 57
10
1
;:2!.:. _..., · t. --.~.;.!! 12 TJU':::.ERs"-l - •••.t I lR 164 rlrl.:.:2a'*.._cl:..;-""ls'+---H-----. r-d:~2 ,~ fii ,
03" 572 N
~ START~~ I ~
14
LD~ FUEL QTY OIL of • AUX FUEL 'f l 164 Cl-34 I • T• .!.£.,2 .... m...... IGI : g:N' <I 416 tlo I WAAHING LICHT CIRCUIT TEST SWITCHES • '
~H. LT
LlL _!!~ ~XI~:. QTY T ~ TERM.-~ BO 166 166 Cl-36 - 129 ::..-2 ~~:4.-:< 29 tt574 H I L-'-' LOW FUEL LOW H.R.G.B. H.R.G.B. T.R.G.B. t~
.......... 57 ~~;o ,.~:_MAIN4~:ELI ~:::~r.~A-----J ~},~.~R6~~!,: -+...J 16 ~·- ~ A~~~ ~:~ :t! I: FUE;~~~;: QT~Cil ;-~ElL 0~ 0~ i~~~p
....'
JUHPERSI ___ Cl-12 TOCOII 176 673 AUX
58
lL...,s. I. ;ys. QTY 1b ~ IG:frtoN ! s 584 584 Cl-ll TRAilSCEIVER
200
s 51a1Dl 1 , 1~ T.. lUJ ... ;1 ~ ~~ ~~ g~
lo~ fUEL QTY
--- GND-- l~~ CASE GilD SWITCII SAT 31 31 Cl-16 • ~~Er j .
52 1
L,J_, 1 , ••• IP
~
'
~AAN.
LT Cl·l 9 19 S ..-'Li OPTIONAL -- , 'l.o' ••• L-----'
129 129 II I 470 "' AVIONICS HAIN fUEL QTY SENDER 'i'
IJ-rn
T!ME ~ElAY 'I.; '---
44 569 'I fl
CIRCUIT 58 ' • - - --
c~~!~9~l~~~~~tt~~~~~~~~~~47~~~~~~~~~~~~~~~~~~~~~~[JEtlr~-~-~rn
y
(J; 92
II It-~~r WAANING LTS I I II

1 1r~;;;;;;~~~~~[~-~~1io~~
I ""z CIRCUIT
D~~-=
470 2 - _JR[LEASEO -
~ H.R.G.B.
J l 1~08,
CLUTCH WARII. LT
............
36 TO OPTIOIIAI.rl, 513
47• " TERM. BLOCK
f -"
19 I Cl-15
IS Cl-14
,
C~~~~~S(~g==;-,
,.....
576....(12
BREAKER INST'L. ~;:t::t1~:t======
471 : 3 I
-._,..,
v--====::::~·
li'-J EIICAGED °
aVER
SWITC.H
TEHP
125 ATT HORIZON 21 ~- c 1 r , , • COLLECTIVE
199 & DIR GYRO ~It· 514 AlTERIIA>OR 199 C2-l t l t l GOVERNOR
~ 46 l~======+~s::wi~T~CH~-fr~~r£t!f"tc-c-c-tr::: ~\JZ,
1 S~ITCH
45
1
Cl=• 1 2 To ~uTR~oHALii 666 I •l ~~~ ~~:~~ T~~~~~~o t~ ::-~
r - 11
:: :: o 011
II.R.G.8
COORDINATOR~I··
!25 C2·Zl
TO OPT
AVIONICS
••....llL
., 125
576 II
ls76 /'-'-'
9
':a:
I 2
er~:~E~
n ;
695 52 Cl-28 CIRC BKR 52 =-:......1' OfF l-l.J
198 5 Cl-4
u: r 199 58 Cl-31
2 c1-1 ·1
LOW VOLTAGE WARil. LT A604
CARS AIR
TEHP GAUGE
..,.., 38
""' I II UPPER LO~R
I
I
"
37 CONSOlE CONSOLE
--------,
(j: R 3 CjQ[fN 4
::21
rrTil BLK
43 I•·
., ~ 65 1
GROUNDS
·•I
1!1
38
tl-24
Cl-10
1£2
I•·
GROUNDS
AI SA DIODE IAFT BATTERY
---~~-------------
37 Cl-21
H.R.G.B. CIIIP WARN. LT
I 1 31 BATTERY S~ITCII ~ ~~
r -- --, 5~0 r:=::::=
66 INSTALLATION
6S tl-33 65
23 1111 FIGURE 14-2N
l
I
1 . BLUE ""' A780-7 , (IZ V)
OUTSIDE AIR f4 REO -- 4 ' - - - - - ..._1:..;:4.:..1 --=-------. 507 (A94Z-l only) : ZI ORAIIGE 1
TlHP GAUGE • s• RED lSI -- f01\ 1 I BATIERY 1 -"> 1 A780-2
115 1114
l ROTOR BRAKE
IS oll 1 ~
ELECTRICAL SYSTEM
~;:·~~ ~1-~-~-~~-~-h~ i
16 1 BLK 15CJDauTSIDE AIR RED I A942 I 64
WARNING l T p:.jl 434
LANDING I ~4-!-;.' ,..----, 141 L!::f-~ TEHP SEtiDER It• 199 .. I Y£11 ow l AlCONTROL
TERNATORI
RELAY I /;
LIGHTS iii l i J.::::lu9 hol SCHEMATIC*
142
16 I ll2 I
58'
I
151 I
PIN 16 FOR ACCEPTANCE 1611 WHITE , ! UNIT
:
i-1 >
as _J
:
I
TESTING DNLY 11
-~1
In
L:tJ
• sLACK :
L--
__ ..J
VERTICAL FIREW.'.t.l/
WIK 8UlliiEAD
*Ship S/N 2115 thru 2588; ships retrofitted with
A569-5 low-rotor RPM warning unit having starter
I
Change 19: 30 JUN 99 lock-out feature enabled (unit's 9-pin connector Page 14.18A
connected to airframe wiring). See Figure 14-2P
if fuseblock is installed on aft side of left
vertical firewall. I
A039 RIGHT
14 600 ELECTRICAL SYSTEM SCHEMATICS (cant' d) A059-3
HARNESS
A059-2
HARNESS n C:~SE
POSITION
VERTICAl FIREWALL/
CABIN BULKHEAD
GROUND G LIGHT
rs 1,---11--1"-,'i--'~"'1;:.<91 _}
ASSEMBLY ASSEMBLY l-:j4:-ll-::!'-69,._2_-lll1·
(Console) (Cabin)
10 ElT I : I:;=-=::; ·II
ORANGE
II
CONSOLE SWITCH 21 689 I I BLUE 690
----------:::-::=------:-;:;-----------, ELEC~Al CE_N~CTOP - - 1-'-17'69,0_;--;,•,..·-----------+----'WH""I:..:T.:;.E_ _ _ _.jj I .-------:6::-73?.(.!!N0o;;S:;.E.,;B,ATT;,:.:;.ER;,:Y~IN~ST;,.'~l)==--..
T r--------------, f'.,
r ~1 ~·
T8-:::::
1"
r 1'0 1 61 ·-- 587 NOSE/DUAl BATTERY INST'L " RELAY
r--j....:WHGR::;EI~TEN::..E _ _ _; !I..:::"L+t1
"'
+~s8o1~((~~~:::1 N~TGE.!:.E,!. l_,1~I,:-'-I_'_· L_
5
_;:.::.!.~-+!:cc.!e1I:'-'53! -+---+---' J ENGINT~ 7 ~ ~~~~§·0ll~~====;=l-l
1 7
TO PITOT swiTCH t+:-'~1l'J~-I--+=::'.::'T~O~H~E~AT~E~D~P~n~o~T"-'-~~s~e£z=t;
581 AFT DUAL BATTERY INST'L -'
'-----,;...---------,11 II
--------, 108 1I '
ENG~,
1
A792 2
YELLOW J 81(BlU£l I I
I 80 ,l, C2-18
CI-IS :[~tR + 42
1 I
LL.n.
I .±i
~ \STARTER
J-!:R.!.EO~:----L..;B,L-i-
1 71
L _ _ _ _,!;B141-+'~C£2•:.J1,!;6+--+ll:-1r-----------r---+--------, ~NO
1 591 8 591 •I) AIIZ- 1
OOAL
TACH
ASSY.
ORANGE
BlUE
I 01 ] .!.
1Z
HI I 83 1 (WHITE) 82 I I C1·17
11
" 6
7
6
585
ENGINE SW.
PRESS. OIL
"'
NC c [ .__ CASE
.__ __ ___)
"'
44 BROWN A 1491 I I 71 - C2-10 X 688 587 .--~"'-----11+-I-IN-4-Eoo::51-oi~t*oo-'1E tP '
lim~> ~ftt~±~~;iJLLk~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~8~~~o~u~N~~~l~G~T~,~~~R~m~
11
1
IL-------;;.83"-iJ..4-1rc"'2"'-I"'5T""_~I~A-l.-----------tti--l---"e3.__,
·~.
--;_OW Oil PRESSURE
WARN. l T 1 P 1 1......, REo r 1, , 70 so " sl(wHITEl 2 EtuE TACH
SEtiDER
87 l~====::;--~89~1jltC~2~-2~4:;-;:;-tlt
1
587 •m 1£ nCu- r-----------=ttt=t==~E9j 82(BLUE) 31 I 6l~ I
--;:mDUAl
YEllOW/WHIT[
,:..;J BlACK
1-'~"'R"':i:':N-'-',
2
7 5 II·
!,._-l-l-!:;-t 1 C2-7 163 I) ~ 1 ,. 85(0RANGE)rJil RED ,---.,
toAi~~M ~ ..... _. E~(•~ITEJI2 1
85
TACHOMETER n 85 c2-2o ,, : BlUE 1 Ito• RPM
~2~N~~~ 76 --'-'-- WARNING REO n_-- 85 (ORANGE) 84 1 1 c 2. 19 11 1
633
c.' B&(BLU£) Ji 1 HK I SENDER LANDING \ \
LIGH_T___ / 78 r49! UNIT r=Y[EjjtL:Qoiw:::lp2[}::~1:§:s4q:pjw~HI:IT~El.l.:.:..._ _ij..r~~T~~~--nrt----' I 83
~ WITH BLUE 3 P6 (BLUE)
1
86 : C2-21
1
: J 15 ~ GEAR '\)
c~~ . .___63~3_:.7::..of-"'c2'--"-9+-+-'cotLECTIV~tswiTcH
STARTERt~B>~O~""==b4~t6~3~1jt~~------~~--l ~Y~p~~i~:;~;i===~'~f~~~~~~~~~==ttti===i==============::::::::::~~~~==~,-~tt~~~~
64
~;;;;;;~tt=hJr-~::~~l;b~~~
4
- ~75 : J
7B LOCKOUT IJ
GREY 51 1631 I 1661 fss4 16 ENGINE LEFT
STROBE
LIGHT
-LOW1---"""\1 ~~:~~:E 1~1 ,----='---,

I
63• ~
STROBE lT
(llJ
75 C2-!3
76 C2-!4
~~OE~ 75 C
- - - - AND
(Rr;;~EJ?DE ljT1
B049-10 HARNESS
108
SSTURPOPBLEY
HELICOPTER)
I•
CASE GND• ::.: :~
RPM ~ VIOlET 81 1633 j s~tTc_y_ 76 FULL DOWN I,----..,Y-i-, (·7,-B;\
-60PT.) BO IN R ~nOU~Tl:[ rT, <, ~~ "'~
o-
W~~RINNG
8320
R! Rl
-
-=~10~4=~H=~~~~2II==~~~~~~~~=~
513
9
L .iJ
10~7 4c2~-ts=t=j=======ttttttti~~~, I r- -
10o t2-4
!01 c 2• 3
121 1
<lf-----t.Jjj
[====::~~=======!:t=~tt~
STARTING
V!ERAIOR ,_ ;
["-
:JL; ~ ~~
~~~d~rr#f==i~~~~=::=====~c~IR~3
~=~====~~o9
A708-3 CABLE ASSY /.
RfO 11
RIK 1 I.".. A708·3~ ~ d
118
TAIL
L~'
.__ ~
lt!l"'L>rtr~~~~Ri=====;~;;~~ ~==:I==!~Oi4pC~2~-2~:::3E::::::::::::::E~:t~~l±f:~~:::}I0~7::::::::::::::::::~~==~=1=IO::::::::::::::::::::::::::::::::::::::::::::::::::::i:::~J!~!:~;·~I0~=l;;;;;JJ;~~~========================~~=;~~~~~~~~~btiJI::~·~·•r-~~~' 9
NOSE BATTERY 79 tl- r-T, ''
INSTALLATION
- j J ----,~ 34 1 1 7 r---4---'~~c:7-"_;..,+--+-------1f+l+-HHI+tt-h
I 3AMP
1? FUSE
(12 V)
694 ...
II
.I
5771
NAV LTS
SWITCH
--
513
10
10
II CJ -8
~0 I ..
34 34 ••• ,..CYL HEAD
TEMP
CASE GND "'"SENDER ' '
Ol~£'·
11
693 8280-4 RELAY 10 C!-7 ;::;::!!tibENTGEJPll - ' •
I~ 141
'1[~::cj";Tl "' -~~· 1 •::;::: ~~~~~~ •• '~it, _db, '- 's"'s"-2~· !-'!- -, I ~ · n" " ~ , ·;~~ ..;~-;;;-j r-:~~l
~~ i!l~ :~; •· ~~r);;/.-e··,. [~~;GE. ~~~~~~ ~~:~; ~~ ~::s ~~N ;...,.,i,i,4r----_-A_9-9::9::MA:·::T::::R::::::t~~44tt:: ~ 4cf·t·ro-r":l~!,·~ ~·-: l.~s'tp 1.'~3~r~R:~@i~ I ~-- ~~G.~
~
(j:: y
694
695
I -44 122
_
II :: I !04
t6~lJ
:
OFF RADIO
...
s"\...
ENGINE
'.,rAcH
CASE rr. -
.-
__ .J
- ]' ·121
GEAR
i"'
'"
n 1¥9.0 DISENGAGE I I 3e t2-35 , ~t 1 LAND LIGHT 583 RELAY RIGHT sw. GND I .: "' ~ : lion I 12 BLd l«lTOR CASE DETECTOR
GoV "OFF"
11 ~
p (
~tj
WARN. LT
1.50RES
1
583 C2-6 1 ~21 '-m":~
1
I•·
~ 1 -~
1,rt TO
swmH ,_ ~~~ rr===1-
r;Jl I _L:!...Pt
MAGNETo ~~~- ,
(LEFT SIDE OF HELICOPTER) 1
97 --
.-J.
GNo
~4~1=6~:::;;::::=:_:::;-rt 200~~ :~I ~:2::: ~~~ i8~4~~~- ::2,: ~Ill~~-~ r~ ~ :~~~~t~~~CH]: ~

98
47
10 A617 or Bl44
INSTRUMENT ClUSTER 125 soflRES ,.,
66 t462
~.AP liGHT
fgJ CYCLIC r- 617336
rl
51006 ,.,
LJ#N.
!354 1355 90 c
.-,, -=r-
r G -r.
-'-'-'-.LI.
28
,.-lli-IIT
71 1
T.R.G.B. CHIP + liGHT !24 (A072CLOCK\ :~: 127 C2-B ,,
127
CIRCUIT SWITCH -21'7 29 IJII l A ., ~ 3 TEST
2I~A~~.M~E-~TE~R.:::J-=~
12~9~"t-~l~IG~H~T~III~G,=,Il~ 9.rt't:..:l...;-6""-t--1h·-~BREAKER ~: ENGOILPRESS.SENDERBEL/~~~ 510~ c 9 al~llfiiPLuG
54
WARN. l T
n+\-
(1: Rl
60
"
f-olt___
'6 PRESS. ' 13 TERM. BLK ...~.d-1-MI+lf-h:
'
I ,, <
~.
•••
A"'-
168
l IS
SWITCHLT
CASE GND Cl·ll -
-
GND
'
LIGHT 1
1r
" '::":'::"!oos:~~DIODr-E-H-1+'1'-"'0:...2_,
!~is
"K.r-r--
,K' 1
~1 1
I
~
i ••
~TO~_ NO ~SPRING SWITCH~$-~
~ <~ =
NO
lt.::tt:l
__
98
_ 503
57
10'-<>S;.~· L. __ A. ., 12 TJEU_~:,IE,....a-~] 1- aor><:-g ~ LR !64 ,-..,pl,o.:28'-ft-"t""l-C!.!B'+--f-1f------, lr~ hov l4 d SJ2 IFil 1 ~
~· ;·j TER-M.,.._~ I I 'I ~ " ~ 1
J
···'j ~ ~ ·.: . ...,. :.. :; -. . .::~ " ""'" I~,
10W FUEL QTY AUX FUEL 1 - 164 C!-34 573,.,.._ IG I ng: •I 416 1111 WARNING LIGHT CIRCUIT TEST SWITCHES
'"-!!~ :x~~:. "',, ·~· ·~ ::.~.:. ·~.~·- ·~.~··

0
WARN. l T 80166 166
..
0
~2~~ ~~1ira ~},~:~~r.=t-----' IG~ftfoN ~ : ~: T.l~s~ ~vER ~ ~I · ~ A~~~ 1;_.,!:-R t:~; !, i~~ '"' ~
.--~---:~~": "~~;.·"~·: :M ;;- ~: "1-;~~L____. J:~
• • ...:·••• •• •• "
58 176
s ss4 584 •
Lo~A~~:\ry --- 1.!~ 9GN'o-- swncH o-, sAT 11 3! c!-16 ~~OPTIONAL
19 ~......._
5~,. r~~~~~~~~~~~,R~~---L~-:~--,-:sl.plq ~;0 ~r~~~:is 4 70 11

44 58
if ••• ..__
Q~~~~~9~3:~~~~~~~.__~'-~~t:;l1~~,~~~f~~~~~~~~~~~~~~~~~~~=~l~1
(C,
TIME DELAY
92
47
It-
I~ +-
129 CASE GND
1-"-
;--TERMINAl
129 Cl-19
wARNING usJWus 1
I
1 1 ~z
10 "" I t'J
tiRtUIT
BREAKERs
L~B~RE~A~KE~R~IN~ST~'::L:...-~t::=t::~=====-.w-1-J
470 2
MAIN FUEL QTY SENDER
31 rj1, LN09--'R£tEAsEo
ROToR sRAKE swncH
"
61 5 nc
M.R.G.B.
O~VERTEHP
E1 : MAIN ROTOR
Ir··To06---,
1
r
TERM. BLOCK w H GEARSOl I
C::UTtH w~KII. u ~~~~ [_4j47'-':J'-f-+-~ 19 cT-15 1 COMPASS!~ 576 471 .1~ I •c"" 1 EIIGAGED "-~~E*E~T~R.HIP 1
60 I 1. / 18 Cl·l4 -2 1
36 TO OPTIONAtri-:11:+-'5"'1;:..3_ __,
:T~~~o~;~~N~II· ,I L~::=4=5====4-::sw~I~Tc~H~+']~l~"t~~1~-=-=1"':::-:-.:"'To
~ORo
LIGHT ......, , , r--1--------i---h COLLECTIVE
-~
o o
RIGHT
lAtiO. LT
(,,..
.. ; I
46
2
199
I 125
TO OTUPTRINONAL[j, 666
198 199 t2-1
204 C2-26
5!3 C!-23
RADIO
liGHTS
tpf 1
,....,.. : ~.
LN -- J :!. o .21Z ,.
GOVERNOR
SWITCH
"2'1 ON
I
r-
1•
I
lr-
~~
jl._
401
6_-y·l •• J
@f ~R.G.B ~~~~~~~~~~~~~~~~~~~!c!oo~R!oJlM~T~oRlLiLi
1
~j ~1 1~l!!!!!!!!!!!!!!!!~~~~~~~~il~~~-~~~~!T~o~o~P~T~~··~~~~~
667
·~
6
~~~~~~~~~~~i~~6~44~!i~~~~l!~~~~~~~~s~!i ~~~~~~~1lt;l~~i!~~~~~::::~~~
76 11 1
W£T· ~ r~
500
OVERTEMP 125 C2-23 AVIONICS •·• ~ !25 TO ItS 643 IEL_/~-' ']::OFF 3 ~,;-::
WARN. lT 695 52 CJ-28 CIRC BKR -•-'<:.<...--!Ill• 52 14 •~.J
n ; ........... 198
(~(!;~~·!lj!299t::::::::::::::::::::-::__.
-::::;:r J
5 Cl-4
5: Cl-31 .I ~ 13 SHUNT
22
2
4RNATOR
.~
..__ Cl-1 I 1iJ~
CA~:o:IR
~ER 1
LOo VOLTAGE WARII. LT BLACK iTll ,__7-:l~~~;.:.:...;:;;,=O;--+--'II Z3 ,.---..:3:..8-ir~T~li--f'h
T[~~~ ~ ~~ I~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~;~;;;;;~==1~~~~~3=9~
2
"'" 1 :~: J'~tA:B ID
LAtiO. lT ":'
~
__, 45
IJ:P 3 I '"'" 'Il
4
L_,_,
37
lf't,l Bl<
II jl'1
43
I
30
"·
I'
•oiL....:.:...- 65
CONSOLE 12 CJ-9 'I coNSOLE
GROUNDS··II----!1;;:52'E'C;.;l·;-:;2;:.4i---+-..!.1':.!"2'---I:I•·GROUNDS
L.---------'3~8't';:C71-~2'f0i--+--------l
2 r.11 ~==:-;:===lf---+-.J.I.I-4-:f-.(,F.';;US~Ei>-_.:.:A;;l5A3-iD~I=;OOE
ITAiiP - -- ~
AFT BATTERY
37 AIR
TEHP SENDER
M.R.G.B. CHIP WARN. lT

1 IJI , BATTERY
- - SWITCH 37
65 Cl-Cl 33I 65 L _ _ _ _ _ _ __j::~2~3~ozlt+:::Q~BllliU~Ej,-[""----, l!O -~ 68 .l.m.t.... INST(At
12tAVT)!ON
~;;a;:::I!L~:-~t~-~t"'-i"::J~::::::::::~-,
I I f:!"
1
OUTSIDE AIR 11 14
I I
RED --
4
'ROTOR BRAKE,t.a ~.,-4"-'3"-4 --1:1•· "-
141
S07(A942-3only).
o21
18 11l'
ORANGE
RED 1 A942I I ! 580 ,...,.-~ AlSO- I : A780 FIGURE 14-2P
TEMP GAUGE ~· _ _ _ _.....::4.!.n~c.!.l·:.;2;;.6.;.1--l-..:4:.c7!.1-, L~=~~~~~~=~~IZ99tt•4!rj~tY~E~u~o~w~ ALTERNATOR ~J·
ll
i
..-----viiS 114 : sl RED !51 -- WARNING LT.'\'9 BATTERY ,64 -2
1 l61 8LK !S~IJOUTSIDE AIR .l. ~
tANDING Ill~r::::::::::::=lRI'---.J
(UPPER CONSOLE) CONTROL ( R CASE : RELAY
ELECTRICAL SYSTEM
'~"~' m.:~'l:.:"': I-IAN. :3c: .3E-ilt:'~l!l:tj-'~"'lA1,~"-:--IL:':_j l'ii/i~oo ~~"g~~4-~~-~-~~-~-~i~~. .~
141
liGHTS f-j.::lt! 9 103 58' 142
RELAY 6 I
Rl
Ill
I
--'z• - -- ' .: T SCHEMATIC*
L--..-J
VERTICAL FIREWAll/
*Ship S/N 2589 and subsequent; ships retrofitted CABIN BULKHEAD
Page 14.188 with fuseblock installed on aft side of left ver- Change 19: 30 JUN 99
tical firewall.
FIGURE 14-3 TACHOMETER & LOW RPM WARNING HORN SCHEMATIC

FIGURE 14-3A TACHOMETER & LOW RPM WARNING HORN SCHEMATIC (EARLIER SHIPS)

FIGURE 14-3B TACHOMETER & LOW RPM WARNING HORN SCHEMATIC (S/N 0002 THRU 0223)
OCT 2018 Chapter 14 Electrical and Avionics Systems Page 14.20A

Intentionally Blank
Page 14.20B Chapter 14 Electrical and Avionics Systems OCT 2018

14.600 ELECTRICAL SYSTEM SCHEMATICS (Cont'dl
359843009335~2-~
~-- 4TL-1 94
+12V DC I TOGGLE SWITCH
BUS BAR r-
1
r ------,
DISENGAGE 1 WARNING LIGHT
I I I 92
(YELLOW)
67 I
93
TO BATTERY 66 583 TO MASTER

RELAY RADIO RELAY
138 TO LANDING
TO TACH 28 113 LIGHTS
BUS BAR
-
95 r---
I
I : r---V-3--1-00_Z___ l
L __ CONSOLE
--
_j OVERTRAVEL
LIMIT SWITCH
....-----_j
139 96 L
,...--------'
98
r--- CONNECTOR
1 2 3
1 2 3 4
4
91 90 97 98
V3-1002
MICRO SWITCH
L V3-1002 V3-1002
~ MICRO SWITCH
---~
DOWN LIMIT
(SPRING SWITCH) SWITCH
~---- (SPRING SWITCH)
COLUMN COLUMN
I
SPRING SPRING
I
L __ 99
ACTUATOR ASSEMBLY
FIGURE 14-4 BELT TENSION ACTUATOR SCHEMATIC

(WITHOUT TEST PLUG; SHOWN FULLY
DISENGAGED)
Change 19: 30 JUN 99 Page 14.21
-u
Q)
-"
co +::-
('!) (j) D
:-'-......-: .......... ,
-" I ' ..__ cno
+:> TO LOW RPM A543 CONSOLE
I ()0
0
N
__. WARNING ELECTRICAL CONNECTOR Im m
UNIT m rm
:t> I ~ ()
-2
I :t> -l
631 1632
~ -l :JJ
- m
() ()
95 :t>
0
r 2
91 (J)
28 ...' I TO TACKBUS. I 94 '" -<

(J) ~
J h
I r--lr=ln - r r==lll_ll -l )>
: I I 96 m
=- ~
-
1.5 AMP FUSE
~ -
2
-1
91
m
90
2
)>
98
95
2
n
.------- --, m
EXTENSION I ~
6 LIMIT )>
66 I SWITCH :
~ ~
'-'+-'
t:,. NO 2
67 c
1/ I 100 139
r _j )>
_ rr., I'"'
A051
RED ( GEAR
,........ BELT TENSION f MOTOR
tl _i2tilI BLACK
ACTUATOR
rnl:;:ro
:z ....... rn """
rtMt 97
G) - t '
)::>:C-1 RETRACTION
G) 2 ~OC NC LIMIT SWITCH
rn -t -t
...__..(./'):z
orn rn ..,
~28 I ·11 ~ A NO
() It 98
:::r -t (./') I-I
I-I G)
72 :r~.' r-,
Q) t---'-<f 21.:~--"i 1355
::::l -u 0 c J.l..J
;o 1354 ~TEST*
co c' : z rn PLUG
('!) G) )::>
__. ~· n ,_..... .LlJ
1-..l
~
-t -+=> 91 c ;;,. 98 0
<.0 (./')C I
:c )::> -+=> D
0 -t )::> ~ cr 09
--~I I 99 ~ '6
qq .£ NC I
N~ ~ - - - v - -~ - I
w :;:o m
0 :z ;o NO A SPRING SWITCHES A NO -- __j I'"'
c.... -u ('"') ·--- --- D
)::> I-I
c ;o ;o IU
z -t ('"') IU
I-I c *If installed.
<.0 )::> I-I
<.0 '-t
'-<
Intentionally blank.
Change 19: 30 JUN 99 Page 14.218

14.600 (cont'd)
12 V. DC LIGHT BUS t------t
INSTRUMENT TRAINER
Terminal Block (After A/C 465)
4 Pin Connector (A/C S/N 416-465)
I
POSITION LIGHTS .,....._ _1;..;0;.;..7_ __,
Terminal Strip (A/C S/N 350-396) j
396 HORIZON IND.
1"+---- 351 NARCO 121
I
DIMMER
RHEOSTAT r l " ' - - - 354 KA 51
r--~1 353 KI525 A I
____ 35_0 K_T7_6A/_KT_78A_!
LIGHTING FOR
ELECTRIC CLOCK
A072
0..
INTERNAL RADIO LIGHTING
_.1 .......
c:::( 0:::
z: I-
l-l V')
In ::E
0::: 0:::
wo
1-
-l<
o::t
I
\.0
.---l
POST LIGHTS I•• "
.---l
t - - - - 1 t-\.O-o_ _ 1_24----+- LAMp COMMON ~---l!l,

r-----' GROUND 68
A617-l ENGINE
INSTRUMENTS
0...
_.1 1-1 CLUSTER
c:::( 0:::
z: I-
l-l V')
::E
0::: 0:::
wo
1-
-l<
o::t
I CONNECTOR *604101-1 Prior to 1/84.
\.0
.---l SPLICES
"0
.---l
\.0
CIRC. BRKR
PANEL POST LIGHT
Page 14.22 FIGURE 14-5 INSTRUMENT LIGHTING SCHEMATIC Issued 5/22/87

FIGURE 14-5A NIGHT LIGHTING SCHEMATIC

FIGURE 14-6 WIRING SCHEMATIC FOR SEARCHLIGHT
Page 14.23A Chapter 14 Electrical and Avionics Systems OCT 2018

FIGURE 14-6A PA SIREN WIRING SCHEMATIC
OCT 2018 Chapter 14 Electrical and Avionics Systems Page 14.23B

FIGURE 14-6B PA SIREN SYSTEM SCHEMATIC (WITH AUDIO CONTROL)
Page 14.23C Chapter 14 Electrical and Avionics Systems OCT 2018

FIGURE 14-6C PA SIREN SYSTEM SCHEMATIC (WITH KING KX 155 OR KY 197)
OCT 2018 Chapter 14 Electrical and Avionics Systems Page 14.23D

FIGURE 14-6D ATTITUDE GYRO AND DIRECTIONAL GYRO INSTALLATION
Page 14.23E Chapter 14 Electrical and Avionics Systems OCT 2018

FIGURE 14-6E ATTITUDE GYRO AND DIRECTIONAL GYRO INSTALLATION (EARLIER SHIPS)
OCT 2018 Chapter 14 Electrical and Avionics Systems Page 14.23F

FIGURE 14-6F GOVERNOR SYSTEM SCHEMATIC
Page 14.23G Chapter 14 Electrical and Avionics Systems OCT 2018

FIGURE 14-6G ELT REMOTE SWITCH WIRING SCHEMATIC
OCT 2018 Chapter 14 Electrical and Avionics Systems Page 14.23H

14.700 Antenna Locations

14.800 AVIONICS SCHEMATICS
Basic communications wiring common to all the COM radio configurations include: Pilot
and Co-Pilot cyclic stick switches (Transmit and Intercom), and an overhead COM box
housing Pilot and Co-Pilot headphone jacks and relays. The intercom system operates
through installed COM radio or audio selector panel.

--
AIRFRAME GROUND
1 4.800 (cont'd)
PILOT COPILOT JACK
HEADPHONE HEADPHONE - PLUG
PLUG r
~ .2r1-
I )
LY
1
0 T Y P . 2 PLC'S.
~
JACK
TYP. 2 PLC'S. r
'!. :2_1_ .,2 212-
[~~~~-- <:.• 227 7

L4·-s.---
3 1 ~ 12V .
BUS
D. c.
BAR I '"' 1 204
228 226 228
~ ~0 TERMINAL BLOCK
22 9 224 200
209 - "" 214 75
.
-~ 218 209
~
RELAY RELAY 221
Gl 223 ~
\ iJ' I "AJ 216 217 ~__.:x

206 206
225\ ~ 215 A 207--
I
222
'--'" I
219 I
I
2i5'
- ~~ ~ ~r
220 216 216
215
220 205
223
PILOT CYCLIC STICK COPILOT CYCLIC STICK

222
TRANSMIT INTERCOM TRANSMIT INTERCOM
S5101 0 SWITCH 223
r - fJ c. : - -
T
~' TYP. 4 PLACES
..__
~-
237
b. ~
~v;,l
231
232
1
219
I
2 ------1-- 2
1 221
FOOT
sw.
-283
238 233 3 I 3 239 201
234 4 I 4 l
235 5 I 5 ,--. ~ 211
236 6 I 6--- --'FOOT _
I
SW.
-284
HOUSING THESE WIRES COMMON
e@e
4
1
0
0
0
0
2
3
PIN 6 REQ.
HOUSING
SOCKET 6 REQ.
FOR ALL HELICOPTERS.
FOR DETAILS OF INDIVIDUAL
RADIO HOOK UPS, SEE
APPROPRIATE INS'L DWG.
FIGURE 14-8 INTERCOM SCHEMATIC

ROBINSON MAINTENANCE MANUAL MCOELR22
14.800 (cont'd)
CO-PILOT CYCLIC STICK PILOT CYCLIC STICK

-,-- -,-- -...- -.--
,s~L-a~o. ,Spa-J.....-.o~·o·
L------Jr-..
S51010L2W S51010L2W S51010L2W S51010L2W
SWITCH SWITCH SWITCH SWITCH
REMOVABLE
CYCLIC
GRIP
~
273 3: 3 277 277 1 : 1 221 . . . .
274 4 14 278 280 2 1 2 219
275 1I 1 279 I 281 3 I 3 2'39--t-
4 I 4 223 >· ~TO INTERCOM
276 2I 2 280 I 234 WIRING (SEE
/ : 235 5 I 5 211 FIG. 14-8)
TJ-120
JACK
.J \ A781-1
236 6 I 6 222
i
CONNECTOR
FIGURE 14-BA INTERCOM SCHEMATIC WITH

REMOVABLE CYCLIC GRIP
S51010L2W
SWITCH
163
162
I l
8121-1 S\HTCH TJ-120
I I_ 162
JACK
-...-
I I 1
I 163
I
,~"")> I 2 163
I I
I1 162 J I
-, LU
2-PIN
CONNECTOR
FIGURE 14-88 REMOTE CYCLIC SWITCH
WIRING DIAGRAM (R22 MARINER)
Change 11: 7 AUG 92 Page 14.26A

14.800 AVIONICS SCHEMATICS (cont d) 1
PILOT CO-PILOT ;--AIRFRAME GROUND

HEADPHONE HEADPHONE
U93A/U JACK
(Typ. 2 places) f
~ACK /
COM ANTENNA
~ ~ TJ-120 JACK 9J J LK 225395-1 PLUG ...

r~-l3- ~ ~(Typ. 2 places)
1 r ~ ~- 2_ r, 212
br3-z-
~r\- ~· 227 >~~-=- 4-=l
:1
tl• 12VDC D
TERMINAL BLOCK
204 ...
22 9
j(
AIRF RAME
228
224
226
218
223
209 '"tf 221
fr1)
1
!4 4J
200
209
It
GRO UNO __..>

217 _.>
rv • 216 ~ I 206 lf121 _C 206
225 '\ ~ ~~313:
--~ r-- ..........
:I 207
]I~
215
222 2~~IP
FW-1111-000
216 216
TO
RELAY 215 RADIOS
(Typ. 2 places) 220 r;ril 205
1
222 13 13
1 1
223 414
8300-2
8227-2 SWITCH
(Typ. 4 places) ---
1212'
221
~I
SWITCH
CO-PILOT CYCLIC STICK PILOT CYCLIC STICK HOT

-).--~\ MIC
605
604
. .JJ~ILP- ..sO:!LP '~~-~Cf.ILP-

'"' I
603 I
PTT
(Y/ cr MIC
v vv
219
1---
...._ / L--J\ ..____ 283
277 lrTlJ,.....J....-
S51010L2H
SWITCH 280 21 'z J 604 603
281 I 239 201
(Typ. 4
-
3 I 13
places) 234 41 I 14 _.J 605 -.t ~ M8805/55- 001
I 235 1
s 1 's ---="-/ 211 ~
SWITCH
273
274
G'3
4 14
277
278
236 6;
L, .L\ I16 - - - - ,
AIRFRAME -'
GROUND
284
C'-- N.O.
FOOT-OPERATED
INTERCOM
I
275 1I1 279
276 212 280 8263-19 HOUSING
/ L.1_ 8263-2 SOCKET (3 Req'd)
8263-4 SOCKET (3 Req'd)
TJ-120 I\ NOTE
JACK .__J A781-l THESE WIRES COMMON TO
CONNECTOR 8263-18 HOUSING ALL HELICOPTERS.
8263-1 PIN (6 Req'd)
FOR DETAILS OF INDIVID-
UAL RADIO HOOK-UPS,
@4@oo ~ ~ 0
FIGURE 14-SC
SEE APPROPRIATE INST'L
DRAWING.
1 3
INTERCOM SCHEMATIC WITH HOT MIC SWITCH
HEADPHONE
COM BOX JACK
_____......-

PILOT CO-PILOT
HEADPHONE HEADPHONE
0
:::;
Q)
::l
ll.ll\11'1./il"tl..
co GROUND
D
CD
N
_,. 'l~ ""- £\
BENDIX/KING
0
,......
NAT AAB0-020 (8338-1)
ICS CONTROL
'l~
,- , r , 05504-0000
212 KY 197A
COM TRANSCEIVER
m
(_ 1- j N M """ -1
225398-1 COM Yl
L.:'N ~,;;.,::'" (:=. ..J
c POWER IN
-
1
644
2.0
L
JACK ~h
~-:: - ANTENNA
~ ANTENNA
-2
z f-- 643 t ~,_I\ 228 ( 1-· tj\ 228
N POWER GND 14 'I•· <- ,...- m
1-- " 657 (BLUE) K INTERCOM AUDIO
0 COM MIC HI 2 L~225395-1 0
0 PLUG I--
f-- 1 I 656 (ORANGE) 7 SHIELD GND
0 COM AUDIO HI 3 I-- 2
1-- 1 I 655 (WHITE) 1358 REM INC
COM MIC KEY 15 L
I I--
1-- 685 I LIGHTING LO
COM AUDIO LO 16 u I--
s:
1-- 603.....---./ ~l 15 PWR GND J>
ICS KEY 25 ~
I I :~ f--
-19 604 601805-1 s -z
CO-PILOT X'MIT KEY '---
,...-- 605 TERMINAL ~~ 6 -1
PILOT X' MIT KEY 17 BLOCK 2~ I-- m
f-- fl 652 (BLUE) A059-201 F PWR GND
I
C.P. MIC HI 6 r-l t-- z
1- II 651 (WHITE) 267 11 SW POWER
C.P. AUDIO HI 7 AIRFRAME I--
J>
f-- , •
:L- '-~'
20 -._) GROUND M
C.P. MIC LO u FLOOR f--
zn
f-- r, 654 (BLUE) INTERCOM 12 VDC ~~ 13
PILOT MIC HI 4 BUS 2~ 1--- 1 m
1- II 653 (WHITE) BAR p SW POWER
PILOT AUDIO HI 5 1--- s:
f-- 14 POWER
PILOT MIC LO 18 l1 ....---- 2~ f-- J>
f-- ~ A059-200 R POWER
L.R. PASS MIC HI 10 I-- z
f-- 603 284 A059-204 B LIGHTING HI
L.R. PASS AUDIO HI 11 642 c
283 1---
f-- \ 939 12 REMOTE X'FER J>
L.R. PASS MIC LO 23 t-- r
f-- 239 r - 1 8 SHIELD GND
R.R. PASS MIC HI 8
1-- 1- t1 )~ 657 (BLUE) ~r ~
MIC HI
R.R. PASS AUDIO HI 9 656 (ORANGE) j 1 t--
f--
r-
IJ 1- v_~ 1/ H AUDIO HI
M <T
R.R. PASS MIC LO 21 ~ 1-r::. ~ 1-"'- ~R FREQUENCY CHANNEL 655 (WHITE) I I t--
SELECT SELECT 9 MIC KEY
EXT AUDIO HI ~ L ·- ,_- 1-- -I-' , ....1--
f--
EXT AUDIO LO 24
1--
~
1358
CO-PILOT CYCLIC STICK 1\ 938 PILOT CYCLIC STICK
TRANSMIT AND INTERCOM 939 ) TRANSMIT AND INTERCOM
938 s:
® @1- ®CDr-- FIGURE 14-80 0
rT, 236 D
6(D INTERCOM SCHEMATIC WITH
Q) 279
., .-k0 CD~- 275 I 11 I 279
co lCD CD NAT AAS0-020 (B338-l*) m
r
CD I® CD 276 : 2 I I 280 281
~
II
273 I 3: : 277 234
ICS CONTROL D
~
274 I 4 I I 278
( (Ship S/N 2967 and on) ro
N ........... 235
ro
(j)
0 236 *RHC part no.
278
14.800 AVIONICS SCHEMATICS (cont'd)

PILOT'S HEADPHONE CO-PILOT'S HEADPHONE
8263-15 HOUSING
8263-2 SOCKET(3 req.) 8263-35
HOUSING
B263-2
STICK SIDE SOCKET
B263-19 OF CONNECTOR (3 req.)
CONNECTOR r,_ _ __,A'---....,.,
542 543 544 545
193
TO
DUAL 195
AUDIO 542
CONTROL
UNIT 543
544
545
239
AIRFRAME
_ GROUND FIGURE 14-8E
• (A365-1 ANGLE)
DUAL AUDIO CONTROL INTERCOM SCHEMATIC
(For R22s with AIR COMM ACS 300*
Dual Audio Control)
*RHC part no. A692-3.

PILOT 1 S HEADPHONE CO-PILOT 1 S HEADPHONE
U93A/U
PLUG
!,lrJ-!20\
-1 / ""1
JACK
2 4
1~ L2
STICK SIDE
B263-19 OF CONNECTOR
CONNECTOR r,---..JA'----..,
II) 0.0
M M
N C\J
FOOT
S~HTCH
654 653 652 651
685
TO
DUAL 605
AUDIO 954 (BLUE)
CONTROL
UNIT 653 (WHITE)
652 (BLUE)
651 (WHITE)
239
AIRFRAME
GROUND FIGURE 14-BF
(A365-l ANGLE)
- DUAL AUDIO CONTROL INTERCOM SCHEMATIC
(For R22s with AIR COMM ACS 300* Dual
Audio Control with NAT AAB0-020** ICS
Control; Ship S/N 2967 and on.)
*RHC part no. A692-3.

Change 21: JUN 2000 **RHC part no. 8338-1. Page 14.26E
211
+14VDC ..--~2;.:;.;
06::;._ (TO COM BOX)
MIC HI
XMIT KEY
207 (TO COM BOX)
--A687--,
7
B263-19 HOUSING
ICS KEY PA/SIREN I
CONTROLLER I
HD PH AUDIO
GROUND -;;.:-1;- ~;-·1
CO-PILOT HEADSET
___ __ J
COM MIG HI
COM KEY
COM AUDIO ... H
'I_-
9 KX 155/165 NAX/COM
.::!2A~C~~-
"'-- KX 155/165
INPUT 1 MIG HI
KEY
1 ---- }
...__,....,...__--i~-P-: UNIT NO. 1
AUDIO KY 197A
INPUT 2 MIG
KEY 1--~---T-~ I_,.l_____ } UNIT NO. 2
AUDIO
INPUT 3 MIG
KEY
AUDIO
l----1r-t------l~-~"'-: ---- } UNIT NO. 3
PA MIG 420 }
PA KEY 1--~1+-_4:.::.2.:..1- - - - - - - PA/SIREN CONTROL
HOT ICS KEY

LITE DIM 186
1----___.;;..;;..;;..._ _ _ JUMPER TO 204 WIRE
187 (IN BACK OF RADIOS)
PWR GND
FIGURE 14-BG
SINGLE AUDIO CONTROL SCHEMATIC
AIR COMM ACS 775 SL (A692-2*)
(Ship S/N 2967 and on)
*RHC part no.
Page 14.26F Change 21: JUN 2000

AIR COMM ACS 775 SL

( A692 -2*) NAT AAS0-020 (8338-1*)
SINGLE AUDIO CONTROL 2 ICS CONTROL
+14VDC
1--
1
950 I 644
,...---
1--
1 POWER IN
.... ,
..-
1-- 952 (BLUE)
MIC HI 2 I
XMIT KEY
1--
3 I
I
.
I 954 (WHITE) 1 1--
2 COM MIC HI
1-- 1--
res KEY 4
I I II
I
3 COM AUDIO HI
I II
HD PH AUDIO
1--
5 I
....
I 953 (ORANGE) r 1--
15 COM MIC KEY
GROUND
1--
6 L 1--
16 COM AUDIO LO
- I....-
-
COM MIC HI
-7 i\ 657 - J 2 BENDIX/KING
COM KEY
-8 ~ : 655
I I
I I
9 6
KY 197 COM TRANSCEIVER
OR
COM AUDIO
-9 \
l'
I
656
\_1
- H 9 KX 155/165 NAX/COM
- . ._I
INPUT 1 MIC HI
-
t--
f--
10
l
I
I
,.
I
I
I
I
1
I
I } UNIT NO. 1
~.:_~c::'~--
KX 155/165
KEY
AUDIO
f--
11
12 I, ·- KY 197A
INPUT 2 MIC
f--
f--
f--
13 II
I
I
~
I
I
I
I
I } UNIT NO. 2
KEY
t--
14
15
,r -
AUDIO
INPUT 3 MIC
t--
I--
f--
16
I
I I
I ~
I
KEY 17
I I } UNIT NO. 3
,_,
AUDIO
t--
18
,I
PA MIC
f--
1--
1--
19
I,l 420
421 ]. PA/SIREN CONTROL
PA KEY 20
1--
21
1--
1--
HOT ICS KEY 34 FIGURE 14-BH
1-- 186 JUMPER TO 204 WIRE
LITE DIM 36 (IN BACK OF RADIOS) SINGLE AUDIO CONTROL SCHEMATIC
1-- 951
PWR GND 37 AIR COMM ACS 775 SL (A692-2*)
1--
.1 with
NAT AAB0-020 (8338-1*) ICS
CONTROL
(Ship S/N 2967 and on)
*RHC part no.
Change 21: JUN 2000 Page 14.26G

N.A.T. DB-25S
INTERCOM INSTALLATION---..;-- - - - - - -1
AA12-004
SINGLE AUDIO CONTROL DB-25P I 11
1CS"
I
+14V DC Ll I
/ ~ I 2
I
POWER GROUND ~ ~ 'I
14~~~--------~~----------------------------------~~....
I 1
I
12V LIGHTING
LIGHT GND
f--lu
11
5 ,
267
204 JUMPER TO 204 WIRE AT
COI'.M OR TRANSPONDER
I 1
PILOT TX KEY
-171------------~~~----------------------------------~-
60 5
! PILOT TRANSMIT KEY
II
- ,-.. 654 (BLUE) ;
PILOT MIC HI
PILOT HEADSET AUDIO
+1----:H'------..::6~53:...(~.::iW:.!;Hl~T!;JE)_______________________________hl- } PILOT HEADSET I
P!LOT AUDIO LO iB__j' 1 I
~ II I
CO-PILOT TX KEY
.--
~
,-.. 652 (BLUE)
604
I CO-PILOT TRANSMIT KEY I
CO-PILOT MIC HI
+l---f-1:------..::6::!.!51:....l!:(W:.=:HI::!:T.!...E)------------------------------....:..,- - } CO-PILOT HEADSET I
CO- PILOT H/S AUD
CO-P !LOT /PAX AUD LO
~L_y· ,-------_j I
~ 422 I I 685
PILOT PTT
res KEY
f-
~
-
603 :
l-::::::::: I 603
CO-P !LOT PTT
L ____________ _
, • 7
PA KEY
- ..... 421 (WHITE) X - 11
ACS-836
~II 420 (BLUE) I j -
PA CONTROL HEAD
(OPTIONAL)
PA MIC HI
PA MIC LO
~' .... .~
-
19~ Lf L~~------------~
COMM 3 KEY ~ II ,------~
COMM 3 MIC HI ..!. I I I I
COMM 3 RECEIVER
9~r-----------------------------~'~--
21 _)~ I
COMM 3 LO
- I OPTIONAL
TRANSCEIVERS
I
COMM 2 KEY
f--
22 , .... I I
COMM 2 MIC HI ~II I I
: I
f-- I
*~ ~ ~i _______ _j
COMM 2 RECEIVER
COMM 2 LO
~ ::
COMM 1 KEY
r-- " - 655 (WHITE) ("\ r~~~~,-------------------~
9 6
24
f-- 1
j 657 (BLUE)
12 ~---J..------=~:::::.=.!....--
I I f- f--
____________________--t-+--1 J 2
KY 197A COMM TRANSCEIVER
or
COMM 1 MIC HI
COMM 1 RECEIVER
~~ 656 (ORANGE) ~{_~~>KX
155 NAX/COMM TRANSCEIVER
COMM 1 LO
~ ~~ FOR KX 155 NAV/COMM;
.----1 L OMIT "246" JUMPER WIRE
f-- ,..,. 684 (WITH KX 155 ONLY) .l. -- IF INSTALLED.
NAV RECEIVER HI 4 ! -.......- .... ~ 10
NAV RECEIVER LO ~~ ~~------------------J
f-- ,.... ,--------,
ADF RECEIVER HI
ADF RECEIVER LO fsLT'
2 ,....
l
I OPTIONAL
I
I
MARKER RECEIVER HI
- _r II RECEIVERS I
DME/MARKER LO
~---;._ I I
DME RECEIVER HI 1 ~
......__ _ _ _ ___.___, FIGURE 14-81 L _ - - - - - _)
NAT AA12-004 SINGLE AUDIO CONTROL SCHEMATIC

Page 14.26H (Ship S/N 2967 and on) Change 21: JUN 2000

AIR COMM ACS 300 CA692-3*)
DUAL AUDIO CONTROL
- 189
+14 VDC 1 ~----~~------~ 5
21-!';..·-,..~5~4~5----;~:;::====::;.,
CO-PILOT MJC HI
CO-PILOT XMIT KEY
- 13 .,___!_1___;1;.;.9.;;.1_ _--1 2
BASE OF
I-
t
r-r• ~
I 2I
I 1
I
I
3
4 - -,
TJ-120 JACK I
I
CO-PILOT ICS KEY 41---__:1;.;.9.;;.,0_ _---i~ CYCLIC ! 1
1 1I I 2 I
CO-PILOT AUDIO
7
--
1 j 544 (BLUE)
>;l~T /
/'----' l'i' 1 3 !
:.. . J....J
1 ........... l
------
(CO-PILOT HEADSET): I
8263-19 HOUSING
-
6
,. ·, 543 (WHITE) "-
,.. r-r.,
228 . . - . - - - - - - - ,
~ 4
I
PILOT MIC HI
PILOT XMIT KEY
- ! ! 195
7 1-----':.=----t 6
' 1-"' 121 I
~Ck-.f.-.!;.-1-44--1 3
....... TJ-120 JACK I
I
7..,____!.;19:.;:3_ _~r-;- 0
Bt/iL r( I j l '"2 I
'---------..J flt
I : 1
PILOT ICS KEY
PILOT AUDIO g: ~~!
i-- 6161-2
542 (BLUE) J3: ! 1........._ ~
l-.&...-'
(PILOT HEADSET) :
- - - - - _,
I
i - SPLICE J 117 A687
COM MIC HI
COM KEY
~
ll
( :
I
206
207
r I
1 1
,I L.7 .__c_6_~~-~-6~-~-~R__. r-r...._J-+-2-4
I _
-BEND-IX/_K_IN;- - :
KY 197A COM TRANSCEIVER I
COM AUDIO
= 'I
-
12
'-'
, 209
'-'
-
J. }
9 6
H 9
L-,_
OR
KX 155/165 NAV/COI4 I
_!R~s~I~~ _ J
~~~==::::~~~~~~~:~:a...:~~~~~~~~-
INPUT 1 MIC
UNIT NO. 1 ""--- KX 155/165
KEY
- I, ·-
AUDIO
- I 15~--~----------
:= =~:-: 1·= = = ~ =~=!

KY 197 A
INPUT 2 14IC
KEY
AUDIO :: =========) UNIT NO. 2
INPUT 3 MIC
KEY ,_,
AUDIO
PA MIC HI 22r--~-4~2;.;.0_ _ _ _ _ _ _ }
i-- 421 Jl PA/SIREN CONTROL
PA KEY ~...._-lf~~~~~--------
SHIELD GND 24
-
- FIGURE 14-BJ
LITE DIM
-36 1------ JUMPER TO 204 WIRE AIR COMM ASC 300 (A692-3*)
PWR GND -;;- (IN BACK OF RADIOS) DUAL AUDIO CONTROL SCHEMATIC
'-----_____.- _j_ *RHC part no.
Change 21 : JUN 2000 Page 14.261

AIR COMM ACS 300 (A692-3*)

DUAL AUDIO CONTROL
+14 VDC ----

-
1
,-,
644
- 5
---,
CO-PILOT MIC HI 2 652 (WHITE) r-r,~ 4
CO-PILOT XMIT KEY
-3 I
! 604 2 I- 1 2l I 1--
3
TJ-120 JA CK I
I
CO-PILOT ICS KEY
-4 603 !"""--
BASE OF
CYCLIC ~ i : 1; ; ~
2 (CO-PILOT HE ADSET):
1-- . 651 (BLUE)
1
1f I 'j' I 3! I ........... r--
,·r
I I
CO-PILOT AUDIO 5 1 I
1-- / -..!.....J ~'------
B263-21 HOUSING
1--- .., 654 (WHITE) 228 ~r--- -- ---,
PILOT MIC HI 6
1-- ! I "' ':BASE OF I , ... r- r- .., r--'-'- 4
I 2I I ~ TJ-120 JA CK I
PILOT XMIT KEY 7 605 6 3 I
PILOT ICS KEY
1--
8 685 -4 CYCLIC Jl:d i 2
~
(PILOT HEA DSET) :
PILOT AUDIO
~
9
.--. j j 653 (BLUE) llr ,3: ! . . . . . . ~1 I
~
L-1~'
8161-~,1 A687
L-.L.~
--- ----~
COM MIC HI
f--
10
SPLICE
' 657 - ~ PA/SIREN J 2
---- ---,
BENDIX/KING
COM KEY
~
11
:
,_,
I 655
I
I
I
I I CONTROLLER
I;= 9 6
KY 197ACOM TRANS CEIVER:
OR
.-...
~ '-' I
COM AUDIO 12 ,- 656 KX 155/165 NAV /COM jl
\ H 9
-~T~N~E.!_I!E R .
I
~
INPUT 1 MIC
-13 1
f-- I
I
I
I
I I
} UNIT NO. 1
KX 155/165
I I
KEY 14
f-- I, ·-
AUDIO
INPUT 2 MIC
~
~
15
16 ! I
I
r
.,
~
I
I
I.
I
I } UNIT NO. 2
KY 197A
KEY
AUDIO
17
1---
18
,I, ·-
INPUT 3 MIC
1--
~
19
1 1
,_.:
~
1--- I I
I I } UNIT NO. 3
KEY 20
AUDIO
f--
21
,I
PA MIC HI
1---
~
22
1---
IX 420
421 } PA/SIREN CONTROl
PA KEY 23
SHIELD GND
1---
24 l
1--
1---
LITE DIM
1---
36 186
JUMPER TO 204 WIRE
FIGURE 14-BK
1-- 643 (IN BACK OF RADIOS)
PWR GND 37 AIR COMM ACS 300 (A692-3* )
1--
j_ DUAL AUDIO CONTROL SCHEMAT IC
(For R22s w1th NAT AAB0-020 [8338-1*]
ICS Control: Ship S/N 2967 and on.)
*RHC part no.

Page 14.26J Change 21: JUN 2000
()
:::1" .......... _.. _
Q) ·------ -----·- Yl
:J
INTERCOM
JJ
(C
(1) ~ 0
[I§= TJ·120 1
N ~ ~ JACK
~ £? y ....-
N ~..,.""l": ..,.~ 12VDC K INTERCOM AUDIO m
TO BOSE f--
HEADSETS
~..,. ""~
v ----.....: . . , &.; ..,. "" .... ~ BUS BAR
7 SHIELD GROUND -
r1492 ct: >< > c ><~: > r-, 1358 2
REM INC
s::)> ,.-, I~ I 7.5
-L
:0 B338-1 ~lr;:k:.ll=. 8.:;:;.:;:;8 L-J -1 LIGHTING LO m
ICS CONTROL
N ~3~~~~
= ~~~~
-~~- 267 ls POWER GROUND 0
0 644 ::::,::: 1::: ~ e e ~ TERMINAL BLOCK
9 TO 32 VDC
0
~J7
f--
1 2.0 ~CX)I~i~
~~ ~ M~~lll
m~~~ 4 267 -s POWER GROUND
.J::>. POWER GROUND 14 643 'I•· ..... ..-tl~ ~ ~ ~ ~ ~ 267 I-- 2
1 6 POWER GROUND
RADIO MIC HI
f--
2
657 (BLUE l 201
·~~ I--
F POWER GROUND
1-- 656 (ORANGE) I--
RADIO AUDIO HI 3
il SW POWER
f-- II 655 (WHITE) r2!-
RADIO KEYLINE M SW POWER -~
~ I--
J "$" 267 13 SW POWER
RADIO AUDIO LO 16
,....-- AIRFRAME
ICS PTT 25
603 ..----..
685 GROUND
~~
267
f-p
f--
SW POWER
~z
1-- 604 .____. 14 POWER
CD·PILOT TX KEY 19 )>
1--
A059·200 -~ f--
605 R POWER z
PILOT TX KEY 17 I--
1--
---. .1. 1493 (WHITE)
A059·204 B LIGHTING HI n
PILOT H/S AUO 5 r- 939 I-- m
1-- 1494 CBLUEl 12 REMOTE X'FER
PILOT AUDIO LO 18 K ~ 1496 (BLUE) f--
8 SHIELD GROUND
1495 (WHITE) 657 .r- f--
PILOT MIC HI
-4 J MIC HI
X 1497 (WHITE) 656: : f--
1-" H AUDIO HI
CO·PILOT H/S AUD
-7
149B CBI UEl
1-- T 655 I I 1--
9 MIC KEY
~
CO·PILOT AUO LO 20 K X 1500 (BLUE)
1-- 1499 CWHITE) FLOOR :
INTERCOM I~1\ I ~
~
CO·PILOT MIC HI 6
r
f-- - r
r~
r1 FIGURE 14-~8L
283 :z~
PAX #1 MIC LO - INTERCOM SCHI MATIC
-21 284
239 NAT AAS0-020 (I 338-1 *)
-642 l 162 ICS CONTR OL
TO REMOTE
l 0 0 TRANSMIT SWITCH WITH PROVI~ ION
\0 \0
""1/..,.1/ 1/m I(
.- ,__ r-;; -~-
FOR BOSE HEA DSETS
N
....: i-.!:' 1- ~ 1-'2. ~~ FREQUENCY CHANNEL
I SELECT SELECT PILOT CYCLIC STICK (SHIP S/N 3273 nd on)
cO·PILOT CYCLIC STICK L. ~- --- TRANSMIT
~
TRANSMIT AND (*RHC part 1 o.) 0
AND
8263·21 ~ INTERCOM 938 c
-c INTERCOM
Q) 0®~ m
(C <D® 1- r
(1)
235 938 236
r-- 27/1'1 279 6@ II
_. 939
.J::>. I I 279 ro
276121 I 280
f@® - I
I® CD 236
®CD ro
N I 27313 I : m 281
(J') 234
7\ 1 1
274 4 I 278
.......... I 278
INTENTIONALLY BLANK
Page 14.26L Change 22: MAR 2004

14.800 (cont'd) KING KY 197 COM TRANSCEIVER

KING KY 197A COM TRANSCEIVER~~
269 "" ~ k--- --,
#269 WIRE HOOK-UP
TO NAV UN IT· PIN 2
IF KING KN53 INSTALL-
J TO AUDIO ADF 272
209
- - -- - - -
(IF INSTALLED)
H B
7 2
PHONES I
I
ED, PIN 36 IF NARCO
NAV 121 IS INSTALLED
206 r' J c MIKE AUDIO I
211
K 0 INTERCOM AUDIO I
207
9 4 MIKE KEY
COt~MON SHIELD~
\~ITH MIKE AUDIO
3
TO CONSOLE LIGHTS ___.: . .;57...:1:..___ _ _-1

TERMINAL BLOCK
200 POWER
K
(SEE FIG. 14-8
FOR WIRING INST'L) 9 POWER
205
J SW POWER
8
KING KY197
COM TRANSCEIVER F
POLARIZING KEY CONNECTORS
~"'""""" 6 SW POWER
lo==:::#llol l2l456789l0
201
A POWER GROUND
KING KY 197 COM TRANSCEIVER
1
POLARIZING KEY L
~
"' B C ~
IoII ?:QDD::~:::# II oI
E F~H J K l M fl P R S
10 POWER GROUND
l Z l 4 5 6 7 8 9 lO ll lZ ll l4 lS
KING KY 197A COM TRANSCEIVER KING KY 197

212 COM TRANSCEIVER
FRONT VIEW-CONNECTORS
(LOOKING IN FROM FRONT OF RACK)
COM ANTENNA
_ _ _ _ _J
FIGURE 14-9 KING KY197/197A COM TRANSCEIVER

KING KY 92
14.800 (cont'd) 212 COt~
---,I
TRANSCEIVER
corv1 ANTENNA
I
I
TYPE 247E-4n-5~6 SPEAKER I
10-WATT RESISTOR
GROUND I
I
XMIT KEY
I
I
I
204
LIGHTS I
211
MIKE AUDIO l
207
206 I
XMIT AUDIO I
200
SEE FIG. 14-8 POWER I
FOR WIRING INS'L POWER I
201
GROUND I
HOOK UP TO PIN 2 GROUND I
WHEN KING KN 53 IS
INSTALLED, PIN 36 -~,._-
269 AUX. 500 ~ I
WHEN NARCO NAV121
---..::..=..:~--+-------,;:~
209
AUDIO I
IS INSTALLED. PHONES
PREAMP OUT
I
205
AUDIO IN I
SW POWER I
SW POWER I
I
202
SW POWER I
SW POWER
I
I
GROUND
FRONT VIEH - CONNECTOR
I
I
___ _j
FIGURE 14-10 KING KY92 COM TRANSCEIVER
14.800 (cont'd)
P401
r-----
I DATA BUS
,-, 435
' ,
,.I,
I CLOCK BUS 436
,I,
' 1
437 TO DME INST'L
I NAV REQUEST
'
(IF INSTALLED}
438
I COMMON
I 267
I COM AUDIO HI , ' 209 TO A060 WIRING

,'x'\ 272 (ADF INST'L)
I NAV AUDIO HI
267
' I 269 (KN 53 INST'L
I COM AUDIO LO
NAV AUDIO LO
I COM MIC AUDIO
267 , \ 206
I I
I
I
I 207
COM MIC KEY \ I
,"r, 211
INTERCOM MIC \ I
POWER IN 200 TO A060 WIRING

POWER IN A448-4
AVIONICS
267 BUS Bft.R
REF.
A/C GROUND
A/C GROUND 201
SH POHER OUT 205

SW POWER IN
SW POWER IN
SW POWER OUT 556
TO VOR INDICATOR
ILS ENERGIZE 252
VOR/LOC OUT 251
r 240
TO NAV ANTENNA
I NAV ANT REAR CONNECTOR
I (VIE\4ED FROM FRONT
212 OF UNIT)
I TO COt1
ANTENNA PBOl 0 POLARIZING KEY
(TxlTO
I COM ANT
L_ _ _ _ P401
FIGURE 14-lOA KING KX155 VHF NAV COM TRANSCEIVER
Change 9: 5 JUL 90 Page 14.28A

Page 14.28B Change 9: 5 JUL 90

14.800 (cont'd)
212 REF.
211 REF.
n-----t ANTENNA
.....__ ____, CONNECT .
i
1
~ GROUND SHIELDS OF
WI RES 209 & 211 206 REF. .-'\ I
TO PIN #2 OF RADIO. I J401B I
209 REF. I I I
SEE FIG. 14-8 I
FOR WIRING INST' L. I
I
15
I
I
200 REF. I4 VDC INPUT I
205 Ref.
SW.A+ OUT I
I
204 REF.
I
r-
0
0
LIGHTS I
z"
i
C>
<
J401A I
..,
:II
1"1
~
I
i I
21 o-~e 1. SK.n
I
~z 8
... zz NAV HOOK-UP:
269 REF. I
~ ~ HOOK UP TO - I
: g PIN 2 ON KING COMMON SHIELD ~
g KN 53 OR PIN . \liTH MIKE AUDIO ~ I
36 ON NARCO I
NAV 121.
207 REF .I I
MIKE KEY
\ I
PHONES I
I
GROUND
I
201 REF. GROUND I
I
*Installed in Earlier _ _ _ _j
Ship S/N.
NARCO 120
FIGURE 14-11 NARCO COM 120 TRANSCEIVER COM TRANSCEIVER

14.800 (cont'd)
271 * or 527 ---,

- oc
-.........
....., oO
00
0
N
=
=
AIR FRAME GROUND REF.
UNIT GROUND THRU
/~
.,• ......
oOJ REAR SUPPORT STUD
log ......
... o• ..........
oD lo PILOT LT .
- ••oo
GO
o• .......
~ GROUND
---...... ao0 ......."'-...

CD
c N
c 268*
or
-....-... loa
Oa ........,
Oo ..,..,
267
-... •a oo ..,...
--... ooo• ............
~
~
CD
PILOT LT.
~- •0 268*
GROUND
or
267
FRONT VIE~-CONNECTOR AVIONICS
(LOOKING IN FROM BUS POWER OUT
FRONT OF UNIT) A448-4
270* or 526
Pm1ER OUT
PILOT LT.
INPUT
WIRE #243/269 COM HOOK-UP
COM UNIT CORE PIN SHIELD PIN
King Ky 92 243** or 269 J
J 5 .. ,-)
500!"~ AUDIO
King KY 197
King KX 155/
B 2
I
KX 165 9(P401) K(P401)
Narco Com 120 7 2 I
Narco Com 810 3 7
I
242** TO NAV ANTENNA
or TRIPLEXER/DIPLEXER
NAV ANTENNA I
with DUAL NAV (-2 inst'l) - - · _ _j
NARCO NAV 121
*Installed in earlier Ship S/N's.

**10-Hole Upper Console
Page 14.30 FIGURE 14-12 NARCO NAV 121 Issued 5/22/87

RCBINSCN MAINTENANCE MANUAL MCCEL R22
14.800 (cont'd)
FRONT VIEW - CONNECTOR
(LOOKING IN FROM FRONT OF RACK l
POLARIZING
~
KEY
S R P N ML K J ~ F E 0 C B A
252
ILS ENERGIZE
251 COMPOSITE
COf~POSITE
COMMON
WIRE #269 COM HOOK-UP
COM UNIT PIN
King KY 92 J
King KY 197 B
King KX 155/
KX 165 10(P401) AUDIO COMMON
Narco Com 120 7
Narco Com 810 3
254
SWITCHED +A
TO 12 VDC
BUS BAR (#214)*
OR Pm~ER
TO MASTER
RADIO RELAY (#176) A448-4 POWER
BUS BAR Pm~ER GROUND
FOR VOR INDICATOR 253.lf..lf.
HOOK-UP SEE POWER GROUND I
FIG. 14-18 &19 AIRFRAME I
GROUND 271 *REF.
FOR COM TRANSCEIVER or
HOOK-UP SEE
FIG. 14-8&10
=
- 527 ,.------f
P531 NAV ANTENNA
I
I
I
=... I
'------'-- - - _j
KING KN53 NAV RECEIVER
*Installed in Earlier Ship S/Ns.
See Page 14.14-15
,.,.Wire #253 excluded after 3-86.
FIGURE 14-13 KING KN53 NAV RECEIVER

14.800 (cont'd)
465
GROUND
466
12 VDC POWER
A448-1 BUS BAR
468
ANTENNA
APOLLO I, I I A-16 ANTENNA

LORAN C
RECEIVER
FRONT VIEW CONNECTOR

(LOOKING FROM REAR OF UNIT)
FIGURE 14-14 APOLLO I, II LORAN C RECEIVER

RCBINSCN MAINTENANCE MANUAL . MOOELR22
14.800 (cont'd)
-----,
AIRFIW1E I
260
GROUND ...
=
I
262* or 204 I
261 I
601805-1 TERMINAL BLOCK
I
I
I
I
TO 12VDC
263
I
BUS BAR (#214)*
OR
TO MASTER
\ 214* or 176 I
A448-4 BUS BAR I
RADIO RELAY (#176)
I
I
I
I
I
I
264 I
I
225395-1 PLUG
A015-18 PANEL KING KT78A I
TRANSPONDER I
___ _j
266 KA60 ANTENNA
POLARIZING
~
KEY
MM L K J H F E D C B A

*Installed in Earlier Ship S/N's

See Page 14.14-15
FIGURE 14-15 KING KT76A/78A TRANSPONDER

ROBINSON MAINTENANCE MANUAL MODEL R_22
14.800 (cont'd)
AIRFRAME~
GROUND
601805-1
TERMINAL
BLOCK 6
TO MASTER 17 6 564
RADIO RELAY - --_,....
A448-4 557
BUS BAR
566
563
560
559
565
562
KING KT76A
TRANSPONDER K 558 3
/LJ
B241-1
WIRE HARNESS /8240-1
BLIND ENCODER
~
87654321
@. oo•••••o
••••••• @
NMLKJHFEOCBA
15 \4 13 l2 ll lO 9
KT76A TRANSPONDER B240-l BLIND ENCODER

FRONT VIEW-CONNECTOR FRONT VIEW-CONNECTOR
FIGURE 14-16 D120-P2-T BLIND ENCODER/DIGITIZER

ROBI·NSON MAINTENANCE MANUAL MCCELR22
14.800 (cont'd)
AI RFR!-If'1E GROUrm
---,I
== 260
~------------------_,
I
261 I
I
262 I
601805-1 TERMINAL BLOCK I
I
I
TO 12 VDC 263 I
BUS BAR (#214)* 214* or 176
OR A448-4 BUS BAR REF.
TO MASTER
RADIO RELAY (#176)
(LOOKING IN FROM FRONT OF RACK l
l~lJVVlJlJUUUVlJU • ..a)
18 17 16 15 14 13 12 1110 9 8 7 6 5 4 3 2 1
© ANT.
264
~ 225395-1 PLUG NARCO AT 150
TRANSPONDER
~ ~ A704-l ANTENNA GROUND
266 - - AT150 ANTENNA ___ _j
*Installed in Earlier Ship S/Ns. See Page

14.14-15
FIGURE 14-17 NARCO AT 150 TRANSPONDER

14.800 (cont'd) FRONT VIEW - CONNECTOR

~
----1
80®0GOG080GBG1~ I
.. GG®®@GGG0@8@1 o I
8@8@8®008888~ I
CONNECTOR PIN LOCATIONS I
B B GROUND
I
_, 256 I
I I
D D +1 4 VDC LTG. I
6018 05-1 TERMINAL BLOCK 255
E E GROUND I
I
I
I
252
K K I LS ENERGIZE
II
251
FOR NAV RECEIVER y y COMPOSITE I
HOOK-UP SEE
FIG. 14-13
253
v v GROUND I
254 / b b +14 VDC I
250
I
I
AIR FRAME GROUNDVzss
=~
KING KI 203 I
= vo R INDICATOR I
""
I
I
.___ ___ _j
FIGURE 14-18 KING KI 203 VOR INDICATOR

(Installed Prior to 1/87)


14.800 (cont'd)
(LOOKING IN FROM FRONT OF RACK I ----1
I
I
l
I
B B GROUND I
TO AVIONICS I
204
LIGHTING i~IRES-----------+--f 0 0 +14 VDC LTG. I
267
E E GROUND
I
KING KI 203
-- VOR INDICATOR
AIRFRAME
GROUND
_ _ _ _J
FIGURE 14-19 KING KI203 VOR INDICATOR

(Installed after 1/87)

14.800 (cont'd)
----, I
I
FOR AVIONICS PANEL INST'L.
I
204 (-2 INST'L)
(A805-2), JUMPER TO OTHER I
#204 AVIONICS LIGHTING WIRES.
OR OR , , ' 1--7+--7--4 +14V D.C. LTG.
I
1
FOR UPPER CONSOLE INST'L. .----.
1
259 ( -3 INSTIL) ,-"
c:1- - - - - - - - - - , 5 5 GROUND
I
(A805-3), CONNECT #259 L---~
WIRE TO 601716-4 LIGHT-
ING TERMINAL BLOCK. 601716-4 LIGHTING I
TERMINAL BLOCK
I
I
I
556 8 8 +14V D.C.
II
FOR NAV RECEIVER
HOOK-UP SEE
1 1 GROUND I
FIG. 14-13 251 2 2 VOR/LOC I
252 4 4 ILS ENERGIZE l
258 I
KING KI208 I
--- VOR INDICATOR I
I
I
___ _j
FRONT VIEW CONNECTOR

(LOOKING FROM INDICATOR)
FIGURE 14-20 KING KI 208 VOR INDICATOR

14.800 (cont'd)
KA44B ANTENNA
I rn- 8lADF RF INPUT --1
RECEIVER
I
I
{\ ANTENNA POWER (RED) I
LOOP ENABLE (GREEN)
32 HZ<~ 90°(BLACK) I
I
I I 32 HZ< 0° (YELLOW) I
I
I
I I
\..I GROUND (BLUE) \.,/
I
(CABLE __ _j
DRAIN WIRE)
2 CONNECTOR AS VIEWED FROM
FRONT
3
253
DC SIN OUT
254
I DC cos OUT 257
+4. 5V COM. OUT I
I DIMMER
INSTIL)
282
DIMMER I
I (- l
(-2 INST'L) I
GROUND
I 14V DC
I
I I
I
II I
AUDIO HIGH WIRE #272 COM HOOK-UP I
I GROUND COM UNIT PIN I
King KY 92 J
I King KY 197
King KX 155/
B I
I KX 165 9 (P401)
I
Narco Com 810 3
I Narco Com 120 7 I
_ _ _J
I 255
u ... z
I ••••• (j) :0: a:
I
AIRFRAME
GROUND (A363-1 REF.)
@
ere
al
••••
c. : :•
LIJ .., ~
-'e ....
L __ Note:
-1 is Lower Panel Inst'l.
L---
L----
314
311 IFR TRAINER ONLY.
ABCDEFHJKLMNPRS
I ••e:•c:::•~c•~•••\ o! -2 is Upper Panel Inst'l. L--.-- 313 SEE KING KCS 55
I0
tvv99v~v•••v••v•
1 2 3 4 56 7 8 910112 I 14 I
L....---
303 (HSI) SCHEMATIC.
11 13 15
CONNECTOR AS VIEWED FROM FIGURE 14-21 KING KR 87 ADF RECEIVER ' - - - - - 312 (-3 Inst'l.)
FRONT OF KR 87

*Installed in Earlier Ship S/N.
14.800 (cont'd)
RCR-650 ADF RECEIVER
r---
II
Pl
~----------~
251
--,
IND-650A ADF
INDICATOR
+COS BEARING l
1 + cos I
I 6 28V DIMMER I
I
I GROUND
252
8 GROUND
I
I POWER IN
214* or 102
TO 12 VDC
BUS
BAR
I
14VDC IN. I
-SIN BEARING I
253 A448- 2 BUS BAR
-SIN 2
254
-COS 4 -COS BEARING I
257
+SIN
601805-1 5 + SIN BEARING I
256
TERMINAL BLOCK
14V DIMMER
282
7 14V DIMMER I
271
GROUND
267
__ _j
28V DIMMER
=.. AIRFRAME *Installed in Earlier Ship S/Ns .
GROUND See Page 14.14-15
AF LOW
AF HIGH 269
ORTO PIN 7 COM 120)
ISENSE ANTENNA
I
I ANT-650A ANTENNA
I y LOOP
I
I X LOOP
I
L __ _j
AIRFRAME GROUND AT
GROUND AT TRAY STUD ..
= '=:= TACH POWER RELAY REF.
Page 14.40 FIGURE 14-22 COLLINS ADF-650A SYSTEM Issued 5/22/87

GPS 100 AVD -

GPS 150/150XL J \V
J
468 ANTENNA
ANTENNA
37
36
--
465
GROUND 26 15
466
POWER 25 14
24
~
I:IJ AVIONICS
BUS
FIGURE 14-22A
GARMIN GPS 100, 150, and 150XL
SCHEMATIC
Change 21: JUN 2000 Page 14.40A

14.800 AVIONICS SCHEMATICS (cont'd}

AIR COMM
ACS 775 SL (A692-2*)
SINGLE AUDIO CONTROL
COMM 2 KEY
COMM 2 MIC HI
COMM 2 AUDIO
GROUND
*RHC part no.

GARMIN
GNC 250XL GPS N.A.T.
or AA12-004
GNC 250 GPS/COM SINGLE AUDIO CONTROL
KEY 705 (WHITE)
COMM 2 KEY
MIC HI 707 (BLUE)
COMM 2 MIC HI
AUDIO HI 706 (ORANGE)
COMM 2 RCV'R
MIC LO COMM 2 LO
AUDIO LO
14V DC 466
14V DC
GROUND ,,.
GROUND
GPS ANT 468

212 GPS/COM ANTENNA
COMM ANT
FIGURE 14-228
GARMIN
GNC 250XL GPS and GNC 250 GPS/COM
SCHEMATIC

14.800 AVIONICS SCHEMATICS (cont'dl
BENDIX/KING
KLN 89/898 GPS
P891
(25 PIN)
LT 14V -25 1-------------~- JUMPER TO "204" WIRE
-
LT 28 V/LO ~ 267 I
A/C GROUND 14 ~267 \ 1 2 VDC BUS
~
~
gP892 PIN) ....---.(}',..,;c._ b

PWR MONITOR 18 267
11-33 VDC PWR Sg~./ 466 BENDIX/KING
KT70, KT76A, or KT76C
A/C GROUND 7o"~ 465 TRANSPONDER
"---
D4 21
Al
-221---~1~3~04~--------------~r::::::::::M A1
557* or 340** 7 -
-23~----_b13~0~5----~====================~
A2 K A2
558* or 333** /
24~----~13~0~6-----4~==================~
-
A4 J A4
559* or 336** / -
Bl 251----___..!1:.:?_3~07~---1--.!-I=========~_J E Bl
560* or 337** / -
82 ~~--_11~30~8~--+-~~================~ c 82
- 7 - 562* or 334**
B4 27~--_!13~0~9---~~~~~==========~_.J B 84
C1 -28~----~13~1~0-----+~~~-+============~
563* or 338** / -
D Cl
C2 -29~----_b13g1~1-----+~4-~-+~==========~
564* or 341** / -
I--
L
556* or 339** / "---
C2
C4 30~----_bl3~1£2____-+~4-~-+~+=========~ C4
565* or 335** / ~
r--- ._
--ANTENNA - -- r--r- NOTE:

WIRES .uo! THRU l1lZ_
USED ONLY WHEN TRANS-
PONDER IS USED WITH
ENCODING ALTIMETER OR
\V BLIND ENCODER.
468
T
ANTENNA TO *BLIND ENCODER OR

**ENCODING ALTIMETER
FIGURE 14-22C
BENDIX/KING KLN 89/898 GPS RECEIVER
SCHEMATIC
Change 21: JUN 2000 Page 14.40C

14.800 AVIONICS SCHEMATICS {cont'dl

BENDIX/KING
KLN 90 GPS
A.D. RCVR B
A.D. RCVR A
267
267
FIGURE 14-220
267 BENDIX/KING KLN 90 GPS RECEIVER
SCHEMATIC
\ 1 2 VDC BUS
.,..:..::..::..oi]
1-------+--if-----:.4=-68
f---
-----16 BENDIX/KING
KT70, KT76A, or KT76C
TRANSPONDER
04 41
r-- 1304 F===
Al 42 M A1
r-- 1305 557* or 340** / r--
A2 43 K A2
A4
-44 1306 558* or 333** / r--
J A4
~ 559* or 336** / r--
1307
B1 45 E Bl
r-- 560* or 337** / r--
1308
B2 46 c B2
B4
r--
47
1309 562* or 334** / -B B4
C1
f---
48 1310 563* or 338** / -D C1
r-- 1311 564* or 341** / -L
C2 49 C2
C4
f---
50
1312 556* or 339** / -
565* or 335** / ~ C4
NOTE:
/ t =--
WIRES .uQ1 THRU .uli T
USED ONLY WHEN TRANS-
PONDER IS USED WITH TO *BLIND ENCODER OR
ENCODING ALTIMETER OR **ENCODING ALTIMETER
BLIND ENCODER.
14.900 UPPER CONSOLE HARNESS PLUGS (STANDARD & HP)
CONNECTOR 1 CONNECTOR 2
PIN WIRE NO. PIN WIRE NO.
NO. NO.
1 A059-2 l Spare
2 A059-3 2 A039-104
3 3 A039-105
4 A059-5 4 A039-106
TOP VIEW 5 A059-6 5 A039-107
(PINS) 6 A059-9 6 Spare
7 A059-10 7 A059-163
8 A059-ll 8 A052-127
9 A059-12 9 A040-70
10 A059-13 10 A040-71
11 A059-15 11 A040-72
12 A059-16 12 A040-74
13 A059-17 13 A040-75
14 A059-18 14 A040-76
15 AOS9-19 15 A040-83
16 AOS9-31 16 A040-81
17 A059-34 17 A040-82
18 A059·128 18 -~040-80
19 A059-129 19 A040-84
20 AOS9-38 20 Spare
21 Spare 21 Spare
22 Spare 22 Spare
23 Spare 23 Spare
24 Spare 24 A053-89
25 Spare 25 *
26 Spare 26 A060-204
27 Spare 27 Spare
28 A059-52 28 Spare
29 A059 29 Spare
30 Spare 30 Spare
31 A059-58 31 Spare
\ 32
33
A059-167
A059-65
32
33
Spare
Spare
34 A059-164 34 Spare
35 A059-67 35 Spare
36 P..059-l66 36 Spare
37 37 Or Avionics
* INSTALL DRAIN WIRE OF THREE-CONDUCTOR

BOTTOM VIEW CABLE (WIRES -80,-81,-82) AT NOTED PIN.
(SOCKETS)
FIGURE 14-23 UPPER CONSOLE HARNESS PLUGS

Change 1: 9/25/87
Page 14.41
14.900 UPPER CONSOLE HARNESS PLUGS (ALPHA & SUBSEQUENT)
CONNECTOR 1 CONNECTOR 2
PIN WIRE NO. PIN WIRE NO.
NO. NO.
1 A059-2 1 A059-199
2 A059-3 2 A039-104
3 Spare 3 A039-105
4 A059-5 4 A039-106
TOP VIEW 5 A059-6 5 A039-107
(PINS) 6 A059-9 6 A059-101
7 A059-10 7 A059-163
8 A059-11 8 A052-127
9 A059-12 9 A040-70
10 A059-13 10 A040-71
11 A059-15 11 A040-72
12 A059-16 12 A040-74
13 A059-17 13 A040-75
14 A059-18 14 A040-76
15 A059-19 15 A040-83
16 A059-31 16 A040-81
17 A059-34 17 A040-82
18 A059-128 18 A040-80
19 A059-129 19 A040-84
20 A059-38 20 Spare
21 Spare 21 Spare
22 8043-416 22 Spare
23 A059-513 23 Spare
24 Spare 24 Spare
25 Spare 25 *
26 Spare 26 A060-204
27 Spare 27 A059-28
28 A059-52 28 A059-66
29 Spare 29 A059-67
30 Spare 30 A053-90
31 A059-58 31 A053-91
32 Spare 32 A053-94
33 A059-65 33 A053-95
34 A059-164 34 Spare
35 Spare 35 A039-138
36 A059-166 36 Spare
37 Spare 37 Spare
* INSTALL DRAIN WIRE OF THREE-CONDUCTOR

BOTTOM VIEW CABLE (WIRES -80,-81,-82) AT NOTED PIN.
(SOCKETS)
FIGURE 14-23A UPPER CONSOLE HARNESS PLUGS
Page 14.42 Change 1: 9/25/87

14.1000 IFR TRAINER
14.1010 IFR Trainer Component Loads
Continuously-Powered Equipment: Max.

Amps Total
Power & Accessories Part Number ~ Each Amps
Battery relay 70-906 1 .7S .75
Alternator control VR418-l 1 4.0 4.0
Master radio relay W389CX-2 1 .13 .13
Night Lights
Anti-Collision light A470 1 3.2 3.2
Position lights A7Sl2/1777 3 2.2 6.6
Instrument lights 330 9 .08 .72
Instruments
Engine gage cluster A617/Bl44 1 .S0/.60 .S0/.60
Dual tachometer A792-.1 1 .10 .10
Hourmeter 773 1 .03 .03
Carb Air temp A604 1 .13 .13
Ammeter shunt MLS-60-100 1 .so .so
Digital OAT gage 310-2 1 .13 .13
Miscellaneous
Heater blower A643-l 1 7.S 7.S
TOTAL = 24.29
Complete Avionics Panel for Instrument Trainer

COM/NAV Receiver KX16S 1 .70 . 70
NAV Receiver NAV121 1 .87 .87
Transponder KT76A 1 1.80 1.80
ADF KR87 1 1.24 1.24
Horizon ref ind AIMSOO 1 1.80 1. 80
Marker beacon KR22 1 .so .so
Turn coordinator 303700 1 .so .so
Encoding altimeter KE127 1 .12 .12
HSI KIS2SA 1 .23 .23
Gyro KG102A 1 3.0 3.0
TOTAL= 10.76
Issued S/22/87 Page 14.43

14.1010 IFR Trainer Component Loads (cont'd)
Intermittently-Powered Equipment: Max

Amps Total
Starting Accessories Part Number ~ Each Amps
Starter relay SAZ4201E 1 4,5 4.5
Starting vibrator 10-176487-121 1 2.5 2.5
Starter motor MZ4224 1 150 150
Drive System
Belt tension actuator 5A505-3 1 1.2 1.2
Lights
Warning lights 330 8 .08 ,64
Landing lights 4509 2 7.7 15.4
Miscellaneous
Map light A-1425A-2-12 1 .58 *.58
Landing light relay MB-1380 1 .20 .20
Low RPM horn & relay 16004042-WlOlPCX 1 .35 .35
TOTAL =*16,18
Instrument Trainer Avionics

COM Transmitter KX165 1 *6 '8 *6. 8

14.1020 IFR Trainer Console Access
Pull circuit breakers on all gyro in-

struments and allow 5 minutes for gyro
run down to prevent gyro damage.
See R22 operator manual for caging in-
structions upon power application.
Remove (6) screws holding faceplate

to console and carefully pull faceplate
and instruments forward.
With cyclic full aft, instrument

faceplate will now rotate to a horiz-
ontal position for access to back of
instruments.
\]
If console shell needs to be removed

for access, place support under face-
plate as shown.
Remove three ground plate screws from
each side of console.
Remove two allen head screws in nose
of console. Remove two screws from each
side of console.
Disconnect wiring from horn. horn rel-
ay,and low RPM unit attached to console
shell.
Carefully remove console shell.

-122 WIRE REF.
LIGHTING AND TERMINAL BLOCKS

ON AIRCRAFT S/N 465 AND PRIOR.
A/C S/N 465 AND ON USE ITEM 8.
SIMILAR POWER BUS CONNECTOR

FOR TURN C., MKR BKN., ALTIM.,
ALSO AT LOCATION A.
{!).Low RPM Horn Relay
0 Flux Transmitter
0 Diplexer {3 Connectors)
Triplexer (4 Connectors)
0 Low RPM Horn
0 Low Rpm Unit (!) (Left

Directional Gyro-Remote
Baggage Compartment)
0 Slave Control @ DME-Remote
{Left Baggage Compartment)
0 Ground Panel ~ Terminal Block, Gyro Ground Wires
0 Terminal Block, Lighting

(Used on A/C after S/N 465)
(§) Terminal Block, Audio
Page 14.46 FIGURE 14-24 IFR TRAINER COMPONENT LOCATION Issued 5/22/87
14.1040 IFR Trainer Avionics Schematics
TERMINAL BLOCK
rD~GROUND- A
344 /GYRO GROUND
399 REF. II•· A 344
I
I
LIGHTING COMMON c 398 llh
{GND THRU CLUTCH
SW POST 1 WHEN
ENGAGED) S/N 0416
c 398
345 .345
1 DC POWER B &ON. 8
I INT. LIGHTING 396

t----
I REVISED WIRING ON
L __ _ 601716-4 CONSOLE LIGHTS S/N 522 & On.
TERMINAL BLOCK
AIM 500 HORIZONTAL REFERENCE INDICAJOR
,--- DC POWER
346
POWER BUS CONNECTOR
C. BREAKER
(TURN C., MKR. BCN.,AL TIM.)
0+-=39;. ; ;9""""R..;.; ;E;. ;. .F____ Ill·'-'

1-
DC GROUND ~.__ _ _3._4_7_ _ _-ta
I TERMINAL BLOCK~ ·~
L __ _ GYRO GROUND (GND THRU CLUTCH SW POST 1
WHEN ENGAGED) A/C 416 AND LATER
ASTRONAUTICS 303700 TURN COORDINATOR
r---
210
1 MARKER ANT.
TERMINAL BLOCK, AUDIO
I (MKR. BCN., ADF, NAV 121, KX 155/165 & WIRE 209)
PHONES 244
POVJER 225
1----------; 2 C. BREAKER
rzo
I POWER GROUND (TURN C., MKR BCN,
1------------------lllt· AL TIM.)
L_---
KING KR 22 MARKER BEACON
Issued 5 I 22/87 FIGURE 14-25 IFR TRAINER AVIONICS Page 14.47

14.1040 (cont'd)
r--- - P901 TOP PLUG
1
I
r-4.
,...._ ,., 285 REF (CONNECT TO PIN H OF PLUG P401)
I VOR/LOC IN E
t--
,_
TO SHIELD OF WIRE 206 KI 525A

I P2 Pl
1-- 286
+ FROM 9 - T
r-- 287
+ TO - z
,...._
H
f .... \* 288
NAV + FLAG B
I I
- K
r-- I 289
I
NAV - FLAG 1 - F
GS + UP
-s \
,z \
I
290
E -
GS + DOWN
-T I
I
I
I 291
B -
t--
\ ,..'
292 J -
GS + FLAG u
r-- 267 293
I GS - FLAG R
1--- 294
- w
I &.. \
I CRS DEV +RT 5
I I
-
-b
~ 295
I CRS DEV +LT K
I
\iT
I
- v
1--
I OBS RES R I D) c I
I
·,
I
296
v -
r-- I 297
I
I OBS RES' R E) 10
1--- 'r'
y -
298
I OBS RES' R F) 3
1---
I
I
\
I -b -
L I I 299 e
OBS RES'R G) \ J - -
II OBS RES. R C)
1--
2
I J: \ 300 a
-
I I
1--
I I 301 X
OBS RES'R H) 11 -
I
\
- J
-
1--
212 REF.
_11:'
I COM ANT. H-I POLARIZING
OPTIONAL
YONI..OC CONII/GS/AUOIO-
L __ _ - P801
KEYS ~901 ~902(GS)
*This Shield Installed on Earlier Ship S/Ns.
REAR CONNECTOR PLATE ) - P 801

VIEWED FROM FRONT OF UNIT (TX)
(
~------~~--------~--~
P301 (NAV)
Page 14.48 FIGURE 14-26 KING KX 165 VHF NAV/COM TRANSCEIVER Issued 5/22/87
(TOP PLUG)
14.1040 (cont'd) P401

r---
BOTTOM PLUG 435
1 DATA BUS \ I
.:X:
436
I CLOCK BUS I \
437 (FOR USE W/ m~E)

I NAV. REQUEST \ I
438
I COMMON
..__GROUND SHIELD TO PIN 15
245
cm1 AUDIO HI
246 TERMINAL BLOCK, AUDIO
COM AUDIO LO
I NAV AUDIO HI
FROM SHIELD OF WIRE 288
I NAV AUDIO LO
206
I COM MIC AUDIO
I
I
I
\
I
I 207
CO~l MIC KEY \. J
211
I INTERCOM MIC SEE INTERCOM
200
I POWER IN
267 TO 10 AMP
SCHEMATIC FOR
WIRING INST'L
I POWER IN C. BREAKER ON
AVIONICS BUS
~----.. 320559 SPLICE REF.
I
A/C GROUND
201
A/C GROUND
205
I sw POWER OUT
I sw POWER OUT
I sw POWER IN
SW POWER IN
I (CONNECT FROM PIN E
285 , OF TOP PLUG P901)
I VOR/LOC OUT 1
'-" 242 TO NARCO
_ _ _ _ _..;;;,_;;;...__-&.NAV. 121
I 213 (A808-2)
I NAV ANT. AV571 TRIPLEXER USED WITH
DUAL NAV.
208
AV570 DIPLEXER USED WITH
I ONE NAV.
L~s _:T._ NAV.
ANTENNA
Change 1: 9/25/87 FIGURE 14-26A KING KX165 VHF NAV/COM TRANSCEIVER Page 14.49
14.1040 (cont'd)
INSTRUMENT LIGHTING
.-----.TERMINAL BLOCK
AIR-FRAME 142 (WIRES SUPPLIED
AlH-FRAME GIWUNU GROUND W/ L!GIIT)
(A365-l) (A974-1) LIGHT
260 POWER BUS CONNECTOR

IN~TRUMENTLIGHTING GROUND
TERM. BLOCK 204 (TURN C., MKR BCN ,AL TM.)
(A052) LIGHTS TURN C.
261 MKRBKH 343
GROUND DC POWER
341
340
339
338
337

336
(LOOKING IN FROM F'RONT OF' A&CK)
335
334
333
332
AVIONICS BUS
449
KEA 129
263 (FOR DME INST'L ONLY) ALTIMETER
HOOK UP TO PIN K OF KN63 DME (-3 INST'L)
264
KT 76A TRANSPONDER
KA60 ANT.
FIGURE 14-27 KING KT76A TRANSPONDER

WITH
KING KEA 129 ENCODING ALTIMETER

14.1040 (cont'd)
KX155/165
,--
1
KA 60 ANT. P601 P401 NAV/COM
....--r---
435
I
436
I
437
I
452
L--
RECEIVER
,-- KN 63 DME P632
I
I
I POWER
KDI 574
P5721 INDICATOR
I POWER
---,
I POWER GROUND I
I POWER GROUND I
I COMMON
I 439 ,,
NAV REQUEST
DATA BUS I "
I CLOCK BUS 440

I DME REQUEST 441 ,'..._...'
I GROUND 442
I
448 TO AUDIO
I AUDIO LOW ,_ . . 8300~TERMINAL
I AUDIO HIGH BLOCK 626
I SUPPRESSION 1-___:~-r--r-~~TO
_.., PIN 9 ON KT76A
443 (SEE A804)
ON
I 444 I
HOLD
I + 9.25 V.
445 I
I 446 I
I_~ 19 ·!:.._V_. __ _j
~
FRONT VIEW CONNECTOR 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
KJHFEDCBA
(LOOKING IN FROM RE-
CEIVER)
•••ooooooeeeooeoe
180 0 0 0 0 0 0 0 0 0 0 0 0 0 0 033
POLARIZING KEY ooooooeoooooooeoo
34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
FIGURE 14-28 KING KN63 DME KDI 574 CONNECTOR P574l/ J5741 PIN 5 KEYED
PIN VIEW OF MALE OR SOLDER CUP VIEW OF FE-
MALE CONNECTOR.
t-d 1-'
Ill P-
OQ
(I)
1-' D
1-'
P- PICTORIAL NAV DIRECTIONAL FLUX VHF NAV/COM 0~ [J
~ ADF INDICATOR IND. (HSI) GYRO XMTR HSI SLAVE TRANSCEIVER II
N KI 227-01 KI 525A KG 102A KMT 112 KA 51 KX 165 (;' -
TOP BOT. AorB WIRE FUNCTION p 901 g 2
I I
~ I
# n:. fD
I I
' ' 353 LIGHTING +14 VDC} TO LIGHTING e []
I I I I I
-n J.L ~67 LIGHTING +14 VDC TERMINAL BLOCK
....... ~ I I I I I
Gl 326 LIGHTING GROUND 2
c: ~ I I I I I
;o
m JL I I I I I
294 VOR/LOC DEV. +RT (CRS DEV. +RT)
295 VOR/LOC DEV. +LT (CRS DEV. +LT)
===$ 5
K ~
~ I I I )II
. p.
I
N
-
~
):::.
ffi
T
I
1 1
I I
I
I
I
287 + TO
286 + FROM
-z
HSI GYRO
...m
I I I I ~
;;<:: c¢J I I I I z
....... D I I 327 NAV. FLAG PWR +14 VDC __..5~0· I )II
:z 1 1
en z
IE I I I I 289 NAV - FLAG n
(/)
"'n K : : : : 288 NAV t FLAG -$ m
U1
U1 ~
):::. I
!tJ : : : : 348 NAV FLAG GROUND )II
-o I
.....
n rWl I I I 1
z
-1 W cp I 1 1 293 G. S. - FLAG c
0 )II
J 1 1 292 G.S. + FLAG
$! 1 ....
r- --fE
:z I1 E II II I 290 G. S. DEV. + UP
1
):::.
< I
tE
B I
I
I
I
291 G.S. DEV. + DOWN
(/) I I I I I
-<
(/) --v I
I
I
I
I
I
I
I
296 OBS RESOLVER (D)
--lE
-1 T 297 OBS RESOLVER (E)
m I I I I
3: ~ 298 OBS RESOLVER (F)
~ I I I I
~ I I I I
299 OBS RESOLVER (G)
~ I I I I
301 OBS RESOLVER (H) ~
I 300 OBS RESOLVER (C) 0
H ~ ~67 I I I I
(/) 2_ OHS RESOLVER (B) D
I I I I I
(/) I m
....
~ + + + + + i ~ ~ D
ft)
U1 CONT. ON NEXT PAGE ft)
N
N
(X)
........
--
H
CJ)
CJ)
CONTINUED FROM PREVIOUS PAGE 1--'
~
(!)
p. • T Y TERMINAL BLOCK, Y 1--'
..s::-. D
I
• •I • 00302 H~RO 3971• o c
I AVJ NI S BUS 0
Ln .e •5 .. o• _ I ~ PO\~ER INPUT +14 VDC I GYRO GROUND .s::-. 0
1 0
N I ~: 1 329 POWER INPUT GROUND -EL:Ql-REF 399
1 m
N (GND THRU CLUTCH SW
. I 1 n
00
~
F I 303 +15 UNREGULATED WHEN ENGAGED) 0
1
- -
:::1
-...,J
D I I I 304 UNREGULATED GROUND A/C 416 rt
z
--
t
AND LATE~ m
p..
-
.._,.
,....... 305 +5 VDC
0
G) 1----;__--~· 306 DIGITAL GROUND
c
----=-·- z
,;;o 307 +15 VDC REGULATED ~
........
)>
-t:- 308 SIGNAL GROUND
1
N 309 -15 VDC REGULATED
-z
1..0
OJ 310 KI 525A VALID
...m
A
z
....... 311 DRIVE MOTOR 1 )>
:z
(j) 312 DRIVE MOTOR 2 z
A 313 DRIVE MOTOR 3 n
n
(/)
m
314 DRIVE MOTOR 4
U1 ~
U1
)::o 315 SLAVING CONTROL TRANSFM'R (H) )>
"'0 316 SLAVING CONTROL TRANSFM'R (C) z
.......
n - 317 SLAVING CONTROL TRANSFM'R (Y)
-f
c)>
0 =---, 318 SLAVING CONTROL TRANSFM'R (X)
;;o r-
)::o 01-:319 SLAVING CONTROL TRANSFM'R (Z)
I
:z , SHIELDING GROUND
)::o {" PLUG 101 CONNECTOR
<
(/)
tl-• 320 FLUX DETECTOR EXCITAT'N HIGH
-<
(/)
~j 321 FLUX DETECTOR EXCITAT'N LOW
,3:-f
~
0
0
m
'"tl r-
Ill 354 + DC LIGHTING H1-EJ TERMINAL BLOCK,
()'Q D
(!)
riiDJ·
328 LIGHTING LO LIGHTING 1\J
~-
1--' 1\J
1 I
..s::-.
Ln
w I
14.1040 (cont'd)
KI 227-01 KI 525A KI 525A KG 102A

I
TOP BOT. I
I
I I I I
I
[!J1-----....._---...;ctJ 303 +15 UNREGULATED

I I
I
~
I
I I I
I
DRIVE MOTOR l
312 DRIVE MOTOR 2
DRIVE MOTOR 3
DRIVE MOTOR 4
__,_..,....__ 315
-;...~- 316
_.__'--..___ 320
-T-..--- 321
0
•c •A
•a
o, en
•£
OK eH
...
0~
•N el
eR •p
CONNECTOR
VIEWED FROM
REAR OF UNIT
FIGURE 14-30 KING KI 227-01 ADF INDICATOR

14.1040 (cont'd)
KI 525A KI 227-01 KG 102A KA. 51 KX 165
I I A" B p 901
I I I I I
I I
y 353 LIGHTING +14 VDC
N
1-- ~267 I I I LIGHTING +14 VDC
l
t
-=- I I I 326 LIGHTING GROUND I
L
f-- I I I 294 VOR/LOC DEV +RT (CRS DEV +RT)
.b. 5
-v I I I 295 VOR/LOC DEV +LT (CRS DEV +L T) ,_...-
K
I I I
S
287 + TO
~
zl
T -~~--~~~--------
~'--
~~~-----~~~~~~----------
286 + FROM
327 +14 VDC NAV FLAG POWER

$ I
I
289 NAV -FLAG
FK-~-----~-----~~~---------------~
. 288 NAV +FLAG
~--------~------------4---------~~~3~4~8~N~A~V~F~L~AG~G~RO~U~N~D______________
$
I
~~----~------------4-------------~~2_9~3-G~S-----F~L_AG~---------------------------
303 + 15 UNREGULATED
~ I
304 UNREGULATED GROUND
I
1---~ 305 +5 VDC
I
L:_f.:J 306 DIGITAL GROUND I
I I
I 307 +15 VDC REGULATED
I
308 SIGNAL GROUND
309 -15 VDC REGULATED
I
I
..... I
-co o•:z:o ......o .... 31e N• ... -.....
"'o -. •o a..
~~
0 •o "'o ..,o 2 o a:o ~o ><o '"o "o ""o eo ~o "'o 0 1010
>. ,......
(\j(\j
uo .... "'.z• .. o ·o -· .........o

1010
1-11-1
:>!::>!:
FIGURE 14-31A KI 525A PICTORAL NAV INDICATOR (TOP PLUG)

14.1040 (cont'd)
KI 525A KI 227-01 KG 102A KMT 112 KA 51 KX 165

BOTTOt~ AB p 901
( P- 2)
$ --~--------------------~
I
I I
292 GS - FLAG
I I 290 GS DEV + UP
E ~------------------------~~--------------------~ s- -
,........- I I 291 GS DEV + DOWN 1-
B ~------------------------------------------------~ T
I I
I I I I 296 OBS RESOLVER ( 0) c
v
I--
y
I I I I 297 OBS RESOLVER (E) ~
10
I-- I I I I 298 OBS RESOLVER (F) ~
3
b
-=-
e
I I II 299 OBS RESOLVER (G) I--
L
.....=....
X
I I I I 301 OBS RESOLVER (H) -11
- a
I I I I 300 OBS RESOLVER (C) -2
r-=-- ~2671 I I I I 267 OBS RESOLVER (B)
-s I II
I
m ~
~--~----14-JI--____;;.,__
310 KI 525A VALID
__-:-1-:-1_.:....:....::.....;.;~;:;..;;..;..;..~:..:;.;;;...---
1 I 311 DRIVE MOTOR 1
I 312 DRIVE MOTOR 2
I 313 DRIVE MOTOR 3
I 314 DRIVE MOTOR 4
II
315 SLAVING CONT. TRANS.(H)
317 SLAVING CONT. TRANS. Y

318 SLAVING CONT. TRANS X
'""""3;:...:.1~9_,S=L.:. .:.AV"""'I"""'N=G_,C=O.:. :. NT.:. . :·-. . . .TR..;.;. A"""N.:. S._..o...::.Z..._
L.:........j----i MD.-
..-
....,;.-..---320
II
-+,--./..--- 321
•• -. c• ·• »o ·o
0 "o••""o"'•'"o....zo "'o"'o>e=>o""•,.•"'•.........
2
0 • •• ·o "o 0
C. Q. ::• ~· o 0... . . . _oJIQ NQ .o ,.0 .-0 .,Q _Q
FIGURE 14-318 KI 525A PICTORAL NAV INDICATOR (BOTTOM PLUG)

14.1040 (cont'd)
KG 102A KI 525A
I TOP BOT.
I I I
~~-----------+'·----------~~~~--~~~~~~--------------
1
I
25,9
I
co a• :z:• ............ 31eN• ... -o .... -. •o

~o
0 "'o "'o ... o 2 0 "'o =>o ><oo• "o ""o eo ~a 0"O
uO .._e ,.e z• .,e >• ,.e ..,e •e _. ,.e .0 ... ,.0
Issued 5/22/87 FIGURE 14-32 KING KG 102A DIRECTIONAL GYRO Page 14.57
14.1040 (cont'd)
KMT 112 KI 525A KG 102A KA 51

BOTO
A B
I I
I I
,..... I
31 7 SLAVING CONTROL TRANSFM'R ( y)
--fT ~ ,-., h
!- I I
I H H
I 318 SLAVING CONTROL TRANSFM'R (X)
,,_,,
I
I
B
D
I
I
I
I
~
m '
I I I
I c A
319 SLAVING CONTROL TRANSFM'R ( z)
d M D
'r -,-- '( \
J_259 I I I
320 FLUX DECT. EXCITAT'N HIGH

321 FLUX DECT. EXCITAT'N LOW
KMTII2
FIGURE 14-33 KING KMT 112 FLUX TRANSMITTER

14 . 1 0 4 0 ( con t ' d)
KA 51 KI 525A KG 102A KMT 112

A B TOP BOT.
I I 1 I I
~--~--~ctJ~-----------3~0_5_+_5__V_DC________________
I ~ I~ I
I
~ CYJ~------------~3~08~S~IG~NA~L~GR~O~UN_.D___________
-
I
I
H H
I
I
nr- ,-
-
I
I I
I
I :':+:-:~~~ ~~~~~~~ ~~~~:~~ ~:~~~~~: R (X)
R (Y)
c A T'•
M D
I - I I
r-cr-~
I ;'(''o~ :319 SLAVING CONTROL TRANSFM' R. ( Z)
.....,....._ 1'1'
~ 2591
~
l
, 320 FLUX DECT. EXCITAT'N HIGH
E E
K B FLUX DECT. EXCITAT'N LOW
l I
-I
I I I
322 SLAVING METER
N F k
I
I : I
I
I
I ~
c
I
I 323 SLAVING SWITCH
J D ~
I I I 324 SLAVE CLOCKWISE SWITCH
L E J
B B
I I ;- l 325 SLAVE CTR'CLQCKWlSE s_wn CH
I I I
I
A A
I I I I 354 +DC LIGHTING HIGH
p I I I I 328 LIGHTING LOW
N
I I I I I I
I I
I
I
I
I
I
I
ll.~.I I
I
311
312
,!:, 313
... .~
,J, 314
,)
I
- 1
315
\,. I
316
B 0 F J L N R
IQ
I r•rmr•r•r•l•a•
A c E H K II p
o) KA 51A
FIGURE 14-34 KING KA 51 (A &B) SLAVING ACCESSORY

14.1100 R22 MARINER

14.1110 R22 Mariner Avionics Schematics
AIR COMM 775-SL 189
AUDIO CONTROL,.... ,-----....0- 2
~63+----20;. 5,;---.TO COM BOX

7.,_._l..,:;;~
3
+14 V. DC
~ ,,
2
..
l 12 2
•
,. '"
21 1 r1-480273-1 HOUSINGJ
MIC HI '--- I I r- r I....__ _=;..._-~
206
207 TO COM BOX
+
.--- I ......-
4 4
~~·-1-4802:~_: :o:~:NG
XMIT KEY 0
res KEY ;
HD PH AUD
~ 1:1 . 209 I,..T-J---12_0_J_A_CK_(_C_O--P-I-LO-T--1)l
GROUND 6 U..SIS 1-480273-0 HOUSING

~ /
/
~
m..
COM MIC HI
KEY
~
7
8
414
I
I }
~~1-+------- COM UNIT
- I
111
AUD
- 9 u...
INPUT 1 MIC HI
KEY
--
~
10
11
..,__-f-._ _ _
1
_·__ }UNIT NO. 1
i--
AUD 12
~
INPUT 2 MIC
- 13
_;.. J }
..,_---+----··-- UN IT NO. 2
KEY
AUD
- 14
15
-
i--
INPUT 3 MIC 16
~ ~ -1 } UNIT NO. 3
KEY
...,._
17
AUD 18
~~
1--
~ 1-4803r HOUTNIT NO.

INPUT 4 MIC 19
~ 4
KEY 20
....,..__
AUD 21
~
1--
i--
HOT ICS KEY 34
~
1--1;;;..;8_6_ _ _ _ _ TO 601716-4 CONSOLE LIGHTS
LITE DIM 36
~ 187 TERMINAL BLOCK
PWR GND 37
....,..__ 1--..:.::.:.--------J GROUN_D ON
'------....--- : A365 l ANGLE
Page 14.60 FIGURE 14-35 AIR COMM 775-Sl AUDIO CONTROL Issued 5/22/87
14.1110 (cont'd)
AUDIO CONTROL
REF.
MIC INPUT MIC
477
PUSH-TO-TALK INPUT KEY
GROUND
GROUND GROUND
AUDIO 476
480 A448-2
+12 VOLTS DC
481 BUS
GROUND BAR
482
#482 CABLE TO
226847-1 PLUG
ANTENNA AND DMC63-31
ANTENNA.
ICOM IC-27A 2 METER
FM TRANSCEIVER
RED BLK
1 2
(LOOKING
TOWARD
AIRCRAFT)
t@ ®]
AUDIO/MIC POWER
CONNECTOR CONNECTOR
FIGURE 14-36 !COM IC-27A 2-METER FM TRANSCEIVER

14 . 111 0 ( con t ' d)
6-PIN CONNECTOR AUDIO CONTROL
GROUND
I REF.
GROUND
MIC 546 ,-
INPUT MIC
PTT 547
INPUT KEY
AF 1 548
INPUT AUDIO
+13.8V.DC 549
551
GROUND
550
A448-2
GROUND SCREW ON BUS BAR
A365-l ANGLE
552
t-----+-+---------4 e DMC63-31A
ANTENNA ANTENNA
!COM IC-M55
MARINE
VHF RECEIVER
6-PIN
AUDIO/POWER •••
•••
3 2 1
CONNECTOR
6 5 4
FIGURE 14-37 ICOM IC M55 MARINE VHF RECEIVER

14.1110 (cont'd)
OPTIONAL
CONNECTOR
12 V. DC 472 \ A448-2
473 BUS
GROUND BAR
-:- GROUND SCREW

ON A292-l PANEL
4,;_
r-+-+--..,;..74_ _ _ _ _ TO 8101X -7
ANTENNA
ANTENNA
VEGA 363X
RADAR
TRANSPONDER
FIGURE 14-38 VEGA 363X RADAR TRANSPONDER


A039 RH
A039 1858 POS
SPOTLIGHT LIGHT G
1859 111 CASE NOTES:
ASSY GND
3
5 INDICATES CONNECTOR
BLACK 1 8 8
416 416
RED 6
52 INDICATES SPLICE & SOLDER SPLICE
52
34 34
2 11 11
4 10 10 ENG OIL PRESS. SWITCH ALTERNATOR LOAD LIMIT: 54 AMPS MAX, 14 VOLT 60-AMP MODEL
591 591 C1-32 591 591
STARTER 751 8
A 592 471 C2-27 471 471 NO
WRG LT 6 C2-4 6 6 6 C INDICATES CONNECTOR WHICH MAY HAVE UNUSED CONDUCTORS
NC
TO OPT'L TURN 2 667
COORDINATOR 470 470
1 666 C1-34 666 P
(SEE B191) TO OPT'L AVIONICS TO XPDR 1556 COLLECTIVE SWITCH
CIRCUIT BREAKER 751
513 513 (HOUR METER)
1 C1-28 (SEE C804) NC 585
ROTOR 471 TO OPT'L ATTITUDE HORIZON & COLLECTIVE SWITCH UP ENGINE - 750 750
DIRECTIONAL GYRO (SEE B191) 2 514 (LOW RPM HORN) NC 76 HOUR C 751
BRAKE A 434 42
WRG LT 152 C1-25 METER +
UPPER CONSOLE GND TO OPT'L 2 2600 NO 2038
A792 DUAL TACHOMETER 160 C1-12 NO AVIONICS 1 FULL DOWN
2599 STROBE
C2-17 FULL DOWN AIR/GROUND SW LIGHT
WHITE M 80 (ORANGE) 80 (ORANGE) C2-14 80 80 80 (ORANGE) 1 RED
LOW 6 GREEN 81 (WHITE) 81 (WHITE) 81 (WHITE) BLUE OR GREEN TACH
L C2-15 81 81 2
OIL PRESS. R 44 SENDER
WRG LT YELLOW J 82 (BLUE) 82 (BLUE) C2-16 82 82 82 (BLUE) 3 BLACK 2309 2 BLK
A792 RED B 71 71 C1-10 1 WHT

DUAL ORANGE 72 72 585
D C1-11 85 (ORANGE) RED
TACH 1
BLUE H 83 (WHITE) 83 (WHITE) C2-18 83 83 84 (WHITE) BLUE OR GREEN LOW RPM
2
BLACK E 89 (BLUE) 89 (BLUE) C2-19 89 89 SENDER
1555 1555 3 YELLOW 86 (BLUE) 3 BLACK
CO DET C696 73 C2-20
WRG LT A 1553 1553 1 RED CARBON 85 (ORANGE) C2-22 85 85
BROWN A 491
1552 MONOXIDE
1554 2 BLACK DETECTOR YELLOW/WHITE P 492 84 (WHITE) C2-21 84 84 2038 4 2038 118
86 (BLUE) C2-23 86 86 109 1 109 TAIL
C2-24 633 5 LIGHT
2
70 C1-9
BLACK 2 87 75 C1-13 503 3
NC 95 95 95 3
694 694 RED 1 70 76 C1-14
GOV OFF 633 C1-33 CIRCUIT 91 91 91 1 D602 503 5
A 695 C NO WHITE 3 75
WRG LT 693 BREAKER LT 90 90 90 2 ACTUATOR
3 GREEN 4 TIME DELAY
2
1
94 94 94 98 4 ASSY
127 C1-21 127 127 EXTENSION LIMIT SWITCH CASE
577 2038 10 96 GND
60 4 A569 BROWN 4 632 2328 506 506
LOW FUEL QTY LOW RPM COMPASS P NC
A B280 RELAY ASSY 50 ohm 10W
WRG LT 57 WARNING GRAY 5 631 LIGHT
(GOV OFF WRG) 100 C NO
126 2 126 (BLU) 108 T.R.G.B. CHIP
UNIT WITH ORANGE 7 634 ENG OIL PRESS.
107 107 109 109 DETECTOR
STARTER 125 C1-20 125 1 125 (WHT) SENDER
LOW FUEL QTY 57 VIOLET 8 633 2233 110
LOCK OUT 96 1 96 139 1 RED
WRG TIME 79 LOW RPM 2289 3 RED G196 31 31 GEAR- A021
58 RED 1 85 (ORANGE)
WARNING 15 15 15 100 2 100 2 BLACK MOTOR
DELAY 78 78
YELLOW 2 2290 4 BLK LT 1.5A TAIL ROTOR
HORN 84 (WHITE) ASSY 164 164 164 GEARBOX
LT BLUE 3 INST LIGHT 16 16
86 (BLUE) A212-1
577 C1-29 577 CASE 2 3 1 4
BLACK 6 114 ENGINE CASE
78 95 95 C1-18 GND A051
115 30 BELT TENSION ACTUATOR
76 76 91 91 C1-16 103 RET SW
LOW RPM 87
A 577 119 1355 3
WRG LT 175 90 C1-15 A212-1
112 1 112 ON 86 TEST
1 934 1354 1
94 C1-17 ENGINE LH MAGNETO PLUG
931 631 632 28 138 2 138 LANDING
4 28 C1-5 (RH SIDE OF HELICOPTER) 2
CONSOLE 138 138 C1-24 LTS SWITCH 112 85
5 932 3 355
198 LIGHT DIMMER 93 ENGAGE 583 C1-30 OFF 91 NC NC 98
LOW DIMMER 6 933 CONTROL 121 C1-19 121 LANDING 99 99
VOLTAGE A 199 133 133 1 133 113 C C
3 LT CLUTCH LTS RELAY 417 2
WRG LT 122 NAV LTS SWITCH NO NO
A072 + 137 3 137 SWITCH OFF 1 WRG LT CIRCUIT
2 121 88 104 939 939 416 1 SPRING SWITCHES
STD CLK 121 TEST SWITCHES
134 2 134 92 C ON 2 1358
- DISENGAGE 1358 TO INTERCOM AUX FUEL QTY SENDER 97 NC LOW FUEL 503
93 583 STROBE LT SWITCH D049-6 3 SYSTEM 139 QTY SWITCH T.R.G.B.
CLUTCH 29 30
A OFF (SEE A060) C 502 CHIP
WRG LT 92 2038 HARNESS 2504 4 2504 2492 87A
90 C NO
94
ON
105 ASSY 582
5 87 RETRACTION LIMIT SWITCH 61
127 59 2
CYCLIC
105 2388
(SEE C058)
TO CYCLIC
C058)
125 OPT'L E 121 107 6 583 85
52 1
(SEE
93 FWD STROBE C 104
585 MAIN FUEL QTY SENDER
45 92 AVIONICS SWITCH J 2038
M.R.G.B. CHIP 121 M 234 4 685 633 86 197 197
WRG LT A 3 B144 INSTRUMENT CLUSTER 2233
204 2234 OFF D 105 TO LOW FUEL
235 5 284 284 INTCM BLU 34 CYL HD 196
+ LIGHT C ON K 2233 STARTER LOCKOUT 31 1 NO RELEASED 196
L 2234 B304 281 3 239 239 SYSTEM CASE TEMP
OIL PRESS. AMMETER
BATTERY SWITCH 470 2 BLK SENDER
129 54 OFF B 65 2627 CAP. (SEE GND
30 OFF 277 1 603 603 2492 30 RED
46 46 13 R 65 A 30 ASSY AP60) 471 3
M.R.G.B. 283 176 87A NC ENGAGED
10 12 L L 15 C ON R 18 71 28
OVERTEMP A 2 S I L A 2 280 2 604 CASE 58 C006
BOTH
S 19 87 ROTOR BRAKE SWITCH 62
WRG LT LR 164 ALTERNATOR SWITCH 6 2057 GND ENG OIL MAIN ROTOR 501 501
AUX FUEL START 236 605
OFF 86 11 TEMP GEARBOX M.R.G.B.
OIL 40 19 500
QTY 18 72 SENDER 2 CHIP
TEMP 418 C ON 2 M.R.G.B.
11 128 CHIP 1 3
S I S I 2233 85 83 (WHITE)
416 BO 166 2487 DETECTOR
2 89 (BLUE) 1
CYL HD MAIN FUEL 204 C1-27 TO RADIO LTS 42 661 AVIONICS MASTER
A045-2
TEMP QTY 66 66 C1-7 66 103 14 574 (WHITE) 2
40 R 16 1A 20
C1-4 2792 X'PDR "KEEP ALIVE" 573 (BLUE)
111 3A
S I S I 52 15 C1-1 CASE
129 16 TACH 505
34 2 GND M.R.G.B.
TERMINAL 634 164 C1-3 4 104 572 F
GND 5 ENGINE RH SW 504 OVERTEMP
C691 JUMPER S 584 16 C1-2 573 G MAGNETO 58
68 67 67 C1-8 67 3
ASSY 5 574 H (LH SIDE OF
BAT. 31 166 C1-26 166 470 105 102 2
36 569 B0 STARTING 5 B278 HELICOPTER)
584 C1-31 584 576 B
A661 IGNITION SWITCH IN VIBRATOR GOVENOR
31 C1-6 70 5
2 577 C CONTROLLER
129 C1-23
13 C2-8 13 200 176 578 D
7.5 A060-12 COM INSTALLATION
504
505
12 C2-7 12 579 E
69
-19 102
2
416 C2-26 5
OPT'L
52 C2-12 576 38
34 2 AVIONICS 1
34 C2-9
1
2
4
3
2 BLACK GOV
2627
11 11 C2-6 GEAR- 37 2
10 2626 1 RED 39
10 C2-5 MOTOR 39
7 A058 CARB AIR TEMP SENDER
TERMINAL JUMPERS
569 128 128 C1-22 AUX PWR (FR RH) 577 OFF 591 M.R.G.B.
2 OVERTEMP
44 44 577
WARNING LIGHT 2690 2691 CASE SWITCH
576 1 ON
1552 1552 TERMINAL BLOCK 200 581 MOTOR GND
TO COM 576 A045-4 CIRCUIT BREAKER
47 47 47 201 2692 2693
X’CVR GOVERNOR SWITCH 582 INSTALLATION
T.R.G.B. CHIP A 60 60
WRG LT 5 198 198 AUX PWR (FR LH) 14 14 14 STARTER
45 45
695 695 507
2489 2626 1
58 58 C2-13 TO OPT’L
THROTTLE 199 199 C2-25 2 EQUIPT. ORANGE 2 507 ALTERNATOR
2488 580 22 22
LT 3 3 C2-2 (5A MAX) A942 + 24
3 BLACK 7 33 33
2 2 C2-1 FULL THROTTLE SW ALTERNATOR AFT SHUNT CASE F1
BLUE 23 23 GND A036-9 ELECTRICAL
NC CONTROL 1 13 12
5 5 C2-3 C 2487 F2 COMPONENTS
UNIT RED 3 18 B304-18
2488 2488 C2-31 2488 A067-2 ELECTRICAL INSTALLATION
NO FUSE ASSY AUX
37 C2-10 YELLOW 4 199 33 HARNESS INSTALLATION
38 C2-11 23 B304 ASSY PROVISIONS
A604 RED 2 36
13 13 13 13 2 FOR RADIO “KEEP ALIVE”
CARB BLACK 1 37 CONSOLE ELEC CONNECTOR 12 12 12 12 1
AIR TEMP 18 581
GAGE GREEN 3 38 4 RED 1 4 4 58 58 580
B341 1 BLACK 2 1615 199
OUTSIDE 3 3
AIR TEMP 6 BLACK 2 2
O.A.T.
GAGE 5 RED SENDER 5 5
114 37 37 64
RH TO RADIO 3 1226 3A
116 38 38 +
LANDING “KEEP ALIVE”
LIGHT 66 66 66 1 66
65 65 65 3A
2 65 A780-2
AVIONICS 2539 2539 PILOT SEATBACK -
B304-4
114 114 GROUND COMPARTMENT
CASE 2560
115 115 115 R
LH GND
LANDING 117 A039 LH
FIREWALL/CABIN BULKHEAD
LIGHT POS LIGHT
A024 REV BO FIGURE 14-39 R22 ELECTRICAL SYSTEM INSTALLATION

(A024 Revision BO shown)

A039 SPOTLIGHT ASSY A039 RH
1858 POSITION LIGHT G
CASE
1859 111 GND
3 416 416 NOTES:
5
52 52
BLACK 1 34 34 INDICATES CONNECTOR
RED 6 591 591 ENGINE OIL PRESSURE SWITCH
591 591 C1-32 471 471
STARTER 7 8 INDICATES SPLICE & SOLDER SPLICE
A 471 C2-27 7 7 NO
WRG LT 592 2 C
6 C2-4 4 6 6 6
NC
11 11 ALTERNATOR LOAD LIMIT: 54 AMPS MAX, 14 VOLT 60-AMP MODEL
2 667
TO OPT’L TURN 10 10
666 C1-34 666 TO OPT’L 470 470 P
COORDINATOR 1
(SEE B191) AVIONICS INDICATES CONNECTOR WHICH MAY HAVE UNUSED CONDUCTORS
471 CIRCUIT ENGINE - TO XPDR COLLECTIVE SWITCH 585
ROTOR 513 C1-28 513 COLLECTIVE 1556
TO OPT’L ATTITUDE 1 BREAKER UP NC HOUR (SEE A804)
BRAKE A 434 HORIZON & DIRECTIONAL 2
SWITCH 76 METER + 42
514 (LOW RPM HORN) 2600 NC
WRG LT GYRO (SEE B191) TO OPT’L 2 C 2200
152 C1-25 AVIONICS 1 2599
160 UPPER CONSOLE GND C1-12
A792 DUAL TACHOMETER NO AIR/GROUND SW
C2-17 NO FULL DOWN 8 8
FULL DOWN
WHITE M 80 (ORANGE) 80 (ORANGE) C2-14 80 80
LOW 6
GREEN L 81 (WHITE) 81 (WHITE) C2-15 81 81
OIL PRESS. R 44
WRG LT YELLOW J 82 (BLUE) 82 (BLUE) C2-16 82 82 80 (ORANGE) 1 RED
STROBE LIGHT
A792 RED B 71 71 C1-10 81 (WHITE) 2 BLUE OR GREEN TACH
DUAL ORANGE 585 SENDER
D 72 72 C1-11 82 (BLUE) 3 BLACK
TACH
BLUE H 83 (WHITE) 83 (WHITE) C2-18 83 83
BLACK E 89 (BLUE) 89 (BLUE) C2-19 89 89 85 (ORANGE) 1 RED 2309 2 BLK
1555 1555 3 YELLOW
CO DETECTOR C696 73 C2-20 LOW RPM WHT
A 84 (WHITE) 2 BLUE OR GREEN 1
WRG LT 1553 1553 1 RED CARBON BROWN 491 85 (ORANGE) C2-22 85 85 SENDER
A
1552 MONOXIDE 86 (BLUE) 3 BLACK
1554 2 BLACK DETECTOR YELLOW/WHITE P 492 84 (WHITE) C2-21 84 84
2038 4 2038 118
86 (BLUE) C2-23 86 86
TAIL
C2-24 633 109 1 109
LIGHT
70 C1-9 2038 2038 5 2
BLACK 2 87 75 C1-13 CIRCUIT 96
NC 95 95 95
76 C1-14 BREAKER LT 503 3
694 694 RED 1 70 EXTENSION LIMIT SWITCH
GOV OFF 633 C1-33 91 91 91 1.5A
A C 96
WRG LT 695 NO 693 WHITE 3 75 127 C1-21 127 127 90 90 90 NC
3 GREEN 4 2328 503 5
94 94 94
COMPASS C NO
577 BROWN 4 632 50 ohm 10W 10
A569 LIGHT 506 506 CASE
1
60 4 126 126 (BLU) 108 P
LOW LOW RPM GRAY 5 631 2 98 GND
B280 RELAY ASSY WARNING 107 107 109 109 96 96 139 1 RED
FUEL QTY A 57 125 C1-20 125 125 (WHT) 1
(GOV OFF WRG) UNIT WITH ORANGE 7 634 1 2233 110 GEAR-
WRG LT ENG OIL PRESS. 100 2 100 2 BLACK
STARTER 2289 3 RED MOTOR
VIOLET 8 633 G196 31 31 SENDER T.R.G.B. CHIP
LOCK OUT
57 2290 4 BLK LT ASSY 15 15 15 DETECTOR
LOW FUEL QTY RED 1 85 (ORANGE)
WRG TIME 79 LOW RPM 164 164 164 2 3 1 4
58 YELLOW 2 84 (WHITE) 16 16 A051
DELAY WARNING INSTRUMENT LIGHT A021
78 78 577 C1-29 577 BELT TENSION ACTUATOR
HORN LT BLUE 3 86 (BLUE) TAIL ROTOR
95 95 C1-18 114 GEARBOX
1355 3
78 BLACK 6 91 91 C1-16 115 30
RE T SW
90 C1-15 103 CASE GND 1354 1
76 76 87 TEST PLUG
LOW RPM 94 C1-17 119
A 577 112 1 112 ON 85 2
WRG LT 175 1 934 632 28 28 C1-5 ENGINE LH MAGNETO
631 138 138
LANDING 91 NC NC 98
138 138 C1-24 2 LTS SWITCH (RH SIDE OF HELICOPTER)
4 931 LT 133 1 133 99 99
93 ENGAGE 583 C1-30 355 (SEE A060)
3 112 86 C C
CONSOLE 5 932 DIMMER A072 + 137 3 137 121 C1-19 121 OFF
LIGHT 113 NO NO
CONTROL STD CLK CLUTCH NAV LTS SWITCH SPRING SWITCHES A936-1
198 DIMMER 6 933 134 2 134 OFF LANDING LTS RELAY
LOW - SWITCH 104 939 1 939 417 2
133 121
VOLTAGE A 3 88 C ON 97 NC
199 122 127 1358 2 1358 416 1
WRG LT 92 139
2 121 125 DISENGAGE 29 30 AUX FUEL
STROBE LT SWITCH 3 C
583 OFF D049-6 TO INTERCOM 2492 87A QTY SENDER WRG LT CIRCUIT
93 93 90 2038 SYSTEM NO
CLUTCH C HARNESS 2504 4 2504
582 TEST SWITCHES
A 94
ON
105 (SEE A060) 87 RETRACTION LIMIT SWITCH
WRG LT 92 92 ASSY
5 503
121 105 2388 121 107 583 85 LANDING GEAR
OPT’L E
LOW FUEL T.R.G.B.
(SEE C058)
TO CYCLIC
104 6 59 502
204 FWD STROBE C 585 2
2038 QTY CHIP
45 B144 INSTRUMENT CLUSTER AVIONICS SWITCH J
M.R.G.B. CHIP 633 86 52 1 SWITCH
54 OFF M 234 4 685
WRG LT A + LIGHT 2234 OFF 2233 MAIN FUEL
3 R D 105
OIL PRESS. AMMETER L 15 C 235 5 284 284 STARTER LOCKOUT QTY SENDER
L ON K 2233 61
129 L 2234 BLU 34
BOTH LR 164 281 3 239 239 31 1 NO RELEASED CYL HD
46 46 13 START BATTERY SWITCH B 65 TO INTCM 2492 30
TEMP
M.R.G.B. CASE
A 10 12 30 OFF 30 277 1 603 603 SYSTEM 176 87A 470 2 BLK SENDER
OVERTEMP 2 S I L A 65 A GND
WRG LT C 18 161 B304 283 (SEE A060)
ON R CAP. 87 471 3 RED 197 197
OIL AUX FUE L S 19 280 2 604 NC ENGAGED
ASSY 2057 LOW
TEMP 40 QTY BO 166 ALTERNATOR SWITCH 86 CASE 196
OFF 71 28 236 6 605 ROTOR BRAKE SWITCH 196 FUEL
418 19 2 GND ENG OIL
11 18
C
S I S I 41 6
ON
11 TEMP
R 16 204 C1-27 2233 85 SENDER
TO RADIO LTS 72 83 (WHITE)
CYL HD MAIN FUEL 66 66 C1- 7 66 2
TEMP QTY C1-4 103 14 AVIONICS MASTER 89 (BLUE) 1 58 C006 A212-1
40 TERMINAL 634 128 20 MAIN ROTOR 62
15 C1- 1
34 JUMPER 2487 574 (WHITE) 2 GEARBOX 501 501 ENGINE CASE
S I S I 52 S 584 164 C1-3 2
573 (BLUE) 500 M.R.G.B.
104 CASE M.R.G.B. 2
GND BAT. 31 16 C1-2 16 GND CHIP
42 5 TACH CHIP
661 572 F 1 3
A045-2
67 67 C1-8 1A SW
58 DETECTOR A212-1
68 A661 IGNITION SWITCH 573 3
166 C1-26 166 111 G
B0 STARTING 3A
36 569 584 C1-31 584 129 105 102 2 505
IN VIBRATOR 2 5 574 H
31 C1-6 4 B278 504 M.R.G.B.
ENGINE RH MAGNETO
129 C1-23 576 B GOVERNOR (LH SIDE OF HELICOPTER) OVERTEMP
67 CONTROLLER
13 C2-8 13 5 577 C
470 5
12 C2-7 12
416 C2-26 70 578 D
2 200 176 38 1 A060-12 COM INSTALLATION
504
505
52 C2-12 7.5 579 E
69
34 34 C2-9 37
2
2
11 11 C2-6 39 39
-19 102
10 10 C2-5 OPTIONAL BLACK GOV A058 CARB AIR TEMP SENDER
2
1
2
4
3
TERMINAL JUMPERS 5 AVIONICS GEAR-
1 RED CASE 591
569 128 128 C1-22 MOTOR GND
44 44 576
200 2
WARNING LIGHT TO COM OFF 581 CASE
1552 1552 TERMINAL BLOCK X’CVR 201 577 MOTOR
577
2 GND
T.R.G.B. CHIP 47 47 47 582
60 60 1 2626 PWR OUTLET (RH), OPT’L 576 1 ON R M.R.G.B. OVERTEMP A045-4 CIRCUIT BREAKER
WRG LT A 5
198 198 2690 2691 576 STARTER SWITCH INSTALLATION
TO OPT’L 2
45 45 EQUIPT. GOVERNOR SWITCH A039 LH
3 2692
695 695 2693 POSITION LIGHT
58 58 C2-13 ALTERNATOR
2627 ORANGE 2 507 580 22 22
2489 199 199 C2-25 PWR OUTLET (LH), OPT’L + 24
3 3 C2-2 F1
A942 BLACK 7 33 33 AFT SHUNT
THROTTLE LT 2488 2 2 C2-1 ALTERNATOR F2
5 5 C2-3 FULL THROTTLE SW CONTROL UNIT BLUE 1 23 23 CASE
507
2488 2488 C2-31 NC RED 18 GND AU X
C 2487 3
A604 RED 2 36 37 C2-10 33 A036-9 ELECTRICAL COMPONENTS
CARB 38 C2-11 2488 YELLOW 4 199 23 INSTALLATION
BLACK 1 37 NO
AIR TEMP 13 13 13 13
GAGE GREEN 3 38 CONSOLE ELECTRICAL CONNECTOR A067-2 ELECTRICAL
12 12 12 12 HARNESS INSTALLATION
4 RED 1 4 4 14 14 14 B304 ASSY PROVISIONS
B341 FOR RADIO “KEEP ALIVE”
1 BLACK 2 1615 18
OUTSIDE
58 58 581
114 AIR TEMP BLACK
RH 6 199 580
GAGE O.A.T.
LANDING 3 3
116 5 RED SENDER
LIGHT 2 2
5 5
37 37 64
38 38 TO RADIO 3 1226 3A +
114 114 "KEEP ALIVE"
66 66 66 1 66
LH 115 115 115 65 65 65 3A
LANDING 2 65 -
117 C448 GND TERMINAL BLOCK 2539 2539 PILOT SEATBACK
LIGHT B304-4
FIGURE 14-40 R22 ELECTRICAL SYSTEM INSTALLATION
A780-2
(A365-1 REF) COMPARTMENT
C448 GND TERMINAL BLOCK 2608 2608 PILOT SEATBACK FIREWALL/CABIN BULKHEAD
A024 REV BL (A024 Revision BL shown) (A407-2 REF) COMPARTMENT

FIGURE 14-41 A804-12 & -13 TRANSPONDER SCHEMATIC (GARMIN GTX 330 ES)

FIGURE 14-42 A804-12 & -13 TRANSPONDER SCHEMATIC (GARMIN GTX 330 ES; EARLIER SHIPS)

FIGURE 14-43 C800-1 ASPEN PFD ELECTRICAL SCHEMATIC

FIGURE 14-44 C800-1 ASPEN PFD ELECTRICAL SCHEMATIC (EARLIER SHIPS)

FIGURE 14-45 C802-2, -3, & -4 COM RADIO SCHEMATIC (GARMIN GTR/GNC 225B)

FIGURE 14-46 C802-2 & -3 COM RADIO SCHEMATIC (GARMIN GTR 225B; EARLIER SHIPS)

FIGURE 14-47 C822-1 AUDIO CONTROL SCHEMATIC (GARMIN GMA 350HC)

FIGURE 14-48 C822-1 AUDIO CONTROL SCHEMATIC (GARMIN GMA 350H; EARLIER SHIPS

FIGURE 14-49 C831 GPS SCHEMATIC (GARMIN GTN 600 SERIES)

FIGURE 14-50 C831 GPS SCHEMATIC (GARMIN GTN 600 SERIES; EARLIER SHIPS)

FIGURE 14-51 C833 GPS SCHEMATIC (GARMIN 400 SERIES)

Intentionally Blank

CHAPTER 15
FURNISHINGS
Section Title Page
15-00 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.1

15-10 Seat Harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.1
15-20 Seat and Seat Back Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.2
15-21 Seat Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.2
15-22 Seat Back Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.2
15-30 Carpet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.4
15-40 Insulation (Foam and Headliner) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.5
15-50 General Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.6
15-51 Pilot’s Operating Handbook (POH) Strap Replacement . . . . . . . . . . . . . . . . 15.6
15-52 License Holder Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.6
15-53 Map Pocket Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.6
15-60 Emergency Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.7
15-61 Emergency Locator Transmitter (ELT) . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.7
15-62 Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.8
OCT 2018 Chapter 15 Furnishings Page 15.i

Intentionally Blank
Page 15.ii Chapter 15 Furnishings OCT 2018

CHAPTER 15
FURNISHINGS
15-00 Description
The seats are not adjustable but each helicopter is delivered with a cushion which can be
placed behind the pilot to position him farther forward. This allows shorter pilots to reach
the pedals, the cyclic grip in its most forward position, and controls on the center console.
Each seat is equipped with a combined lap belt and inertia reel shoulder strap. The inertia
reel is normally free but will lock if there is sudden movement as would occur in an accident.
A baggage compartment is located under each seat. Seat cushions hinge forward for
access.
15-10 Seat Harnesses

A. Removal
1. Hinge seat assemblies forward.
2. Remove hardware securing F628-8 buckle assemblies to inboard anchors. Remove
hardware securing lap belt fittings to outboard anchors.
3. Remove shoulder strap guide covers. Remove hardware securing guides to A259
bulkhead.
4. Remove inertia reel covers. Remove hardware securing reels to bulkhead. Remove
A628-6 connector assemblies.
B. Installation
1. Install hardware securing A628-6 connector assembly inertia reels to A259
bulkhead. Install reel covers. Verify security.
2. Install hardware securing shoulder strap guides to bulkhead. Standard torque bolts
per § 23-32. Install guide covers. Verify security.
3. Install hardware securing F628-8 buckle assemblies to inboard anchors; rotate
buckles 20° forward from vertical. Standard torque bolts per § 23-32. Verify
security.
4. Install hardware securing lap belt fittings to outboard anchors. Standard torque
bolts per § 23-32. Verify security.
OCT 2018 Chapter 15 Furnishings Page 15.1

15-20 Seat and Seat Back Assemblies
15-21 Seat Assemblies

A. Removal
Remove hardware securing seat assembly to support and remove seat.
B. Installation
Position seat assembly on support and install hardware. Verify security.
15-22 Seat Back Assemblies

A. Removal
Left Seat Back
1. Remove screws securing pilot’s collective boot and ring to A654-4 (vertical)
panel assembly, remove ring, and unsnap boot. Remove screws securing panel
to cabin and remove panel.
2. Remove screws securing A670-1 (fuel) valve’s A798 plates to A003-13 seat
back assembly and remove A798-1 plate.
3. Tilt seat assembly forward and remove screws securing co-pilot’s collective
boot and ring to seat back, remove ring, and unsnap boot. Remove screws
securing seat back to cabin and remove seat back. (Remove A798-3 plate.)
Right Seat Back
1. Remove screws securing pilot’s collective boot and ring to A654-4 (vertical)
panel assembly, remove ring, and unsnap boot. Remove screws securing panel
to cabin and remove panel.
2. Remove screws securing A003-14 seat back assembly to cabin and remove
seat back.
Page 15.2 Chapter 15 Furnishings OCT 2018

FIGURE 15-1 A798-1 PLATE ORIENTATION (VIEW LOOKING DOWN)
15-22 Seat Back Assemblies (continued)

B. Installation
Left Seat Back
1. Position A798-3 plate on A670-1 (fuel) valve. Tilt seat assembly forward
and position A003-13 seat back assembly on cabin and install screws. Verify
security.
2. Install screws securing co-pilot’s collective boot and ring to seat back and snap-
up boot. Verify security.
3. Refer to Figure 15-1. Install A798-1 plate on seat back as shown. Special
torque screws to 16 in.-lb.
4. Install screws securing A654-4 (vertical) panel assembly to cabin. Install screws
securing pilot’s collective boot and ring to panel and snap-up boot. Verify
security.
Right Seat Back
1. Refer to Figure 15-1. Tilt seat assembly forward and position A003-14 seat
back assembly on cabin and install screws. Verify security.
2. Install screws securing A654-4 (vertical) panel assembly to cabin. Install screws
securing pilot’s collective boot and ring to panel and snap-up boot. Verify
security.

15-22 Seat Back Assemblies (continued)
C. Back Rest Assembly (Cushion) Replacement
1. Remove seat back assembly per Part A.
2. Drill out rivets securing back rest assembly (cushion) to seat back panel and
deburr holes. Remove cushion.
3. Center and straighten new back rest 1.00 ± 0.10 inch above top edge of seat
back panel. Match drill seat back panel #30 holes through back rest. Deburr
holes and clean up debris.
4. Attach back rest cushion to seat back panel with rivets. Verify security.
15-30 Carpet
A. Removal
1. Floor carpets: Remove hardware securing scuff plates (and carpet) to cabin floor
and remove scuff plates, if installed.
CAUTION
Use caution when removing adhered carpet if carpet is intended
for reuse.
2. Starting at corners, gently peel back carpet by hand, or with plastic wedge or putty
knife.
3. Dampen old adhesive with Dupont Prep-Sol (or equivalent) to facilitate removal.
B. Installation
1. Verify proper carpet fit. Trim as required (do not trim carpet welt).
2. Apply B270-8 adhesive to bonding surface and carpet backing. Press carpet to
surface, smooth wrinkles, and remove excess adhesive prior to curing.
3. Install hardware securing scuff plates (and carpet) to cabin floor if removed. Verify
security.

15-40 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. Peel off insulation by hand.

2. Using plastic wedge or putty knife, carefully remove residual insulation and old
adhesive.
3. Wipe bonding surface with clean cloth, wet with acetone.
B. Installation
1. Verify proper insulation fit. Trim as required.
2. Apply B270-8 adhesive to bonding surface and insulation backing. Press insulation
to surface, smooth wrinkles, and remove excess adhesive prior to curing.

15-50 General Maintenance
15-51 Pilot's Operating Handbook (POH) Strap Replacement

A. Removal
Remove POH. Drill out rivets securing POH retaining strap to chin and remove strap.
Deburr holes and clean up debris.
B. Installation
Cleco POH retaining strap to chin. Progressively remove clecos and install rivets.
Verify security. Install POH.
15-52 License Holder Replacement

A. Removal
Remove contents. Drill out rivets securing license holder to chin and remove license
holder. Deburr holes and clean up debris.
B. Installation
Cleco license holder to chin. Progressively remove clecos and install rivets. Verify
security. Install contents and tuck holder under frame.
15-53 Map Pocket Replacement

A. Removal
Remove contents. Drill out rivets securing map pocket to seat support. Remove
pocket, washers, and retaining strips. Deburr holes and clean up debris.
B. Installation
1. Fold (long) outboard pocket edge around (long) A913-1 strip, align holes, and
align holes with front of forward seat box. Cleco in place.
2. Pull material taut, fold (short) inboard pocket edge around (short) A913-2 strip,
align holes, and align holes with front of forward seat box. Cleco in place. Trim
excess material.
3. Progressively remove clecos and install washers and rivets.

15-60 Emergency Equipment
15-61 Emergency Locator Transmitter (ELT)

A. Description
The ELT activates when subjected to a significant change in velocity (as in an
accident), by remote control switch located on the cyclic control panel, or by a
switch on the ELT transmitter. Refer to § 33-80 for system description.
Refer to Kannad Aviation AF Integra / AF-H Integra or 406 AF-Compact/406 AF-
Compact (ER) ELT Installation and Operation Manual for maintenance requirements
and procedures. Refer to § 1.100 for scheduled maintenance.
Register an ELT when first purchased, when contact information changes, or when
aircraft ownership, or tail number changes. Registration information is available
online at: www.cospas-sarsat.org.
Dongles contain a memory chip that must be programmed with aircraft-specific
information prior to installation for the ELT to function. The dongle may be removed
and shipped to RHC or a Kannad Service Center for reprogramming. Kannad Aviation’s
Programming Data Sheet is available online at: www.robinsonheli.com.
B. Transmitter
Removal
1. Release D693-4 strap assembly or B359-2 (reusable) ty-rap.
2. Release Velcro strap; disconnect dongle and antenna wiring from transmitter at
connectors and remove transmitter.
Installation
1. Connect dongle and antenna wiring to transmitter at connectors. Verify security.
2. Position transmitter on mounting bracket and secure with Velcro strap. Secure
D693-4 strap assembly or install B359-2 (reusable) ty-rap around transmitter
and bracket. Verify security.
C. Dongle
Removal
Cut and discard ty-raps as required, disconnect dongle from transmitter and airframe
harness at connectors, and remove dongle.
Installation
1. Connect programmed dongle to transmitter and airframe harness at connectors.
2. Install ty-raps as required. Cinch ty-raps until snug without over-tightening, and
trim tips flush with heads. Verify security.

15-62 Fire Extinguisher
CAUTION
Extinguisher is rated for a 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.
A. Inspection
Every month: Visually inspect fire extinguisher and perform weight check (a scale
with 1 gram precision or better is required). Remove extinguisher from service if
weight decreases by more than 3.2 grams per year, or total weight falls below 500
grams. If desired, order one G654-15 decal (blank maintenance log) and attach to
extinguisher, to record weight checks.
Every 12 years: Remove fire extinguisher from service. Year of manufacture is
labeled on bottom of extinguisher; remove extinguisher from service at end of 12th
year from labeled date.
B. Bracket Removal
1. Unlatch fire extinguisher bracket and remove extinguisher.
2. Remove hardware securing bracket to chin and remove bracket.
C. Bracket Installation
1. Install hardware securing fire extinguisher bracket to chin. Select screw length
as required to provide 0.00–0.06 inch thread exposure. Verify security.
2. Install fire extinguisher and latch bracket.

CHAPTER 16
DIMENSIONS AND DESCRIPTIONS
Section Title Page
16-10 Version Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.1

16-20 Datum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.2
16-30 Method of Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.2
16-40 External Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.3
16-50 Station Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.6
16-60 Access and Inspection Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.6
16-61 B526 Screws and B527-08 Washers . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.6
16-70 Antenna Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.7
OCT 2018 Chapter 16 Dimensions and Descriptions Page 16.i

Intentionally Blank
Page 16.ii Chapter 16 Dimensions and Descriptions OCT 2018

CHAPTER 16
DIMENSIONS AND DESCRIPTIONS
16-10 Version Description

Refer to § 3.200 for Type Certificate Data Sheet.
WARNING
Refer to R22 Illustrated Parts Catalog (IPC) for specific part
number differences between versions.
R22 Standard: Approved March 16, 1979. Serial numbers 0002 thru 0199, except 0175.
Lycoming O-320-A2B or Lycoming O-320-A2C engine normally rated at
150 horsepower and derated to 124 horsepower. 80/87 minimum grade
aviation gasoline. Gross weight 1300 pounds. Stabilizer angle 1.8–2.3
degrees nose up.
R22 HP: Serial numbers 0175, 0200 thru 0255, 0257 thru 0300, 0302 thru
0349, 0352 thru 0356. Lycoming O-320-B2C engine normally rated
at 160 horsepower and derated to 124 horsepower. 100LL or 91/96
minimum grade aviation gasoline. Gross weight 1300 pounds. Stabilizer
angle 1.8–2.3 degrees nose up.
R22 Alpha: Approved October 12, 1983. Serial numbers 0256, 0301, 0350, 0351,
0357 thru 0500. Lycoming O-320-B2C engine derated to 124 horsepower.
Extended lower steel frames. Tailcone higher than Standard/HP. Aft
battery installation. Gross weight 1370 pounds. Stabilizer angle 2.8
–3.3 degrees nose down. Auxiliary fuel tank optional for serial numbers
0457 and subsequent.
R22 Beta: Approved August 12, 1985. Serial numbers 0501 thru 2570. Lycoming
O-320-B2C engine derated to 124 horsepower. 131 horsepower five-
minute take off rating. Extended lower steel frames. Higher tailcone
than Standard/HP. Aft battery installation. Seven-hole instrument panel.
Larger oil cooler. 1370 pounds gross weight. Stabilizer angle 2.8–3.3
degrees nose down. Auxiliary fuel tank optional. A569-5 low-rpm
warning unit with starter lockout feature installed in serial number 2115
and subsequent. Starter lockout prevents starter activation at less than
62% rotor rpm when actuator is not fully disengaged; starter may be
activated above 69% rotor rpm to allow an in-flight engine start.
OCT 2018 Chapter 16 Dimensions and Descriptions Page 16.1

16-10 Version Description (continued)
R22 Mariner: Approved September 12, 1985. Serial numbers 0364, 0501 thru
2570 eligible (suffix “M” added to ship serial number). Similar to Beta
configuration except includes utility floats and additional corrosion
protection. Different tailcone with 1.8–2.3 degrees nose-up horizontal
stabilizer angle. Battery in nose when floats installed. Float stabilizer on
lower vertical stabilizer in place of tail skid. May be flown without floats
VFR day or night. Day VFR flight only with floats installed. Auxiliary fuel
tank optional. Marine radio package optional.
Instrument Alpha, Beta, or Beta II configuration with 10-hole instrument panel. VMC
Trainer: operations only.
Police Alpha, Beta, or Beta II configuration with searchlight, police radio package,
Helicopter: and 70 amp alternator.
R22 Beta II: Approved January 31, 1996. Serial numbers 2571 and subsequent.
Lycoming O-360-J2A engine derated to 124 horsepower maximum
continuous power. 131 horsepower 5-minute take-off rating. Carburetor
heat assist. 1370 pounds gross weight. Stabilizer angle 2.8–3.3 degrees
nose down. Throttle only engine governor standard. A569-5 low-rpm
warning unit with starter lockout feature standard. Auxiliary fuel system
optional.
R22 Mariner II: Approved January 31, 1996. Serial numbers 2571 thru 3414 eligible
(suffix “M” added to ship serial number). Similar to Beta II configuration
except includes utility floats and additional corrosion protection. Battery
in nose when floats installed. Different tailcone with 1.8–2.3 degrees
nose-up horizontal stabilizer angle. Float stabilizer on lower vertical
stabilizer in place of tail skid. May be flown without floats VFR day or
night. Day VFR flight only with floats installed. Marine radio package
optional.
16-20 Datum
The datum is located 100 inches forward of main rotor centerline.
16-30 Method of Measurement

Fuselage station, tailcone station, water line station, and butt line station values are
measured in inches, rounded to the nearest hundredth.
Page 16.2 Chapter 16 Dimensions and Descriptions OCT 2018

16-40 External Dimensions
FIGURE 16-1 EXTERNAL DIMENSIONS

16-40 External Dimensions (continued)

16-40 External Dimensions (continued)

16-50 Station Locations
Reserved.
16-60 Access and Inspection Panels

Refer to R22 Illustrated Parts Catalog Chapter 6 for access and inspection panel locations.
16-61 B526 Screws and B527-08 Washers

B526 (TORX Plus®) truss head screws may be used to secure cowlings and access
panels. A B527-08 nylon washer may be used under a B526 screw head to further
protect thin or painted surfaces.
B526 screws are interchangeable with MS27039C080_ screws used to secure cowlings
and access panels as follows:
PART: INTERCHANGEABLE WITH:
MS27039C0806 screw . . . . . . . . . . . . . . . . . B526-6 screw
MS27039C0807 screw . . . . . . . . . . . . . . . . . B526-8 screw
MS27039C0808 screw . . . . . . . . . . . . . . . . . B526-8 screw
B526 screws are interchangeable with AN525-832R_ & AN526C832R_ screws as

follows:
AN525-832R6 or AN526C832R6 screw . . . . B526-6 screw
NOTE
B526 screws are compatible with T20 or 20IP drivers.

16-70 Antenna Locations
NO. ANTENNA PART NO. NO. ANTENNA PART NO.

1 NAV . . . . . . . . . . . . . . . . . . . CI 259E 6 ADF . . . . . . . . . . . . . . . . . . . KA44B
NAV . . . . . . . . . . . . . . . . . . . CI 259E (W/DIPLEXER) 7 Cowling GPS . . . . . . . . . . . . . GA 35
2 RH Belly FM . . . . . . . . . . . . . . CI 292-3 8 Fwd Tailcone COM . . . . . . . . CI 121 or CI 248-5
RH Belly FM . . . . . . . . . . . . . . CI 177-20 Fwd Tailcone COM/GPS . . . . . CI 2580-200
RH Belly FM . . . . . . . . . . . . . . CI 273 OR CI 271 9 RMS/GPS . . . . . . . . . . . . . . . 921-00003-001
RH Belly COM . . . . . . . . . . . . CI 122 10 Aft Tailcone COM . . . . . . . . . CI 121 or CI 248-5
RH Belly FM . . . . . . . . . . . . . . CI 272-1 Aft Tailcone GPS/COM . . . . . . CI 2580-200
3 LH Belly FM . . . . . . . . . . . . . . CI 292-3
LH Belly FM . . . . . . . . . . . . . . CI 177-20
LH Belly FM . . . . . . . . . . . . . . CI 273 OR CI 271
4 Marker Beacon . . . . . . . . . . . CI 102
5 Transponder/UAT (ADS-B) . . CI 105-16 OR KA60, FWD
Transponder . . . . . . . . . . . . . CI 105-16 OR KA60, AFT
DME . . . . . . . . . . . . . . . . . . . CI 105-16 OR KA60
FIGURE 16-4 ANTENNA LOCATIONS

Intentionally Blank

CHAPTER 17
JACKING AND HOISTING
Section Title Page
17-10 Jacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.1

17-20 Hoisting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.5
OCT 2018 Chapter 17 Jacking and Hoisting Page 17.i

Intentionally Blank
Page 17.ii Chapter 17 Jacking and Hoisting OCT 2018

CHAPTER 17
JACKING AND HOISTING
17-10 Jacking
CAUTION
When jacking helicopter, use mechanical or locking hydraulic
jacks, when available. Unlocked hydraulic jacks are subject
to pressure-loss which can affect critical measurements during
leveling or cause a raised helicopter to become unstable.
CAUTION
Never jack helicopter in windy conditions.
CAUTION
Perform jacking on a clean, flat, hard surface free of water,
oil, solvent, grease, or residue that could cause equipment or
personnel to slip during jacking procedure.
CAUTION
Do not actuate jacks from underneath helicopter. Remain clear
of landing gear skid tubes when helicopter is raised.
OCT 2018 Chapter 17 Jacking and Hoisting Page 17.1

FIGURE 17-1 JACKING
Page 17.2 Chapter 17 Jacking and Hoisting OCT 2018

17-10 Jacking (continued)
A. Jacking
1. Two methods may be used to jack helicopter:
a. Refer to Figure 17-1. Place a foam-covered contour block under vertical

firewall. Install skid stand under tail. Place an appropriate capacity jack under
each end of contour block.
CAUTION
Contour block must be directly under vertical firewall to support
weight of helicopter.
b. Place an appropriate capacity jack under each (landing gear) aft cross tube,
one inch inboard of elbow fittings, and under the ground handling ball as
required.
CAUTION
Ground handling ball must slide unrestricted across a flat surface
during jacking. When weighing, verify ball is not under side
load which could produce an erroneous weight indication.
2. Position jack levers for convenient access and engage jacks. 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 (at least 4
inches off ground if removing landing gear).
CAUTION
Minimize personnel movement around raised helicopter.
B. Lowering
CAUTION
Skids spread as aircraft weight settles on landing gear.
1. Slowly and simultaneously (one person per jack recommended) lower each jack
ram, maintaining helicopter stability. Lower aircraft to ground.
2. Clear jacking equipment from area.

FIGURE 17-2 HOISTING

17-20 Hoisting
CAUTION
Avoid hoisting helicopter in windy conditions.
CAUTION
Verify ground is free of water, oil, solvent, grease, or residue
that could cause equipment or personnel to slip during hoisting
procedure.
CAUTION
Remain clear of area beneath helicopter when helicopter is
raised. Minimize personnel movement around raised helicopter.
A. Hoisting with Lifting Fixture

1. Refer to Figure 17-2. Verify hoisting equipment has minimum load capacity of 1000
lb.
2. Position main rotor hub directly under hoist to minimize helicopter swing once aloft.
3. Remove two spring pins and four nylon bushings from MT234-1 lifting fixture and
install bushings in main rotor hub lightening holes. Position lifting fixture on hub
then insert spring pins through fixture and bushings until pins lock. Verify security.
4. Connect hoist to lifting fixture. Verify security.
5. Stabilize helicopter as required by guiding tail skid, but do not exert force (tail skid
is secondary structure). Raise helicopter to required height.
B. Hoisting with Nylon Rope
1. Refer to Figure 17-2. Verify hoisting equipment has minimum load capacity of
1000 lb. Verify minimum work load limit for 1-inch diameter twisted or double
braided (preferred) soft nylon rope is 1000 lb.
2. Position main rotor hub directly under hoist to minimize helicopter swing once aloft.
3. Insert rope through main rotor hub lightening holes, form a double loop, and knot
ends. 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.

17-20 Hoisting (continued)
C. Lowering
CAUTION
Skids spread as aircraft weight settles on landing gear.
1. Refer to Figure 17-2. Stabilize helicopter as required by guiding tail skid, but do
not exert force (tail skid is secondary structure). Slowly lower aircraft to ground.
2. Disconnect hoisting equipment, remove lifting fixture or nylon rope from main rotor
hub, and clear equipment from area.

CHAPTER 18
WEIGHT AND BALANCE
Section Title Page
18-10 Leveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.1

18-11 Leveling at Lower Right Side Frame Tube & Aft Landing Gear Cross Tube . . 18.1
18-12 Leveling at Main Rotor Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.3
18-13 Leveling at Keel Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.3
18-20 Weighing and CG Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.4
18-21 Preparing Helicopter for Weighing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.4
18-22 Weighing Procedure and Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.5
18-30 Fixed Ballast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.9
OCT 2018 Chapter 18 Weight and Balance Page 18.i

Intentionally Blank
Page 18.ii Chapter 18 Weight and Balance OCT 2018

CHAPTER 18
WEIGHT AND BALANCE
18-10 Leveling
NOTE
Perform leveling and weighing in a zero-wind environment.
NOTE
Verify spirit level is calibrated by placing level on a designated
surface and noting bubble position. Rotate spirit level 180°;
verify bubble is in the same position.
18-11 Leveling at Lower Right Side Frame Tube & Aft Landing Gear Cross Tube
NOTE
Use this leveling method for R22 Standard & R22 HP models only.
1. Place a bubble level on lower right steel tube frame horizontal member at location
marked LEVEL HERE.
2. Level helicopter longitudinally by placing shims under landing gear skid tubes or jacks
under outboard edge of aft cross tube.
3. Place bubble level on center of landing gear aft cross tube.
4. Level helicopter laterally by placing shims under landing gear skid tubes or jacks under
outboard edge of aft cross tube.
5. Recheck level per steps 1 & 3 and adjust as required.
OCT 2018 Chapter 18 Weight and Balance Page 18.1

FIGURE 18-1 LEVELING AT KEEL PANELS
FIGURE 18-2 DETERMINING CG USING WATER LEVEL
Page 18.2 Chapter 18 Weight and Balance OCT 2018

18-12 Leveling at Main Rotor Hub
NOTE
Use this leveling method for all R22 models.
1. Place a bubble level atop MR hub.
NOTE
Level must be parallel to teeter hinge bolt.
2. Rotate main rotor until teeter hinge bolt is aligned with longitudinal axis of helicopter.
4. Rotate main rotor until teeter hinge bolt is aligned with lateral axis of helicopter.
NOTE
Jacks may be used under aft cross tube 1 inch inboard from
each elbow.
18-13 Leveling at Keel Panels
NOTE
Use this leveling method for all R22 models.
1. Remove horizontal panel between seat bottoms and remove cyclic box cover.
2. Place a bubble level on top edge of right keel panel per Figure 18-1 Detail A.
4. Place a bubble level across two keel panels per Figure 18-1 Detail B.

18-20 Weighing and CG Calculation
Reweigh helicopter when helicopter empty weight and empty weight center of gravity have
been modified and if the accuracy of additional calculations is suspect.
Maintain a continuous record of the helicopter’s weight and balance using the Weight and
Balance Record in R22 Pilot’s Operating Handbook (POH) Section 6.
NOTE
Verify scales are calibrated. Operate scales according to scale
manufacturer’s instructions.
NOTE
Never weigh the helicopter in the wind. Weigh helicopter on a
level, flat, hard surface in a zero-wind environment for accurate
scale readings.
18-21 Preparing Helicopter for Weighing

1. Defuel helicopter per § 22-52.
2. Service engine oil per R22 Pilot’s Operating Handbook (POH) Section 8. Fill main and
tail gearboxes to center of sight glass with A257-2 oil.
3. Clean aircraft per POH Section 8. Verify helicopter is completely dry.
4. Remove items that are not installed equipment (tools, rags, charts, etc.) from baggage
compartments and stowage areas.
5. Verify cowlings, removable panels, cabin doors, removable controls, and POH are
installed.
6. Verify Equipment List/Weight and Balance Data sheet (RF 134) and modifications
recorded in the Weight and Balance Record correspond with installed equipment and
recorded equipment locations.

18-22 Weighing Procedure and Calculations
NOTE
• Arm is the distance in inches from datum.
• Datum is located 100 inches forward of main rotor centerline.
• CG (arm) is determined by dividing total moment by total weight.
1. Refer to § 18-20. Prepare helicopter for weighing per § 18-21.

2. Hoist helicopter per § 17-20 approximately one foot above the ground. Have one
person hold tail of helicopter while hoisting to stabilize helicopter.
3. With main rotor blades oriented approximately fore and aft, raise both blades off of
droop stops to allow hub to teeter freely. Raise tail slightly and allow to settle.
4. Refer to Figure 18-2. With aircraft hanging freely and steady, use a water level and
measure difference in vertical height between tail rotor gearbox centerline and cabin
belly at vertical firewall. Ensure no air bubbles in water level tube.
Record height difference: inches
5. Determine longitudinal center of gravity:

114.47 – [0.315 x (height difference from step 4)] = inches
6. Place a 1000-lb capacity (minimum) scale under each skid. Locate center of scales
approximately 10 inches forward of (ground handling wheel ) skid supports.
7. Lower helicopter until it rests entirely on scales. Helicopter must be well balanced
on scales before releasing tail. Be sure helicopter is level laterally by placing level on
center of aft landing gear cross tube.
8. Determine empty weight:
Right scale reading: lb
Left scale reading: + lb
Tare (leveling shims, hoist fixture, etc.): – lb
Empty weight: = lb

18-22 Weighing Procedure and Calculations (continued)
9. Determine CG with full fuel and minimum solo pilot:
a. Bladder tank(s):
i. With aux tank:
(CG from step 5) x (Empty weight from step 8) + 28495
=
(Empty weight from step 8) + 303 in.
ii. Without aux tank:

=
b. All-aluminum tank(s):
i. With aux tank:
=
ii. Without aux tank:

=
10. If CG from step 9 is aft of aft limit (refer to R22 Pilot’s Operating Handbook [POH]
Section 2 for model-specific data), determine required nose ballast:
[CG from step 5 – (model’s aft limit)] x (Empty weight from step 8) – 2358
=
64.5 lb
11. Adjust weight and balance to correct for drained unusable fuel and ballast:
Longitudinal CG
Item Weight (lb) (arm, inches) Moment (in.-lb)
Multiply empty weight from
step 8 by CG from step 5 x =
Nose ballast: x 37.5 =
10.2*, 6.0**,
Unusable fuel (add): or 3.6*** x 100.0 =
* Bladder tanks
** All-aluminum tank(s) with aux tank
*** All-aluminum tank(s) without aux tank

18-22 Weighing Procedure and Calculations (continued)
CAUTION
CG with full fuel and minimum solo pilot weight must be at or
forward of aft CG limit.
12. Determine lateral center of gravity:

(Right scale reading – Left scale reading)
x 37 =
(Right scale reading + Left scale reading) in.
13. Determine lateral moment:

(Basic Empty Weight) x (lateral CG)= in.-lb

FIGURE 18-3 NOSE BALLAST
(View inside lower console assembly with upper console hinged aft)

18-30 Fixed Ballast
NOTE
Maximum allowable nose ballast is 10.0 lb.
CAUTION
Altering fixed ballast can appreciably affect helicopter center of
gravity (CG). If fixed ballast information is unknown, reweigh
helicopter per § 18-22.
1. Remove screws and hinge upper console assembly aft. Insert foam support or equivalent
between console and cyclic to protect instrument faces.
2. Refer to Figure 8-3. Remove hardware securing A941-2 or -3 ballast plate(s), if installed,
to A363-1 cover.
3. If A941 ballast attach holes are not previously drilled, use A941 ballast as template and
mark hole locations. Drill 0.198 inch diameter (#8 drill size) hole at marked locations.
4. Remove or install ballast plates per calculations in § 18-22. Select NAS6603 bolt length
to meet torque requirements per § 23-30. Install hardware, standard torque bolts per §
23-32, and torque stripe per Figure 2-1.
5. Remove foam, hinge upper console assembly forward, and install screws. Verify
security.
6. Reweigh and/or calculate basic empty weight and CG per § 18-22.
7. Revise Weight and Balance Record in R22 Pilot's Operating Handbook (POH) Section 6
to reflect ballast removal or installation using the following data:
Longitudinal Longitudinal Lateral

Weight Arm Moment Lateral Arm Moment
Nose ballast 0–10.0 lb 37.5 in. Variable 0.0 in. 0.0 in.-lb

Intentionally Blank

CHAPTER 19
GROUND HANDLING
Section Title Page
19-10 Ground Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.1

19-11 Ground Handling Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.1
19-12 Moving Helicopter on Ground Handling Wheels . . . . . . . . . . . . . . . . . . . . 19.6
19-13 Ground Handling Carts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.6
19-20 Trailering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.7
OCT 2018 Chapter 19 Ground Handling Page 19.i

Intentionally Blank
Page 19.ii Chapter 19 Ground Handling OCT 2018

CHAPTER 19
GROUND HANDLING
19-10 Ground Handling
19-11 Ground Handling Wheels
NOTE
R22 ground handling wheels are installed outboard of landing
gear skid tubes. A063-1 wheel assemblies are interchangeable
(may be installed in right or left skid support). When wheels are
installed and in locked position, handle on right skid tube points
forward and handle on left skid tube points aft.
CAUTION
Handle has a tendency to snap over when raising and lowering the
helicopter. Grip handle firmly with both hands during operation.
CAUTION
Remain clear of landing gear skid tubes when helicopter is
raised.
WARNING
Remove ground handling wheels for flight.
OCT 2018 Chapter 19 Ground Handling Page 19.1

FIGURE 19-1 GROUND HANDLING WHEELS (LEFT SKID SHOWN)
Page 19.2 Chapter 19 Ground Handling OCT 2018

19-11 Ground Handling Wheels (continued)
A. Installation
NOTE
Verify proper inflation of ground handling wheel tires. Maximum
tire inflation pressure is 60 psi (4 bar).
NOTE
Refer to Figure 19-2 for float ship landing gear ground handling
wheels installation.
1. Refer to Figure 19-1. Hold ground handling wheel assembly outboard of skid with
handle left, wheel right, and spindle pointed inboard. Insert spindle completely
into skid-mounted support, then pull handle in rightward arc (raises helicopter) until
handle is in locked position, parallel with the skid.
2. Repeat step to install second wheel assembly (helicopter will rest on skid toes).
B. Removal
NOTE
Refer to Figure 19-3 for float ship landing gear ground handling
wheels removal.
1. Refer to Figure 19-1. Pull ground handling wheel handle in leftward arc (lowers
helicopter) until handle is in unlocked position, parallel with the skid. Remove
spindle from skid-mounted support and remove wheel assembly.
2. Repeat step to remove second wheel assembly.

INSTALLATION
1. Pull tail down. Insert forward blocks

at their lower height under both skids
at forward marks.
2. Push tail up. Insert rear blocks at

their lower height under both skids at
rear marks.
3. Pull tail down. Move forward blocks

“inside” to their upper height under
skid tubes.
4. Push tail up. Slide rear blocks out

(upper height of rear blocks is not
used) and insert wheels under skids
at rear marks.
NOTE
Adjust wheel placement as necessary

to reduce force required to pull tail
down.
5. Pull tail down and remove forward

blocks. Installation is completed.
FIGURE 19-2 FLOAT LANDING GEAR GROUND HANDLING WHEELS INSTALLATION

FIGURE 19-3 FLOAT LANDING GEAR GROUND HANDLING WHEELS REMOVAL

19-12 Moving Helicopter on Ground Handling Wheels
1. Position main rotor blades approximately fore and aft and apply rotor brake.
2. Install ground handling wheels per § 19-11.
3. Verify ground handling area is free of foreign object debris.
4. Have one person pull down on tail rotor gearbox until skid tubes are parallel with the
ground. During ground handling, balance helicopter to minimize wear on forward skid
shoes and rear extensions.
NOTE
Steer helicopter by gripping the tail rotor gearbox, aft tailcone
section, or inboard part of horizontal stabilizer between tailcone
and vertical stabilizers.
CAUTION
Do not steer helicopter by gripping the tail rotor guard, vertical
stabilizers, outboard part of horizontal stabilizer, tail rotor, tail
rotor controls, or tail skid.
5. If additional help is needed, a second person may push on one of the aft vertical frame
tubes or on the nose.
19-13 Ground Handling Carts

The R22 can be handled by one person using the MT900-1 or MT950-1 ground handling cart.
MT900 and MT950 Operating Instructions, Maintenance Manuals, and Illustrated Parts
Catalogs are available online at www.robinsonheli.com.

19-20 Trailering
CAUTION
Trailering the R22 is not normally recommended. Most trailers

large enough to accommodate the helicopter are designed for
much heavier loads; the trailer’s springs and shock absorbers
will not function properly when lightly-loaded. Also, without
support, the tailcone can resonate with trailer vibrations,
subjecting the tailcone to greatly amplified loads.
If trailering is unavoidable, observe the following precautions:

1. Load trailer with ballast to an average weight the trailer is designed to carry.
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 § 26-10. Pack blades in shipping crate.
b. Fabricate blade supports to unload droop stops. Position supports approximately
five feet from blade tips. Cushion support points to prevent blade damage.
4. Restrain tail rotor to prevent teetering.
5. Fuel helicopter per § 22-51.
6. Protect windshield, windows, rotor systems, and all fragile equipment from exposure
to highway debris and subsequent damage.
7. After trailering, perform 100-hour maintenance and inspection per § 2.400.

Intentionally Blank

CHAPTER 20
PARKING AND STORAGE
Section Title Page
20-10 Parking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.1

20-11 Parking in High Wind or Turbulent Air . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.1
20-12 Main Rotor Blade Tie-Downs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.3
20-13 Main Rotor Blade Supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.4
20-20 Storage (Greater than 30 Days) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.4
OCT 2018 Chapter 20 Parking and Storage Page 20.i

Intentionally Blank
Page 20.ii Chapter 20 Parking and Storage OCT 2018

CHAPTER 20
PARKING AND STORAGE
20-10 Parking
1. Place cyclic control in neutral and apply friction.
2. Put collective full down and apply friction.
3. Align rotor blades approximately fore and aft. Apply rotor brake. Install main rotor
blade tie-down(s) in windy conditions per § 20-12.
CAUTION
Do not pull down on blades to teeter rotor. To lower a blade,
push up on opposite blade.
4. During storm conditions, helicopter should be hangared or moved to a safe area (refer
to § 20-11).
20-11 Parking in High Wind or Turbulent Air

A. High Wind or Turbulent Air
Helicopter should be hangared or moved to a safe area during storm conditions or
when storm conditions are forecasted. When parking helicopter in high winds or
when aircraft is exposed to prop/rotor wash or jet blast:
1. Position helicopter with nose pointed in the direction of prevailing wind or
turbulent air.
2. Park helicopter per § 20-10. Position rotor blades slightly offset from fore and
aft to prevent aft blade from flapping into tailcone, and apply rotor brake.
3. If helicopter is hangared, turn fuel shutoff valve off.
OCT 2018 Chapter 20 Parking and Storage Page 20.1

FIGURE 20-1 MAIN ROTOR BLADE TIE-DOWNS
Page 20.2 Chapter 20 Parking and Storage OCT 2018

20-11 Parking in High Wind or Turbulent Air (continued)
B. Extreme Conditions
In extreme conditions, at the operator’s discretion:
1. Remove main rotor blades per § 26-10. Remove tail rotor assembly per § 9.210.
Store main rotor blades and tail rotor assembly in hangar or safe area.
2. Remove main rotor pitch links per steps below, or temporarily secure links
together using ty-rap(s) or safety wire:
a. 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.
b. Remove hardware securing pitch links to swashplate assembly.
3. Remove tail rotor pitch links per steps below:
a. Refer to Figure 9-11. Tag each pitch link with corresponding blade serial
number. Disconnect pitch links from tail rotor blades; keep associate
balancing hardware with each link.
b. Remove hardware securing pitch links to tail rotor pitch control assembly.
20-12 Main Rotor Blade Tie-Downs
CAUTION
Overtightening tie-down straps can damage main rotor blades.
Maximum tie-down tension is 5 lb.
1. Park helicopter per § 20-10.

2. Refer to Figure 20-1. Slide MT290-1 tie-down jacket over forward (lowered) main
rotor blade tip, white lettering facing down. Tie strap to windshield center post or
thread strap through post and secure hook and loop tape. Push up on secured blade
to remove slack in tie-down strap.
3. As required, install MT290-1 tie-down on aft main rotor blade. Slide jacket over
blade tip, white lettering facing down. Wrap strap around tailcone forward of strobe
light, then tie around strobe light base or secure hook and loop tape around strobe
light base. Push up on secured blade to remove slack in tie-down strap.
OCT 2018 Chapter 20 Parking and Storage Page 20.3

20-13 Main Rotor Blade Supports
Reserved.
20-20 Storage (Greater than 30 days)

1. Record the date helicopter is prepared and placed in storage.
CAUTION
To minimize risk of electrical discharge: when disconnecting
battery, disconnect negative (ground) cable from battery first,
then the positive cable. When connecting battery, connect
positive cable to battery first, then the negative (ground) cable.
2. Turn battery off. Remove cotter rings and wing nuts securing battery box cover to box
and remove cover. Remove hardware securing cables to battery. Remove battery.
Inspect and service battery according to battery manufacturer’s instructions.
3. Preserve engine for storage per Lycoming Service Letter no. L180 (current revision).
4. Fill main and tail gearboxes to center of sight glass with A257-2 oil.
5. Fuel helicopter per R22 Pilot’s Operating Handbook (POH) Section 8.
NOTE
Fuel lubricates bladder inner liner and keeps it from drying out
or cracking. Refuel helicopter after run-ups during storage.
6. Clean aircraft per POH Section 8. Verify helicopter is completely dry.

7. Refinish main rotor blades per § 26-10. Refinish tail rotor blades per § 9.220. If blade
painting is not feasible, wax blades.
8. Position helicopter in a hangar or protected environment.
9. Apply suitable non-drying corrosion preventive compound to A166 clutch shaft adjacent
to seals (where shaft enters and exits upper sheave).
10. Open door vents or remove doors to ventilate cabin as required.
11. Close and latch access doors.
NOTE
During storage, periodically inspect helicopter for corrosion;
helicopters stored in humid environments will require more
frequent inspection.
Page 20.4 Chapter 20 Parking and Storage OCT 2018

CHAPTER 21
PLACARDS AND MARKINGS
Section Title Page
21-10 Placards and Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.1
OCT 2018 Chapter 21 Placards and Markings Page 21.i

Intentionally Blank
Page 21.ii Chapter 21 Placards and Markings OCT 2018

CHAPTER 21
PLACARDS AND MARKINGS
21-10 Placards and Markings

Refer to R22 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. Remove decal entirely.
B. Installation
Verify surfaces are clean and dry before attaching decals. Use a clean cloth wet
with acetone or mild soapy water to clean surfaces, but use caution when using
acetone near silk-screened lettering on console and circuit breaker panel. Acetone
can smudge or remove silk-screened letters. Attach decal and rub decal surface with
finger, applying slight pressure.
OCT 2018 Chapter 21 Placards and Markings Page 21.1

Intentionally Blank
Page 21.2 Chapter 21 Placards and Markings OCT 2018

CHAPTER 22
SERVICING
Section Title Page
22-10 Main Rotor Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.1

22-11 Cleaning Chip Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.3
22-12 Cleaning Sight Gage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.3
22-13 Main Rotor Gearbox Drain and Flush . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.4
22-20 Tail Rotor Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.5
22-21 Cleaning Chip Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.6
22-22 Cleaning Sight Gage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.6
22-23 Tail Rotor Gearbox Drain and Flush . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.7
22-30 Clutch Assembly Lubricant Inspection and Servicing . . . . . . . . . . . . . . . . . . 22.8
22-40 Clutch Actuator Upper and Lower Bearings . . . . . . . . . . . . . . . . . . . . . . . . . 22.9
22-41 Upper Bearing Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.9
22-42 Lower Bearing Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.10
22-50 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.11
22-51 Fueling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.11
22-52 Defueling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.11
22-60 Main Rotor Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.13
22-61 Pitch Bearing Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.13
OCT 2018 Chapter 22 Servicing Page 22.i

Intentionally Blank
Page 22.ii Chapter 22 Servicing OCT 2018

CHAPTER 22
SERVICING
22-10 Main Rotor Gearbox
NOTE
Inspect main rotor gearbox for leaks when “top off” is required.
NOTE
Verify aircraft is on level ground when evaluating gearbox oil
level.
WARNING
Refer to Safety Data Sheets (SDS) and observe precautions
when working in proximity to hazardous materials.
A. Draining Oil
1. Run-up helicopter for approximately five minutes at 70-75% RPM per R22 Pilot’s
Operating Handbook (POH) Section 4 as required to warm oil and expedite draining.
2. Disconnect chip detector wiring from airframe harness at connectors. Remove
chip detector from housing.
3. Refer to Figure 22-1. Insert MT054-1 drain assembly (or MT053-1 drain assembly
for threaded chip detector) into housing. Position drain hose overboard into a
suitable drain container. Jam wedge between firewall and drain assembly to
open valve and drain oil. Remove drain assembly after oil has drained.
B. Adding Oil
1. Install chip detector in housing, if removed. (Special torque threaded chip detector
per § 23-33.) Connect chip detector wiring to airframe harness at connectors.
2. Remove gearbox filler-plug. Fill gearbox to center of sight glass using A257-2 oil.
Rotate rotor system by hand for several revolutions and pull down on tail rotor
gearbox several times. Check gearbox oil level and adjust as required. Install
gearbox filler-plug and special torque plug per § 23-33.
3. Run-up helicopter approximately five minutes at 70-75% RPM per R22 Pilot’s
Operating Handbook (POH) Section 4.
4. Check gearbox oil level, and adjust as required.
OCT 2018 Chapter 22 Servicing Page 22.1

FIGURE 22-1 DRAINING MAIN ROTOR GEARBOX
Page 22.2 Chapter 22 Servicing OCT 2018

22-11 Cleaning Chip Detector and Chip Detector Housing
WARNING
1. Disconnect chip detector wiring from airframe harness at connectors. For tail gearbox
chip detector, place suitable drain container below gearbox. Remove chip detector
from housing or gearbox.
2. Clean chip detector using a toothbrush and approved solvent (refer to § 23-70).
Remove debris using compressed air or masking tape; do not use a magnet. Dry chip
detector using compressed air or a lint-free cloth. Inspect condition.
3. Connect chip detector wiring to airframe harness at connectors. Turn battery on.
Touch detector’s magnet to airframe and verify appropriate gearbox caution light
illuminates. Turn battery off. Disconnect chip detector wiring from airframe harness
at connectors.
4. Install chip detector in housing or gearbox. Special torque threaded chip detector per
§ 23-33. Connect chip detector wiring to airframe harness at connectors.
5. Turn battery on. Depress push-to-test button(s) and verify appropriate gearbox caution
light illuminates. Turn battery off.
6. As required, remove filler-plug. Fill gearbox to center of sight glass using A257-2 oil.
Rotate rotor system by hand for several revolutions and pull down on tail rotor gearbox
several times. Check gearbox oil level and adjust as required. Install filler-plug in
gearbox and special torque plug per § 23-33.
22-12 Cleaning Sight Gage

1. Drain main rotor gearbox oil per § 22-10.
2. Remove sight gage from gearbox.
3. Clean sight glass using a toothbrush and approved solvent (refer to § 23-70). Dry
sight gage using compressed air or a lint-free cloth. Inspect condition.
4. Install sight gage in gearbox and special torque gage per § 23-33. Verify security.

22-13 Main Rotor Gearbox Drain And Flush
WARNING
2. Disconnect chip detector wiring from airframe harness at connectors. Remove chip
detector from housing.
3. Refer to Figure 22-1. Insert MT054-1 drain assembly (or MT053-1 drain assembly
for threaded chip detector) into housing. Position drain hose overboard into a suitable
drain container. Jam wedge between firewall and drain assembly to open valve and
drain oil.
4. Remove drain assembly after oil has drained. Install chip detector (special torque
threaded chip detector per § 23-33). Connect chip detector wiring to airframe harness
at connectors.
5. Remove filler-plug. Fill gearbox to center of sight glass using SAE30, SAE40, SAE50,
or SAE20W50 mineral oil. Install filler-plug and special torque plug per § 23-33.
6. Run-up helicopter for approximately five minutes at 70-75% RPM per POH Section 4.
7. After shutdown, drain mineral oil per steps 2 thru 4. Remove drain assembly after oil
has drained.
8. Remove chip detector housing. Clean chip detector and housing using a toothbrush
and approved solvent (refer to § 23-70). Remove debris using compressed air or
masking tape; do not use a magnet. Dry chip detector and housing using compressed
air or a lint-free cloth. Inspect condition.
Touch detector’s magnet to firewall and verify MR CHIP caution light illuminates. Turn
battery off. Disconnect chip detector wiring from airframe harness at connectors.
10. Install chip detector housing in gearbox and special torque housing per § 23-33.
Install chip detector in housing. (Special torque threaded chip detector per § 23-33.)
Connect chip detector wiring to airframe harness at connectors.
11. As required, remove sight gage and clean glass using approved solvent (refer to
§ 23‑70). Install sight gage and special torque gage per § 23-33.
12. Remove filler-plug. Fill gearbox to center of sight glass using A257-2 oil. Rotate rotor
13. Turn battery on. Depress push-to-test MR CHIP button and verify caution light
illuminates. Turn battery off.

22-20 Tail Rotor Gearbox
NOTE
Inspect tail rotor gearbox for leaks when “top off” is required.
NOTE
Verify aircraft is on level ground when evaluating gearbox oil
level.
WARNING
A. Draining Oil
1. Cut and discard ty-raps as required and disconnect chip detector wiring from
airframe harness at connectors.
2. Place a suitable drain container under tail rotor gearbox to catch oil, then remove
chip detector.
B. Adding Oil
1. Install chip detector in tail gearbox and special torque detector per § 23-33.
2. Connect chip detector wiring and install ty-raps, as required. Cinch ty-raps until
snug without over-tightening, and trim tips flush with heads.
3. Turn battery switch on. Verify TR CHIP caution light illuminates when test button
is depressed. Turn battery switch off.
4. Remove gearbox filler-vent plug and fill gearbox with A257-22 lubricant to center
of sight glass. Rotate rotor system by hand for several revolutions and pull down
on tail rotor gearbox several times. Check gearbox oil level and adjust as required.
5. Install filler-vent plug in gearbox and special torque plug per § 23-33.

22-21 Cleaning Chip Detector
1. Drain tail rotor gearbox oil per § 22-20.
detector using compressed air or a lint-free cloth. Inspect condition.
3. Connect chip detector wiring to airframe harness at connectors. Turn battery switch
on. Touch detector’s magnet to airframe and verify TR CHIP caution light illuminates.
Turn battery switch off. Disconnect chip detector wiring from airframe harness at
connectors.
4. Install chip detector in gearbox and special torque detector per § 23-33. Connect chip
detector wiring to airframe harness at connectors. Verify security.
5. Turn battery switch on. Depress push-to-test button and verify TR CHIP caution light
illuminates. Turn battery switch off.
12-22 Cleaning Sight Gage
1. Drain tail rotor gearbox oil per § 22-20.
2. Remove sight gage from gearbox.
3. Clean sight gage using a toothbrush and approved solvent (refer to § 23-70). Dry
sight gage using compressed air or a lint-free cloth. Inspect condition.
4. Install sight gage in gearbox and special torque gage per § 23-33. Verify security.

22-23 Tail Rotor Gearbox Drain And Flush
WARNING
2. Disconnect chip detector wiring from airframe harness at connectors. Place a suitable
drain container below tail rotor gearbox and remove chip detector.
3. Remove filler-plug. Fill gearbox to center of sight gage using SAE30, SAE40, SAE50,
or SAE20W50 mineral oil. Install filler-plug and special torque plug per § 23-33.
4. Run-up helicopter for approximately five minutes at 70-75% RPM per POH Section 4.
5. After shutdown, drain mineral oil per step 2.
detector and housing using compressed air or a lint-free cloth. Inspect condition.
Touch detector’s magnet to airframe and verify TR CHIP caution light illuminates. Turn
battery off. Disconnect chip detector wiring from airframe harness at connectors.
8. Install chip detector in gearbox and special torque detector per § 23-33. Connect chip
detector wiring to airframe harness at connectors.
9. As required, remove sight gage and clean glass using approved solvent (refer to
§ 23‑70). Install sight gage and special torque gage per § 23-33.
10. Remove filler-plug. Fill gearbox to center of sight gage using A257-2 oil. Rotate rotor
11. Turn battery on. Depress push-to-test TR CHIP button and verify caution light
illuminates. Turn battery off.

22-30 Clutch Assembly Lubricant Inspection and Servicing
A. Clutch Assemblies with A168-4 (Forward) Retainer
WARNING
Avoid contaminating drive belts and sheaves with lubricant.
Clean contaminated surfaces with mild soap and water solution,
followed by a warm water rinse. Place a clean, absorbent rag
beneath MT147-2 fittings, when installed, to catch any drips.
1. Open main rotor gearbox compartment access doors.

2. Rotate clutch shaft until bolts securing yokes to shaft are vertical. Engage rotor
brake.
3. Remove A168-4 (forward) retainer’s top B289-3 screw and install clean MT147-2
fitting. Attach drain hose.
4. Rotate sheave until fitting and attached drain hose are on bottom. Route drain hose
into a suitable, clean container. Remove top B289-3 screw and allow lubricant to
drain into container.
5. Install second clean MT147-2 fitting at top of retainer and connect a clean supply
of A257-4 lubricant to fitting. Flush sprag clutch housing until exiting lubricant is
obviously red. Disconnect lubricant supply and allow lubricant to drain completely
into container.
6. Strain all lubricant from container through a 180-200 micron paint filter/strainer.
Fluid may be dark, and may sparkle with very fine metallic debris; this is normal. If
metallic debris is trapped in the filter/strainer, remove clutch assembly and return
it to RHC, or an R22 Service Center authorized to overhaul clutch assemblies, for
disassembly and inspection.
7. If metallic debris is not found in the filter, attach drain hose to top fitting. Route
drain hose into a suitable container. Connect a clean supply of A257-4 lubricant
to bottom fitting. Fill sprag clutch housing thru bottom fitting until no air bubbles
are visible in drain hose. Shut-off fluid flow.
8. Remove top fitting and install screw. Rotate sheave until opposite fitting is on
top. Remove fitting and verify lubricant level contacts threads; add lubricant as
required. Install forward screw.
9. Close main rotor gearbox compartment access doors.
B. Clutch Assemblies with Retainer without B289-3 Screws
1. Perform clutch assembly (aft) seal replacement per § 7.213.

22-40 Clutch Actuator Upper and Lower Bearings
The actuator upper bearing is located on the clutch shaft, and the actuator lower bearing is
located on the fanshaft. Failure of either actuator bearing in flight could cause loss of power
to rotor system and result in a serious accident. Refer to § 2.110 for general indications
of bearing failure. In addition, just before failure of an actuator bearing, clutch light may
flicker (on and off in less than one second) constantly or illuminate for a longer time than
usual. Do not be confused with normal retensioning in flight (light on for up to 8 seconds,
then off). Flight should not be resumed until cause of abnormal clutch light illumination has
been determined.
Perform the following bearing inspections whenever an actuator bearing discrepancy is
suspected or fanwheel is removed:
22-41 Upper Bearing Lubrication
WARNING
NOTE
Kl-115 Special Tools Kit (syringe and probe) required to perform
the following procedure.
1. Fill syringe with 2-3 grams A257-12 grease (refer to § 23-70). Note: 2.5 grams of
grease fills a 0.5 inch (13 mm) long space inside a syringe body with a 0.63 inch (16
mm) inner diameter.
2. Thoroughly clean an accessible portion of A184 bearing assembly aft rubber seal and
surrounding surface.
3. Gently press plastic tip of syringe against cleaned seal inner lip until lip deflects inward
and tip slips into bearing. Do not damage seal. Inject grease with syringe perpendicular
to seal. Withdraw syringe. Part of seal’s inner lip remains deflected inward.
4. Slide tip of steel probe under seal inner lip and return deflected portion of lip to original
position. Do not damage seal.
5. Run-up helicopter for approximately two minutes 104% RPM per R22 Pilot’s Operating
Handbook (POH) Section 4. Shut down, inspect bearing, and clean off any escaped grease.
WARNING
Bearing used in A184 bearing assembly has modified internal
clearance for use on R22. Do not substitute any other bearing.

22-42 Lower Bearing Lubrication
WARNING
A181-1 & A181-3 bearings are obsolete and must be removed
from service.
1. Remove fanwheel per § 6.210.

2. Disconnect lower end of belt tension actuator from bearing housing.
3. Rotate bearing housing. Verify no roughness, scraping, or excessive looseness (0.010
inch maximum axial play). Verify no seal damage, and no heat damage. Lubricate
bearing:
a. Remove four perimeter screws, nuts, and washers.
b. Remove bearing block with attached outer race (bearing outer race is split type).
Forward seal retainer, forward seal, bearing inner race and bearing rollers will
remain on fan shaft.
c. Clean parts, including seals, and inspect for obvious damage.
d. Lubricate bearing by filling openings on both sides of roller cage with A257-12
grease, but do not fill spaces between rollers.
e. Reassemble. Ensure forward seal fits properly into recess provided in forward
seal retainer (not applicable to Rev L bearings).
f. Standard torque MS24694-S61 screws per § 23-32.
g. Rotate bearing housing. Verify no roughness and no excessive looseness.
4. Inspect bearing inner race on fanshaft. No movement or fretting is allowed between
inner race and fanshaft.
5. If any indication of bearing failure is found, replace A007-3 or -5 shaft and bearing
assembly per § 7.290.
6. Install fanwheel per § 6.220.
7. If bearing was lubricated, inspect & clean off any escaped grease after balancing
fanwheel.

22-50 Fuel System
WARNING
WARNING
Always fuel or defuel helicopter in a well-ventilated area. No
smoking within 100 feet of aircraft during fueling.
22-51 Fueling
2. Ground helicopter and ground fuel vehicle. Ground fuel vehicle to helicopter.
3. Verify proper grade of aviation fuel. See R22 Pilot's Operating Handbook (POH)
Section 2 for approved fuel grades and instructions for use of anti-ice additive.
NOTE
Refer to Figure 2-4A. Verify A689-6 fuel cap is revision J or
subseqent if bladder tanks are installed (revision J or subsequent
caps may also be used on all-aluminum tanks).
4. Remove fuel cap(s) and fuel helicopter as required.

5. Install fuel cap(s); verify security.
6. Remove grounding equipment.
22-52 Defueling
1. Turn battery switch and fuel valve off.
2. Place suitable drain container beneath carburetor and ground container to helicopter.
3. Disconnect fuel hose assembly from carburetor.
4. Turn fuel valve on to drain fuel. (Perform low-fuel switch operation check per § 12.430,
if desired.)
5. Connect fuel hose assembly to carburetor, special torque hose assembly nut per
§ 23‑33, and torque stripe per Figure 2-1.

FIGURE 22-2 FILLING PITCH BEARING HOUSING

22-60 Main Rotor Blades
22-61 Pitch Bearing Housing
NOTE
MT147-1 Main rotor blade spindle air bleed tool includes supply
container, hose assemblies, and bleed fittings.
WARNING
1. Remove main rotor blades per § 26-10.

2. Refer to Figure 22-2. Place a suitable drain container below main rotor pitch horn.
Remove two B289-2 bolts from pitch horn and drain fluid.
3. Install MT147-2 bleed fittings into pitch horn openings. Attach drain hose assembly
to (top) bleed fitting, secure with two wraps of lockwire. Position drain hose into drain
container.
4. Place supply container with sufficient A257-4 fluid approximately 3 feet above spindle.
Route fill hose assembly into drain container and open brass valve. Open supply
container plastic valve and purge air from fill hose. Close valves.
5. Connect brass valve to (bottom) bleed fitting by tightening brass compression sleeve.
6. Open valves and fill spindle housing until no air bubbles are visible in drain hose
assembly. Massage spindle boot, oscillate spindle, and raise blade tip up & down to
remove trapped air.
7. Remove drain hose assembly and (top) bleed fitting, and install B289-2 bolt. Roll the
blade over. After five minutes, inspect the boot for leaks. If no leaks are found, close
valves, remove fill hose assembly brass valve and (bottom) bleed fitting, and install
other bolt.
8. Special torque B289-2 bolts per § 23-33 and torque stripe per Figure 2-1.
9. Repeat steps for opposite blade.

Intentionally Blank

CHAPTER 23
STANDARD PRACTICES
Section Title Page
23-10 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.1

23-20 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.3
23-30 Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.5
23-31 Torque Stripe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.7
23-32 Standard Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.8
23-33 Special Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.9
23-34 D210-series Nuts on Critical Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . 23.13
23-40 Non-Destructive Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.14
23-41 Magnetic Particle Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.14
23-42 Fluorescent Penetrant Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.15
23-50 Corrosion Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.15
23-60 Priming and Painting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.16
23-70 Approved Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.19
23-71 Paint Strippers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.19
23-72 Solvents and Cleaners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.19
23-73 Fillers and Putty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.20
23-74 Torque Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.20
23-75 Primers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.21
23-76 Powder Coat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.21
23-77 Paints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.22
23-78 Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.25
23-79 Adhesives and Sealants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.26
23-80 Miscellaneous Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.28
23-81 Part Interchangeability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.28
23-82 Thermal Fitting Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.28
23-83 Replacement Component Identification (Data) Plates . . . . . . . . . . . . . . . . 23.28
23-84 Crimp Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.29
23-85 Storage Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.30
23-86 B526 Screws and B527-08 Washers . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.30
OCT 2018 Chapter 23 Standard Practices Page 23.i

Intentionally Blank
Page 23.ii Chapter 23 Standard Practices OCT 2018

CHAPTER 23
STANDARD PRACTICES
23-10 Cleaning
CAUTION
Wash helicopter exterior surfaces, windshields, and windows
with mild soap and water. Harsh abrasives, alkaline soaps, or
detergents can scratch painted or plastic surfaces, or cause
corrosion of metal. Protect areas where cleaning solution could
cause damage.
CAUTION
Never use high-pressure spray to clean helicopter. Never blow
compressed air into main or tail rotor blade tip drain holes, pitot
tube, or static ports.
WARNING
Refer to Safety Data Sheet (SDS) and observe precautions
A. Cleaning Exterior Surfaces

1. Rinse away loose dirt and debris from exterior surface with clean water.
2. Apply mild soap and clean warm water solution to exterior surface using a clean,
soft cloth, sponge, or soft bristle brush. Use caution near antennas and sensitive
equipment.
3. Remove oil and grease using a cloth wetted with aliphatic naphtha.
4. Rinse all surfaces thoroughly.
5. If desired, polish painted surfaces with a good quality automotive wax using soft
cleaning cloths, or a chamois cloth, free of abrasive debris.
OCT 2018 Chapter 23 Standard Practices Page 23.1

23-10 Cleaning (continued)
B. Cleaning Windshield and Windows
CAUTION
Do not use gasoline, other alcohols, benzene, carbon tetrachlo-
ride, thinner, acetone, or window (glass) cleaning sprays.
1. Rinse away loose dirt and debris from windshield and windows with clean water.
2. Apply mild soap and clean warm water solution, or aircraft plastic cleaner, to
windshield and windows using a clean, soft cloth or sponge in a straight back and
forth motion. Do not rub harshly.
3. Remove oil and grease using a cloth wetted with isopropyl alcohol (rubbing alcohol)
or aliphatic naphtha.
4. After cleaning plastic surfaces, apply a thin coat of hard polishing wax. Rub lightly
with a soft cloth. Do not use a circular motion.
5. To remove scratches, rub windshield or windows with jeweler’s rouge then hand
polish with commercial plastic polish. Polish in figure eight motion.
C. Cleaning Seat Assemblies and Back Rests
1. Vacuum and brush, then wipe with damp cloth. Dry immediately.
2. Soiled upholstery, except leather, may be cleaned with a good upholstery cleaner
suitable for the material. Follow manufacturer’s instructions. Avoid soaking or
harsh rubbing.
3. Leather should be cleaned with saddle soap or a mild hard soap and water.
D. Cleaning Carpet
Remove loose dirt with a whisk broom or vacuum. For soiled spots and stains, use
nonflammable dry cleaning liquid.
Page 23.2 Chapter 23 Standard Practices OCT 2018

23-20 Lubrication
WARNING
Most bearings are sealed or self-lubricated and do not require periodic lubrication. Bearings
with scheduled lubrication intervals are listed in Table 1-1 (see Chapter 1).
Engine lubrication requirements are located in the R22 Pilot’s Operating Handbook, the
appropriate model Lycoming Operator’s Manual, and Lycoming Service Instruction No.
1014 (current revision).
Main and tail gearboxes require servicing when indicated by sight gage level. Additionally,
change gearbox oil and clean respective sight gage when oil becomes so dirty its level
cannot be determined.
WARNING
A257-2 oil is the only approved oil for use in gearboxes.
When installing a new or overhauled gearbox, drain and flush gearbox after the first 4
hours of flight or first chip light, whichever occurs first. Thereafter, change gearbox oil at
intervals listed in Table 1-1 (see Chapter 1).

Given Symbols
Y = Unknown Y = Torque wrench setting
T = 135 in.-lb T = Torque applied to fastener
L = 10 in. L = Length of torque wrench
A = 1.5 in. A = Length of adapter
When using an adapter that lengthens torque wrench effective length,

calculate torque wrench setting using the formula below:
EXAMPLE
TxL 135 x 10 1350
Solve for Y = = = = 117.39
L+A 10 + 1.5 11.5
Set torque wrench to 117 in.-lb to torque fastener to 135 in.-lb.
FIGURE 23-1 LENGTHENING TORQUE WRENCH EFFECTIVE LENGTH
Given Symbols
Y = Unknown Y = Torque wrench setting
T = 135 in.-lb T = Torque applied to fastener
L = 10 in. L = Length of torque wrench
A = 1.5 in. A = Length of adapter
When using an adapter that shortens the torque wrench effective length,
calculate torque wrench setting using the formula below:
EXAMPLE
TxL 135 x 10 1350
Solve for Y = = = = 158.82
L–A 10 – 1.5 8.5
Set torque wrench to 159 in.-lb to torque fastener to 135 in.-lb.
FIGURE 23-2 SHORTENING TORQUE WRENCH EFFECTIVE LENGTH

23-30 Torque Requirements
A. Tool Calibration
Dimensions and tolerances given in this manual are critical. Calibrate measuring tools
per manufacturer’s recommendation at least once a year, when tool is dropped, misused,
or calibration is suspect. Measuring tools include torque wrenches, micrometers,
calipers, dial indicators, spring scales, protractors, and balancing equipment.
WARNING
Proper torque is critical. Always use calibrated wrenches and
undamaged, properly lubricated (where applicable) hardware.
Ensure clamping surfaces are clean, and clamp only bare metal
or wet-primed surfaces. Improper torque or dirty or painted
clamping surfaces may result in loss of clamp-up, hardware or
part damage, and premature failure.
B. Torque Value
Torque fasteners to standard dry values listed in § 23-32 unless otherwise specified.
If torque is applied by rotating bolt, increase torque value by 10% to account for
higher friction at bolt head and shank.
For example, the torque wrench setting for an NAS6605 bolt used with an MS21075
nutplate is determined as follows:
NAS6605 bolt (5 indicates 5/16 inch size) dry torque per § 23-32 240 in.-lb
Add 10% because torque must be applied at bolt head + 24 in.-lb
Torque wrench setting 264 in.-lb
C. Secondary Locking Mechanism

A secondary locking mechanism is required on all critical fasteners. B330 stamped
nuts (palnuts) serve as the secondary locking mechanism in most areas on the
helicopter, and are torqued per § 23-32. Palnuts must be replaced when removed.
The R22 Illustrated Parts Catalog (IPC) lists secondary locking mechanisms for specific
fasteners.

23-30 Torque Requirements (continued)
D. Critical Fastener
CAUTION
D210-series nuts, which supersede MS21042L-series and
NAS1291-series nuts, are required on critical fasteners.
WARNING
by a qualified person. If a second person is not available,
RHC recommends the installer take a 5-minute break prior to
inspecting flight control connections he has assembled.
A critical fastener is one which, if removed or lost, would jeopardize safe operation
of the helicopter. This includes joints in the primary control system, and non-fail-safe
structural joints in the airframe, landing gear, and drive system.

23-30 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.
3. If chattering or jerking occurs, disassemble and re-torque fastener.
4. If special adapters which change effective length of torque wrench are used, final
torque value must be calculated using formulas in Figures 23-1 and 23-2.
5. Unless otherwise specified, proper thread engagement requires:
a. If palnut is not required, one to four threads exposed beyond primary nut.
b. If palnut is required, two to four threads exposed beyond primary nut.
c. For B526-8 screws, one to five threads exposed beyond primary nut.
WARNING
Proper thread engagement ensures proper locking of fastener.
Exceeding maximum thread exposure beyond primary nut
may allow nut to seat against unthreaded shank, resulting in
insufficient joint clamping.
6. Refer to Part A. Torque wrenches must be calibrated annually, when dropped, or

when a calibration error is suspected.
23-31 Torque Stripe
WARNING
Refer to Figure 2-1. Lacquer-paint Torque Seal® is applied to all critical fasteners after
palnut installation in a stripe (“torque stripe”) extending from the fastener’s exposed
threads across both nuts and onto the component. Subsequent rotation of the nut or bolt
can be detected visually. Position torque stripes for maximum visibility during preflight
inspections. Approved Torque Seal® is listed in § 23-74.

23-32 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.
6. Tolerance is ± 10% unless range is specified.
7. Unless otherwise specified, thread sizes 8-32 and smaller are not used for
primary structure and do not require control of torques.
FASTENER SERIES SIZE EXAMPLE FASTENER DRY TORQUE

10-32 NAS6603 50 in.-lb
NAS6603 thru NAS6608 Bolts 1/4-28 NAS6604 120 in.-lb

NAS1303 thru NAS1308 Bolts 5/16-24 NAS6605 240 in.-lb
NAS623 Screws
NAS1351 & NAS1352 Screws 3/8-24 NAS6606 350 in.-lb
NAS600 thru NAS606 Screws 7/16-20 NAS6607 665 in.-lb
1/2-20 NAS6608 995 in.-lb
AN3 Bolts
10-32 AN3 37 in.-lb
AN4 Bolts
AN6 Bolts
AN8 Bolts 1/4-28 AN4 90 in.-lb
AN502 & AN503 Screws
AN509 Screws 3/8-24 AN6 280 in.-lb
AN525 Screws
MS24694 Screws 1/2-20 AN8 795 in.-lb
MS27039 Screws
10-32 B330-7 (MS27151-7) 6–15 in.-lb
1/4-28 B330-13 (MS27151-13) 11–25 in.-lb
STAMPED NUTS 5/16-24 B330-16 (MS27151-16) 20–40 in.-lb

(PALNUTS) 3/8-24 B330-19 (MS27151-19) 29–60 in.-lb
7/16-20 B330-21 (MS27151-21) 42–85 in.-lb
1/2-20 B330-24 (MS27151-24) 54–110 in.-lb
1/8-27 N/A 60 in.-lb
1/4-18 N/A 85 in.-lb
TAPERED PIPE
3/8-18 N/A 110 in.-lb
THREADS
1/2-14 N/A 160 in.-lb
3/4-14 N/A 230 in.-lb
10-32 AN315-3 15 in.-lb
ROD END JAM NUTS 1/4-28 AN316-4 40 in.-lb

(AN315 and AN316) 5/16-24 AN316-5 80 in.-lb
3/8-24 AN316-6 110 in.-lb

23-33 Special Torques
These torques are non-standard and supersede those in § 23-32.
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. For elbow and tee fittings which require alignment, torque to indicated
value, then tighten to desired position.
6. Tolerance is ± 10% unless range is specified.
7. Unless otherwise specified, thread sizes 8-32 and smaller are not used for
primary structure and do not require control of torques.
AREA (QUANTITY) FASTENER TORQUE

(1) AN320-15 nut (1½ inch socket) on A007-3 shaft assembly 183–233 ft-lb wet
DRIVE
(1) AN320-18 nut (111/16 inch socket) on A007-5 shaft assembly 340–400 ft-lb wet
SYSTEM
(6) NAS6606-24H bolts, lower sheave 300 in.-lb
EMPENNAGE (4) NAS6603-2 & (4) NAS6603-5 bolts, vertical stabilizer attach 70 in.-lb
(1) AN320-15 or AN320-18 nut – see DRIVE SYSTEM
(8) or (12) NAS6603-3 or -6 bolts and D210-3 nuts, cone-to-
FANWHEEL 70 in.-lb
fanwheel
(6) NAS6605-12, -13, or -14 bolts, hub 300 in.-lb
(1) A457-15 bulkhead union and nut 285 in.-lb
(1) A657-1 nut, fuel valve elbow-to-bulkhead union 120 in.-lb
(1) A726-1 line assembly, bulkhead union-to-gascolator 285 in.-lb
(2) B254-3 strainer assembly, tank outlets 200 in.-lb wet
(1) B283 hose assembly nuts, gascolator-to-carburetor 120 in.-lb
(5) B289-1 bolts, fuel sender (torque in criss-cross pattern) 37 in.-lb
(2) B330-5 palnut, fuel sender ground stud 9 in.-lb
(2) B330-6 palnut, fuel sender center stud 11 in.-lb
FUEL SYSTEM (1) D205-32 hose assembly nuts, main tank-to-fuel valve 120 in.-lb
(1) D205-33 hose assembly nuts, tank interconnect 120 in.-lb
(1) D205-34 hose assembly nuts, main tank drain 60 in.-lb
(1) D210-4 nut, gascolator mounting plug 70 in.-lb
(16) AN805 nuts, fuel primer line 20–30 in.-lb
(1) AN815-4D union, main tank, drain hose (bladder tanks) 145 in.-lb
(1) AN815-6D union, main tank, tank interconnect hose 200 in.-lb
(1) AN894D4-2 bushing, primer system 50–65 in.-lb
(1) AN894D6-4 bushing, primer system 110–130 in.-lb

23-33 Special Torques (continued)

(1) AN924-4D nut, main tank, drain valve (bladder tanks) 145 in.-lb
(1) AN924-5D nut, low-fuel warning switch 150 in.-lb
FUEL SYSTEM (4) MS27039C1-06 screws, fuel valve 16 in.-lb

(continued) (4) MS27039DD1-26 screws, air bypass door 22–25 in.-lb
(1) MS27769D2 plug, gascolator 60 in.-lb
Primer system line assembly nuts, flared end fittings 20–30 in.-lb
(1) B277-052 clamp, lower rib 50 in.-lb
FUSELAGE (1) D210-5 nut, tow ball 240 in.-lb
(8) MS51861-37C screws, door hinges 36 in.-lb
(4) AN4-25A bolts, ground handling support 70 in.-lb
LANDING
GEAR (56) NAS6604 bolts, floats to skids and skid extensions 50 in.-lb
(2 per blade) A722-4 screw, tip weight retaining 40 in.-lb wet

MAIN ROTOR
(2 per blade) B289-2 self-sealing bolts in pitch horn 70 in.-lb
BLADE
(2 per blade) NAS1351N3-10P screw, cover retaining 40 in.-lb wet
(1) AN320-8 nut, gearbox pinion 290–410 in.-lb

(1) AN10-41A bolt, gearbox mounting
90 ft-lb dry torqued from
(3) A650-1 fittings, gearbox mounting
bolt head or nut
(requires MS21044N10 nuts)
(1) F650-3 bolt, gearbox mounting
65 ft-lb, wet
(3) A650-3 fittings, gearbox mounting
torque from bolt head or nut
(requires D210-10 nuts)
MAIN ROTOR (6) NAS1352-4-14 screws in end cover 140 in.-lb
GEARBOX
Large nut 150 in.-lb
(1) chip detector (threaded, non-quick-disconnect type)
Small nut 75 in.-lb
(1) chip detector housing 150 in.-lb
(1) nut, chip detector wiring 4–6 in.-lb
(1) filler plug 150 in.-lb
(1) sight gage 150 in.-lb
New bolt: 0.016–0.017 inch
(1) NAS630-80 (or MS21250-10080) teeter hinge bolt; elongation (stretch), wet
(2) NAS630-80 (or MS21250-10080) coning hinge Used bolt: 0.015–0.017
bolts in A154-1 hub inch elongation, wet, &
MAIN ROTOR cotter pin holes must align
HUB New bolt: 0.011–0.012 inch
elongation (stretch), wet
(2) NAS632-82 (or MS21250-12082) coning hinge
Used bolt: 0.010–0.012
bolts in B370-1 hub
inch elongation, wet, &
cotter pin holes must align


OVERTRAVEL
(1) A486 screw, upper rod end 37 in.-lb
SPRING
(1) A058-5 carburetor air temp probe 36–48 in.-lb
(1) A760-1 oil temperature sender 300 in.-lb
(2) B277-024 clamps, carb heat scoop 30 in.-lb
(2) A740-1 manifold pressure line nuts 25–35 in.-lb
(4) AN818-8 nuts, oil cooler line (stainless-steel lines) 40 ft-lb
(4) AN818-8 nuts, oil cooler line (aluminum lines) 230–260 in.-lb
(1) AN894D4-3 bushing, manifold pressure line,
135–150 in.-lb
at firewall
(4) MS20074-04-04 bolts, airbox-to-carburetor 30 in.-lb
(1) 3080-00038 cylinder head temperature probe 70–80 in.-lb
(1) bolt, alternator belt tension 204 in.-lb
(4) bolts, D723-1 oil adapter 90–100 in.-lb
96 in.-lb initial, 204 in.-lb
(4) carburetor-to-engine nuts final, torque in a crisscross
pattern
(8) exhaust riser flange nuts, plain 160–180 in.-lb
(8) exhaust riser flange nuts, self-locking 200–220 in.-lb
POWERPLANT (2) ground strap-to-engine nuts 96 in.-lb

(1) nut, B315-1 clip for magneto harness clamp 60 in.-lb
(1) nut on A462-1 carburtetor heat control wire-to-slider
25–30 in.-lb
valve attach fitting
(1) nut on A462-4 mixture control wire-to-carburetor
25–30 in.-lb
mixture arm attach fitting
420 in.-lb wet with A257-10
(8) spark plugs
thread lubricant
(1) thermostatic oil cooler bypass valve 290–310 in.-lb
(6 per cover) NAS1352-4H10P valve cover retaining screws
25 in.-lb cold engine,
when used with clean, dry, red silicon gasket on clean,
20 in.-lb warm engine
dry valve cover and cylinder head mating surfaces
(1) terminal retaining nut, alternator output terminal (use
back-up wrench on stud retaining nut to prevent loss 50 in.-lb
of stud clamp-up)
(2) terminal retaining nuts, D748-3 alternator field and
aux terminals (use back-up wrench on stud retaining 14 in.-lb
nuts to prevent loss of stud clamp-up)
(2) terminal retaining nuts, D748-4 alternator field and
aux terminals (use back-up wrench on stud retaining 20 in.-lb
nuts to prevent loss of stud clamp-up)
(1) terminal retaining nut, oil temperature sender 20 in.-lb


(2) NAS1351-8H40P internal-wrenching screws 70–75 ft-lb wet
STEEL TUBE 120 in.-lb with
FRAME (3) NAS6604-3 bolts – (1) lower-left frame aft strut-to-upper
B270-1 on shank to
frame, and (2) on removable aft, right strut
seal strut holes
(2) NAS1352N08-6 screws, magnetic pick-up bracket 35 in.-lb
(16) NAS1352N08-8 screws 35 in.-lb
SWASHPLATE
(1) NAS6605-8 bolt clamping early revision A203 yokes 190 in.-lb
(1 per link) 21FKF-616 jam nut, main rotor pitch link barrel 100 in.-lb
(1) B549-1 retainer, input seal 70 ft-lb wet
(3) MS20074-04-06 bolts, gearbox-to-tailcone mounting 100 in.-lb
(8) MS20074-04-06 bolts on A021 gearbox 60 in.-lb
(12) MS20074-04-06 bolts on B021 gearbox 100 in.-lb
(1) NAS679A4 nut, A031 pitch control housing stud 90 in.-lb
(1) NAS679A4 nut, A119-1 bumper retainer 120 in.-lb
70 ft-lb wet with
(1) D210-8 nut retaining B546 input yoke on B021 gearbox
B270-11
TAIL ROTOR
GEARBOX (1) NAS1304-38 bolt, spherical tail rotor teeter (delta) hinge 150 in.-lb
(1) NAS6604-38 bolt, elastomeric tail rotor teeter (delta) hinge 150 in.-lb
(1) chip detector on A021 gearbox 100 in.-lb
(1) chip detector on B021 gearbox 60 in.-lb
(1) nut, chip detector wiring on B021 gearbox 4–6 in.-lb
(1) filler plug vent assembly 100 in.-lb
(1) sight gage on A021 gearbox 150 in.-lb
(1) sight gage on B021 gearbox 100 in.-lb
WINDSHIELD (24) AN526C832R12 screws, on center outside retainer 16 in.-lb

23-34 D210-series Nuts on Critical Fasteners
When performing maintenance that involves disassembly of a critical fastener (joints with
a secondary lock), reassemble the fastener using a D210-series nut.
If a fastener is disassembled that has an MS21042L-series or NAS1291-series nut with
a B330-series palnut or B332-series lockwasher (secondary lock),
replace MS21042L08 nut or NAS1291-08 nut with D210-08 nut,

replace NAS1291-7 nut with D210-7 nut,
replace NAS1291-8 nut with D210-8 nut, or
replace NAS1291-10 nut with D210-10 nut.

23-40 Non-Destructive Testing
WARNING
23-41 Magnetic Particle Inspection

Ferromagnetic steel parts are inspected for structural defects using magnetic particle
inspection. Steel parts covered by this specification are inspected per ASTM E1444 wet
continuous process with ultra-violet light. Applicable requirements and limitations of the
above standard apply.
Procedures and equipment used to perform the inspection shall conform to requirements of
ASTM E1444. Produce magnetization using direct current. A magneto test penetrameter
or a 30–60 gauss meter is used to verify the direction and effectiveness of all magnetic
fields produced. Whenever possible, parts shall be inspected with both circular and
longitudinal magnetization, but at least in two directions at right angles to each other.
Minimum duration of application is ½ second.
Pre- and post-solvent clean parts using PCBTF or similar solvent. Demagnetizing is
accomplished using AC±3 oersteds maximum. Verify part is demagnetized using a magnetic
field strength indicator which does not exceed an absolute value above three gauss.
Area of part to be examined, position of part, directions of magnetization to be used and
method of establishing the magnetization are presented within the inspection section of
individual parts. Record the size and location of all rejectable indications.
A. Inspection Criteria
Parts (except gears) which are inspected by magnetic particle inspection shall be
accepted or rejected according to the following criteria:
Acceptable indications:
yy Indications smaller than 0.015 inch are not considered rateable.
yy Indications caused by sharp changes in cross‑section or part geometry.
Rejectable indications:
yy Indications interpreted as cracks, seams, laps, shuts, or any flaws which are
open to the surface.
yy Indications oriented at an angle of more than 15 degrees from the longitudinal
axis with length exceeding 0.125 inch.
yy Circumferential indications on any shoulder or fillet (changes in diameter).
yyAny indications which break over an edge, shoulder, fillet radius, keyway,
spline, or an adjacent area of part more than 0.015 inch.
yy Indications caused by undercuts at the toe of a weld.
yy Indications caused by cracks in the weld or parent metal.
yy Indications caused by inclusions in weld material exceeding 0.1 inch in length.

23-42 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 E1417 shall apply. After inspection is
complete, solvent clean parts.
The step‑by‑step procedure and equipment used to perform the inspection shall be
accomplished per ASTM E1417.
A. Inspection Criteria
Parts inspected by fluorescent penetrant method shall be accepted or rejected
on basis of acceptance limits specified. If acceptance limits are not specified,
rejectable surface defects and any of the following:
yy Cracks
yy Seams
yy Cold shuts or laps
yy Surface inclusions
yy In castings, aligned discontinuous surface indications other than cracks, cold
shuts and inclusions are rejectable if more than 3/8 inch in length.
23-50 Corrosion Control
[Reserved].

23-60 Priming and Painting
This specification outlines preparation and application requirements for primers and topcoat.
Primers provide corrosion protection and a final finish or a base for topcoat. Use only
approved materials listed in § 23-70.
Do not prime or paint with a topcoat finish the following areas (unless directed):
yy Sliding friction joints.
yy Stainless steel parts.
yy Swivel joints and adjustable rod ends.
yy Plastic, rubber, electrical components and wires or similar materials.
yy Bolted joints where torque is a specific requirement for clamping action.
yy Bearing press fit or close tolerance slip fit joints (except where wet chromate primer is
part of the assembly procedure).
WARNING
A. Priming
1. Cleaning
a. Alkaline clean is the preferred method for cleaning aluminum and stainless
steel except where immersion is not practical. Do not immerse assembled
components.
b. Do not alkaline clean steel as it may cause a corrosive reaction. Clean steel
using QSOL 220 or equivalent solvent.
c. Extremely greasy or dirty parts may be pre-cleaned in a solvent vapor bath
or hand wiped with QSOL 220 or equivalent solvent.
d. Air dry. Do not touch cleaned parts with bare hands.
2. Surface Preparation
Unless otherwise specified, chemical conversion coating is the standard treatment
before priming aluminum. However, if bare or clad aluminum is primed without
conversion coating, the following procedure must be used:
a. Alkaline clean if immersion is practical, otherwise wipe clean with QSOL
220 or equivalent degreasing agent.
b. Lightly scuff the surface with Scotch-Brite pads.
c. Wipe with a tack rag to remove any foreign material or damp wipe with
QSOL 220 or equivalent solvent.
d. Air dry. Do not touch parts with bare hands.

23-60 Priming and Painting (continued)
A. Priming (continued)
3. Primer Application
Apply primer after mixing per manufacturers recommendations. Allowable
thickness of primer is 0.0005 – 0.0020 inch, per coat. For parts with internal
openings, such as tubes, prime the inside as follows:
a. Thin primer to watery consistency using required reducer.
b. Pour in primer, slosh around, then drain immediately.
c. Dry parts at least six hours before using.
4. Inspection
Inspect for complete coverage and (excessive thickness) runs in paint. If primer
has runs, strip part and re-prime. Refer to § 23-70 for approved methods.
NOTE
Primed areas that have been sanded to bare metal must have
conversion coating (if required) and primer re-applied prior to
topcoat to restore anti-corrosion properties.
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. However, in some
cases, such as the gearbox assembly, this is not practical and primer and topcoat are
applied on the assembled component.
Previously primed surfaces, or primed surfaces that have completely cured require the
following preparation before paint:
1. Lightly sand using 220-grit or finer aluminum-oxide abrasive paper.
2. Lightly scuff with Scotch-Brite pads (optional).
3. Wipe with clean cloth and QSOL 220 or equivalent solvent.
4. Wipe with tack cloth.
5. Apply topcoat.

Intentionally Blank

23-70 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
CAUTION
Follow product manufacturer’s instructions for handling and
storage.
23-71 Paint Strippers
PRODUCT MANUFACTURER/SUPPLIER APPLICATION

Cee-Bee Stripper McGean-Rohco: Cee-Bee Division Metal parts, except blades and flex plates.
A-292 Downey, CA
Plastic Media Pauli & Griffin Co. Metal parts except blades and unsupported
Blasting System Vacaville, CA sheet metal less than 0.040 inch thick.
23-72 Solvents and Cleaners

QSOL 220 Safety-Kleen Systems, Inc. General use and for cleaning prior to applying
Plano, TX primer, topcoat, adhesive, or sealant.
Benzene, 1-Chloro-4 Any ““
(Trifluoromethyl)
PCBTF***
Final Klean 3909S Du Pont Chemical Remove adhesive residue on cabin and
Los Angeles, CA windshield.
EM-Citro* LPS Laboratories, Inc. ““
Tucker, GA
Acetone*** Any ““
Lacolene Any Windshield and plastic cleaning.
(Aliphatic
Hydrocarbon)
Plexus® B.T.I. Chemical Co. ““
Oak Park, CA
Presolve LPS Laboratories, Inc. Hydraulic components only.
Tucker, GA
Tetrachloroethylene Any Vapor degreaser.
(Perchloroethylene)

23-72 Solvents and Cleaners (continued)

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.
& rinse solution
Cleanup Wipe E-4365 Sontara Cleaning and drying.
Candler, NC
* May be used on acrylic plastic.
** Mix 5%-20% by volume; titration not required.
*** Acetone and PCBTF may be mixed together at 1:1 ratio.
23-73 Fillers and Putty

05096 Glazing Putty 3M Minor surface imperfections.
05861 Dry Guide Coat St. Paul, MN
31180 Finishing Glaze
SBF1191 Filler Gearhead Products ““
Indianapolis, IN
FE-351 Cream Hardener Catalyst Systems ““
Gnadenhutten, OH
23-74 Torque Seal

83314 thru 83321 Dykem Cross-Check Torque seal.
Except 83316 (red) ITW Pro Brands

23-75 Primers

Desoprime CF PPG Industries Unlimited.
CA 7422 or CA 7502 Irvine, CA
Water Reducible Epoxy PPG Industries Use only where specified.
Primer 44GN072 Irvine, CA
Gray Urethane Primer Filler Axalta Coating Systems Scrolls.
LE 3404S Philadelphia, PA
High Solids Epoxy Primer Transchem Coatings Unlimited.
53022 Type III Los Angeles, CA
High Solids Epoxy Primer AkzoNobel Use only where specified.
10P20-44 Waukegan, IL
Spray2Fix HS Epoxy Primer AkzoNobel Limited or touch-up use only.
10P20-44SC (Aerosol) Waukegan, IL
23-76 Powder Coat
PRODUCT MANUFACTURER
Interpon 100-AL101QF Gray AkzoNobel
Zinc Rich Epoxy Powder* Santa Fe Springs, CA
81-2158 Vitralon Gray 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 ““
Gray RAL 7043
49/22460 Smooth Glossy ““
Yellow RAL 1028
PFWF104S9 White Dupont Co.
Polyester Topcoat Powder* Wilmington, DE
* Shelf life is 12 months from date of manufacture at ambient temperature.

FIGURE 23-12 PAINT CODES
(Refer to Chapter 26 for rotor blade paint dimensions.
Exterior surface codes are D & F unless otherwise specified.)
23-77 Paints
Refer to Figures 23-12 & 23-13 for paint code application. Paint codes for specific helicopter
serial numbers are listed on the inside cover of Airframe Maintenance Record (logbook).
NOTE
Use fisheye eliminator, accelerator, or other additives per
manufacturer's recommendations.

23-77 Paints (continued)
CODE MATERIAL MANUFACTURER

Flat Black 18BK06 with 18BK006CAT Catalyst
PPG Aerospace; Irvine, CA
PC-216 Curing Selection
A1 Abrasion Resistant CTG 23T3-90 Black with
AkzoNobel; Waukegan, IL
PC-216 Curing Selection
Cardinal Industries Finishes;
A2 Semi-gloss Black 3900-05 with 39-SG Catalyst
El Monte, CA
Dark gray Imron AF400/AF700 Axalta; Wilmington, DE
B Alumigrip 4200G15290 AkzoNobel; Waukegan, IL
Randolph Products Co.;
Engine gray IE-8948
Chicopee, MA
Randolph Aircraft Products Co.;
C Lycoming Gray G-5436 fast dry engine enamel
Riverside, CA
Lycoming A219 gray engine enamel
Tempo Products; Cleveland, OH
(aerosol can-touch up; shelf life 2 years)
White Imron AF400/AF700 Axalta; Wilmington, DE
D Alumigrip 4200G10208 AkzoNobel; Waukegan, IL
Yellow Imron AF400/AF700 Axalta; Wilmington, DE
E Alumigrip 4200G40227 AkzoNobel; Waukegan, IL
F Imron AF400/AF700 Colors Axalta; Wilmington, DE
G Clear Imron AF740 ““
H Flat Clear 666-58-9000 with X-503 activator AkzoNobel; Waukegan, IL

White Imron 2.1 FT flat polyurethane enamel with 9T00-A activator,
J D-121 & D-101 tints, 2100-P 2.1 binder, & 9T20 flattener
Axalta; Wilmington, DE
Deco Technology Group Inc;

Printcolor White Ink MS Series 750-9005
Orance, CA
Printcolor Black Ink MS Series 750-8005 ““
K Printcolor Maize Yellow Ink MS Series 750-1205 ““
Printcolor Carnation Red Ink MS Series 750-3005 ““
Printcolor Glass Hardener Series 700 ““
Gensolve normal speed thinner GS-017L ““
Red Imron AF400/AF700 Axalta; Wilmington, DE
L Alumigrip 4200G4 AkzoNobel; Waukegan, IL
M Orange Imron AF400/AF700 Axalta; Wilmington, DE
Krylon 1311 (shelf life 2 years) Krylon Div. of Borden
N Matte Clear (aerosol can) Columbus, OH
O Light gray Imron AF400/AF700 Axalta; Wilmington, DE
Silver Bullet AM Tracer Black Burke Industrial Coatings
P 20-452AM-F1 with 16-CURE-F4 activator Ridgefield, WA

FIGURE 23-13 PAINT CODES

23-77 Paints (continued)
For limited touch-up of interior and landing gear only:
CODE MATERIAL MANUFACTURER

Cardinal Industries Finishes;
Cardinal A-2000-05 Flat black (aerosol can)
Cleveland, OH
A3 Krylon Div. of Borden
Krylon 1613 Semi-Flat Black (aerosol can)
Columbus, OH
23-78 Lubricants
RHC MANUFACTURER’S
LUBRICANT TYPE MANUFACTURER
PART NO. PART NO.
A257-1 Grease 101 Southwestern Petroleum Corp.
(general purpose) Fort Worth, TX
A257-2 Gear oil 201 Southwestern Petroleum Corp.
SAE 90 Fort Worth, TX
A257-3 Grease Aero Shell 14 Shell Oil Co.
MIL-G-25537
A257-4 Oil Dexron II or Any
(automatic Dexron II/Mercon or
transmission fluid) Dexron III/Mercon
A257-6 Grease Fuelube Fleet Supplies Inc.
(fuel resistant) Cleveland, OH
EZ Turn United-Erie Div. of Interstate Chemical Co.

Erie, PA
A257-7 Dry film lubricant Lubri-Kote Mealey Ind. Lubricants
Type A 1040 CR Cleveland, OH
A257-8 Rubber lubricant P-80 International Products Corp.
Trenton, NJ
A257-9 Anti-seize Silver Grade Loctite Corp.
Newington, CT
A257-10 Substitute A257-16
A257-12 Grease MobilGrease 28 Exxon Mobil Corp.,
MIL-PRF-81322 Fairfax, VA
A257-16 Engine Oil Type M 20W-50, Any
Approved for 0–90° F SAE J1966
ambient). Substitute
A257-24 as required.
A257-17 Substitute A257-19
A257-19 Valve lubricant and 111 Dow Corning Corp.
sealant compound Midland, MI
A257-24 Engine oil SAE 50, Any
(Approved for >60°F SAE J1966
ambient)

23-79 Adhesives and Sealants
RHC
DESCRIPTION COLOR MFR. PART NO. MANUFACTURER
PART NO.
B270-1 Sealant – manganese-cured, fuel Gray AC-730 B-* 3M Co.
resistant (2-part) St. Paul, MN
B270-2 Substitute B270-1
B270-5 Sealant – synthetic rubber putty White Q4-2805 Dow Corning Corp.
(1-part) Light Gray 94-031 Midland, MI
B270-6 Sealant & lubricant – thread Gray Titeseal 55 Radiator Spec. Co.
(1-part) Charlotte, NC
B270-8 Adhesive – rubber, nitrile/acetone Tan C 160 Stabond Corp.
(1-part) Gardena, CA
Adhesive – rubber, nitrile/acetone Tan 843 3M Co.

(1-part) St. Paul, MN
B270-9 Adhesive – epoxy, structural, Gray 2216 B/A 3M Co.
flexible (2-part) St. Paul, MN
B270-10 Adhesive/sealant – threadlocker, Red 271 Henkel Loctite Corp.
anaerobic, tight-fits (1-part) Rocky Hill, CT
B270-11 Adhesive/sealant – threadlocker, Red 277 Henkel Loctite Corp.
anaerobic, loose-fits (1-part) Rocky Hill, CT
B270-12 Sealant – electrical potting (2-part) Any color MIL-PRF-8516 Any
except red Type II, Class 2,
Category A or B
B270-13 Sealant – silicone rubber, Translucent 3145 Dow Corning Corp.
noncorrosive (1-part) Midland, MI
B270-15 Adhesive – plastic, for vinyl Clear 2262 3M Co.
B270-17 Adhesive – cyanoacrylate, instant Clear Super Bonder Henkel Loctite Corp.
(1-part) 495 Rocky Hill, CT
B270-18 Adhesive – weatherstrip (1-part) Black 051135-08008 3M Co.
St. Paul, MN
B270-19 Adhesive – epoxy structural, rigid Green 1838 B/A 3M Co.
B270-20 Adhesive/sealant – threadlocker, Purple 222 or 222MS Henkel Loctite Corp.
anaerobic, non-permanent (1-part) Rocky Hill, CT
B270-21 Protectant – corrosion, non-drying Lt. Amber LPS 3 LPS Laboratories, Inc.
(1-part) Tucker, GA

23-79 Adhesives and Sealants (continued)
RHC PART
DESCRIPTION COLOR MFR. PART NO. MANUFACTURER
NO.
B270-22 Protectant – corrosion, drying Amber LPS Hardcoat LPS Laboratories, Inc.
(1-part) Tucker, GA
B270-23 Sealant – gasket (1-part) Brown GM3H (Gasket Perfect Seal, Inc.
Maker #4) Cincinnati, OH
Sealant – gasket (1-part) Brown JV66B Dana Corp.;

Churubusco, IN
(Victor Reinz Brand)
B270-24 Activator/primer – anaerobic Translucent 7649 Henkel Loctite Corp.
adhesive (1-part) Green Rocky Hill, CT
B270-25 Clear coat – automotive touch Clear Clear Coat Automotive Touchup
up, brush in bottle (1-part) Touch up Bottle Harahan, LA
B270-26 Sealant – polysulfide, window Black AC-251 B-1 3M Co.
glazing (2-part) St. Paul, MN
B270-27 Adhesive – epoxy, high strength Translucent EA 9309NA Henkel Loctite Corp.
structural, flexible (2-part) Red Blue EA 9309.2NA Rocky Hill, CT
* Dash number for minimum hours application life may be -½, -2, -6, or -12.

23-80 Miscellaneous Practices
23-81 Part Interchangeability

Refer to R22 Illustrated Parts Catalog for part interchangeability information.
23-82 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 200º F for more than 5 minutes. Higher
temperatures or longer times adversely affect strength and corrosion properties. Scrap
any aluminum parts suspected of going above 325º F regardless of time at temperature.
Steel parts (bare) – Maximum temperature 300º F. Higher temperature can reduce the
strength or cause temper brittleness in some alloys.
Steel parts (cadmium plated) – Maximum temperature 300º F. Higher temperatures
will melt the plating and adversely affect steel strength by a process called liquid metal
embrittlement.
Bearings and carburized parts such as gears, clutch shafts, and clutch housings should
not be heated above 300º F. Higher temperatures will reduce the surface hardness and
increase wear rates.
Always heat parts in an oven with temperature control set no greater than the maximum
temperature allowed for the part.
Always attach a pyrometer and thermocouple to the smallest aluminum part in the oven.
Never depend on the oven control to determine part temperature.
Cooling a part for thermal fitting at assembly is not recommended. Water vapor from the
air will condense on the part and frequently introduce water into the assembly causing
severe internal corrosion over time.
23-83 Replacement Component Identification (Data) Plates

In order to issue a replacement component identification plate for field installation, RHC
must first receive the old identification plate in legible condition. If old identification
plate is lost or destroyed, then RHC must have an original letter (photocopies or faxes
are NOT acceptable) from customer’s Civil Aviation Authority authorizing identification
plate replacement AND stating component name, part number, and serial number for each
requested identification plate. There is a charge for each plate issued.
Identification plates may be carefully removed using a sharp plastic scraper. If necessary,
use a heat gun to soften plate adhesive. Retain in a dry, contaminate-free area until ready
for reinstallation.
Damp wipe local area with acetone or equivalent solvent prior to reinstallation. Residual
adhesive on identification plate is usually sufficient for good adhesion. If necessary, use
B270-9 adhesive or equivalent to secure.

23-84 Crimp Inspection
FIGURE 23-14 CRIMP INSPECTION

23-85 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.
2. Elastic cords have a shelf storage life of 5 years. Elastic cord service life is “on condition”,
with a maximum of 12 years. Use invoice or FAA Form 8130 date as start date.
3. Store V-belts at less than 85º F (30º C), with relative humidity below 70%. Avoid
solvent and oil vapors, atmospheric contaminants, sunlight, and ozone sources (electric
motors, arc welding, ionizing air purifiers, etc.). Belt shelf life is 4 years if preceding
recommendations are followed. Use invoice date or FAA Form 8130 date as start date.
4. Oils and greases have a 5 year shelf life when stored and kept sealed in their original
container. Use invoice date or FAA Form 8130 date as start date unless the manufacturer
has marked container with manufacture date (in which case use manufacture date as
start date).
5. Rubber o-rings, seals, and gaskets have a twenty (20) quarter, five (5) year shelf life
from the indicated cure date. Fluorocarbon (Viton) and silicon rubber products shall
adhere to manufacturer’s expiration date(s). Service life is “on condition” with a
maximum of 12 years.
6. Store uninstalled fuel bladder in original container (if available) at 70°F to 80°F and
below 70% humidity. Coat bladder with clean, non-detergent engine mineral oil to
prevent rubber from drying out and cracking. Store bladder in relaxed condition free
from tension, compression, or other deformation such as creases or folds.
23-86 B526 Screws and B527-08 Washers

B526 (TORX Plus®) truss head screws may be used to secure cowlings and access panels.
A B527-08 nylon washer may be used under a B526 screw head to further protect thin
or painted surfaces.
B526 screws are interchangeable with MS27039C080_ screws used to secure cowlings
and access panels as follows:
MS27039C0806 screw . . . . . . . . . . . . . . . . . B526-6 screw
MS27039C0807 screw . . . . . . . . . . . . . . . . . B526-8 screw
MS27039C0808 screw . . . . . . . . . . . . . . . . . B526-8 screw
B526 screws are interchangeable with AN525-832R_ & AN526C832R_ screws as follows:
NOTE
B526 screws are compatible with T20 or 20IP drivers.

CHAPTER 24
LIGHTS
Section Title Page
24-00 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.1

24-10 Exterior Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.1
24-11 Strobe Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.1
24-12 Navigation Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.2
24-13 Landing Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.3
24-20 Interior Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.4
24-21 Instrument Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.4
OCT 2018 Chapter 24 Lights Page 24.i

Intentionally Blank
Page 24.ii Chapter 24 Lights OCT 2018

CHAPTER 24
LIGHTS
24-00 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. Post and internal lights (earlier aircraft) or a light at the top of the
windshield (later aircraft) illuminate the instruments. Instrument lighting is active when the
nav lights switch is on and lighting is dimmed via the knob above the nav lights switch.
An overhead map light mounted on a swivel is controlled by an adjacent switch. The map
light may be used for emergency lighting of the instrument panel.
Two landing lights are installed in the nose at different vertical angles to increase lighted
area. One landing light switch controls both lights and is located on the cyclic center post
or near OAT gage.
NOTE
Landing lights operate only when clutch actuator switch is in
the engage position.
24-10 Exterior Lights
24-11 Strobe Light

A. Removal
1. Turn battery switch off. Pull out STROBE circuit breaker (5 amp) at panel.
2. Remove hardware securing A708 strobe light assembly's retainer (or clamp),
lens, and gasket to strobe (or flash tube assembly).
3. Remove screws securing A708-14 strobe to tailcone mount.
4. Disconnect strobe (or flash tube assembly) wire harness from airframe harness at
connectors and remove strobe (or flash tube assembly).
OCT 2018 Chapter 24 Lights Page 24.1

24-11 Strobe Light (continued)
B. Installation
1. Turn battery switch off. Pull out STROBE circuit breaker (5 amp) at panel.
2. Connect A708 strobe light assembly’s wire harness to airframe harness at
connectors. Verify security.
3. Loop wires and connectors inside mount and install screws securing A708-14
strobe to tailcone mount.
4. Assemble gasket, lens (red forward if red/white), and retainer (or clamp) on
tailcone mount and install hardware. Verify security.
5. Push in STROBE circuit breaker (5 amp) at panel. Turn battery switch and strobe
switch(es) on and verify function. Turn battery switch off.
24-12 Navigation Lights

A. Removal
1. Turn battery switch off. Pull out LTS circuit breaker (5 amp) at panel.
2. a. Position Lights: Remove screw, retainer, lens, (lamp), and gasket to light
assembly. Remove hardware securing light assembly, gasket, and ground
wire to chin. Cut and discard ty-rap securing excess wire to light assembly,
pull out light assembly, and disconnect light assembly harness from airframe
harness at connectors.
b. Tail Light: Remove screws securing retainer, lens, gasket, (lamp), and light
assembly to stabilizer mount. Pull out light assembly and disconnect light
assembly harness from airframe harness at connectors.
B. Installation
2. a. Position Lights: Connect light assembly harness to airframe harness at
connectors. Install hardware securing light assembly, gasket, and ground wire
to chin. Verify security. Install ty-rap securing excess wire to light assembly.
Cinch ty-rap until snug without over-tightening, and trim tip flush with head.
Install lamp (earlier R22s). Install screw securing retainer, lens, and gasket to
light assembly. Verify security.
b. Tail Light: Connect light assembly harness to airframe harness at connectors.
Position light assembly in stabilizer mount and install screws securing retainer,
lens, gasket, and light to mount. Verify security.
3. Push in LTS circuit breaker (5 amp) at panel. Turn battery switch and NAV LTS
switch on and verify function. Turn battery switch and NAV LTS switch off.
Page 24.2 Chapter 24 Lights OCT 2018

24-13 Landing Lights
NOTE
A. Removal
1. Turn battery switch off. Pull out LAND LT circuit breaker (15 amp for HIDs, 20
amp for B196-26 lamps) at panel.
2. Remove screws securing A526-1 retainer to chin and remove retainer.
3. Unplug landing light cable from (or remove hardware securing landing light wires
to) lamp and remove lamp.
B. Installation
1. Turn battery switch off. Pull out LAND LT circuit breaker (15 amp for HIDs, 20
amp for B196-26 lamps) at panel.
2. a. HIDs: Connect landing light cable to B557-1 (spot; LH) landing light or B557‑2
(flood) taxi light, as required. Verify security.
b. B196 lamps: Install hardware securing landing light wires to lamp. Verify
security.
3. Install screws securing A526-1 retainer to chin.
4. Push in LAND LT circuit breaker (15 amp for HIDs, 20 amp for B196-26 lamps)
at panel. Turn battery switch and landing light switch on (cyclic center post) and
verify function. Turn battery switch and landing light switch off.
OCT 2018 Chapter 24 Lights Page 24.3

24-20 Interior Lights
24-21 Instrument Lighting

A. LED Assembly Replacement
2. Remove hardware securing G196-6 light assembly to windshield stiffener.
Remove two cap screws securing cover and LED-lamp assembly to housing.
Disconnect lamp wires from airframe harness and remove lamp.
3. Connect A238-2289 (white) airframe harness wire to LED-lamp assembly red
wire, and A238-2290 airframe harness wire to lamp black wire. Install cover
(chamfer facing away from housing) and install two cap screws. Install hardware
securing G196-6 light assembly to windshield stiffener. Verify security.
4. Push in LTS circuit breaker (5 amp) at panel. Turn battery switch and NAV LTS
switch on and verify function. Verify dimming knob adjusts brightness. Turn
battery switch and NAV LTS switch off.
Page 24.4 Chapter 24 Lights OCT 2018

CHAPTER 25
DOORS AND WINDOWS
Section Title Page
25-00 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.1

25-10 Door Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.1
25-20 Windshield Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.3
OCT 2018 Chapter 25 Doors and Windows Page 25.i

Intentionally Blank
Page 25.ii Chapter 25 Doors and Windows OCT 2018

CHAPTER 25
DOORS AND WINDOWS
25-00 Description
Both cabin doors may be removed and installed by maintenance personnel or pilots.
25-10 Door Assembly

A. Removal
Remove cotter pins from door hinge pins. Open door and lift door pins from door
frame hinge assemblies and remove door. Adjust weight and balance as required.
B. Installation
WARNING
Failure to install a cotter pin in each door's two hinge pins may
allow door to depart aircraft in flight.
1. Align and insert door hinge pins in door frame hinge assemblies; latch door.
2. Install a cotter pin in both upper and lower door hinge pins.
3. Adjust weight and balance as required.
OCT 2018 Chapter 25 Doors and Windows Page 25.1

FIGURE 25-1 WINDSHIELD INSPECTION
Page 25.2 Chapter 25 Doors and Windows OCT 2018

25-20 Windshield Assembly
A. Removal
1. Remove forward door and hinges.
NOTE
To prevent scratching windshield, a protective cover should
be taped to the inside and outside of the windshield prior to
removal.
2. Remove screws and side retainer holding windshield.

3. Reinstall hinges and doors for cabin structure support with windshield removed.
4. Remove screws and retainers (upper, lower, and middle) holding windshield.
5. Clean silicone from retainers.
6. Clean silicone from windshield for reinstallation.
B. Installation
1. Remove all old silicone from cabin, retainers and windshield.
2. Install windshield and cleco retainer strips.
3. Mask windshield along edge of retainer strips with 1/2” masking tape. This will
catch silicone rubber squeeze-out on installation of retainer strips.
4. Remove retainer strips.
5. To ensure a proper seal, run a bead of B270-13 silicone rubber along entire edge
of tape line.
6. While holding windshield in place, cleco retainer strips (center, upper and lower)
into place.
7. With doors installed and closed, tighten center retainer strip first. Then tighten
upper and lower retaining strips. A second person will be required to tighten nuts
inside ship.
8. When center, upper and lower retaining strips are secure, remove door and hinges
for side strip installation.
9. Install side retainer strip.
10. Reinstall hinges and door. Ensure all fasteners are tight.
11. Fill any gap between retainer and window with B270-13 silicone rubber.
12. Remove masking tape next to retainers. Be careful not to smear wet silicone.
13. Clean any silicone off windshield after it has been allowed to dry.
OCT 2018 Chapter 25 Doors and Windows Page 25.3

25-20 Windshield Assembly (continued)
C. Inspection
1. Inspect windshield for cracks and crazing adjacent to retainer strips per Figure
25‑1. If cracks exceed these limits, replace windshields per § 25-20 Part D.
D. Replacement
1. Remove all old silicone on cabin and retainers if they are to be reused.
2. Cleco all window retaining strips in place, checking for proper alignment.
3. Install hinges and doors in door frames and secure. Remove bottom and center
retaining strips, leaving side retaining strip to hold door and door frame in position.
4. Hold windshield in place by hand, and align it with frame according to contour of
frame and windshield.
5. Mark windshield for trim using non-permanent marker, such as grease pencil or
masking tape.
6. Trim to mark. A band saw is recommended. Band saw blade should contain at
least 24 teeth per inch.
NOTE
Tape cardboard to band saw table to prevent scratching of
windshield. Saw carefully to prevent binding of saw blade and
cracking windshield.
7. Hold windshield in place and check for fit. Re-trim as necessary.

8. After windshield is fitted, carefully sand or scrape edges smooth.
9. Install windshield per § 25-20 Part B.
Page 25.4 Chapter 25 Doors and Windows OCT 2018

CHAPTER 26
MAIN ROTOR
Section Title Page
26-00 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.1

26-10 Main Rotor Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.1
26-11 Blade Boots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.6
26-12 Filling Pitch Bearing Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.9
26-20 Main Rotor Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.10
26-21 Bearing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.12
26-30 Main Rotor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.15
26-31 Journal and Shim Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.15
26-32 Adjusting Hinge Friction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.20
26-33 Shifting the Main Rotor Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.21
26-34 Drilling Installed Main Rotor Hub Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . 26.21
26-40 Inspection of Main Rotor Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.23
26-41 Scratches and Corrosion on Blade Skins and Doublers . . . . . . . . . . . . . . . 26.23
26-42 Dents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.25
26-43 Root Fitting Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.27
26-44 Voids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.29
26-50 Repair of Main Rotor Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.31
26-51 Trimming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.33
26-52 Painting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.33
OCT 2018 Chapter 26 Main Rotor Page 26.i

Intentionally Blank
Page 26.ii Chapter 26 Main Rotor OCT 2018

CHAPTER 26
MAIN ROTOR
26-00 Description
The main rotor has two all-metal blades mounted to the hub by coning hinges. The hub is
mounted to the shaft by a teeter hinge. The coning and teeter hinges use self-lubricated
bearings. Droop stops for the main rotor blades provide a teeter hinge friction restraint
which normally prevents the rotor from teetering while starting or stopping. Pitch change
bearings for each blade are enclosed in a housing at the blade root. The housing is filled
with oil and sealed with an elastomeric boot. Each blade has a thick stainless steel spar at
the leading edge which is resistant to corrosion and erosion. The skins are bonded to the
spar approximately one inch aft of the leading edge. Blades must be refinished if the paint
erodes to bare metal at the skin-to-spar bond line. Bond may be damaged if bond line is
exposed.
26-10 Main Rotor Blades
WARNING
Due to potentially destructive results, use of blade tape (anti-
erosion tape) is prohibited.
A. Removal
Refer to Figure 26-1. Four people will be required to remove the blades. One person
must support the blade near the blade tip while another supports the root and removes
or installs the attachment bolt.
FIGURE 26-1 SUPPORTING MAIN ROTOR BLADES DURING BLADE REMOVAL OR INSTALLATION
OCT 2018 Chapter 26 Main Rotor Page 26.1

FIGURE 26-2 MEASURING BOLT STRETCH (SHOWN ON TEETER BOLT, BLADES REMOVED)
Page 26.2 Chapter 26 Main Rotor OCT 2018

26-10 Main Rotor Blades (continued)
A. Removal (continued)
1. Mark one main rotor blade and its corresponding hub location, pitch link, and
retaining nut & bolt with “X” using a marker or grease pencil. Mark opposite blade
and its hub location, pitch link, and retaining nut & bolt with “O”.
2. Measure and record coning hinge axial gaps per Figure 26-8.
3. Remove hardware securing main rotor pitch links to blade pitch horns.
4. Remove cotter pins and loosen blade coning hinge retaining nuts until finger tight.
CAUTION
After removing one blade, support installed blade in a level
position until it is removed.
5. Remove nut, thrust washer, and trailing-edge shims (if used) from one blade. Cone
blade as required to position spindle tusk off of droop stop. Supporting blade at
root, rotate pitch horn down, and remove hinge bolt and thrust washer.
CAUTION
Do not drop journals (inside hub bearings) which can slide out
when removing blade bolt.
NOTE
Blade installation hardware is specific to each blade, each
blade’s leading and trailing edge, and each blade’s location in
hub. It is good practice after blade removal to install hardware
in hub finger tight exactly as removed.
6. Place blade on a cushioned surface to prevent damage to skins.

7. Remove opposite blade per steps 5 and 6.

B. Installation
1. Identify hub and spindle part numbers and ensure correct corresponding installation
hardware.
2. Check teeter hinge friction and adjust as required per § 26-32.
3. If coning hinge axial gap recorded during blade removal was beyond tolerance, or if
corresponding hub bearing(s) or spindle was replaced, perform coning hinge journal
and shim calculation per § 26-31.
4. Level hub and insert journals in hub bearings. Install thrust washer on blade bolt.
5. Insert main rotor blade spindle in hub and align spindle and journal bores. Cone
blade as required to position tusk off of droop stop. Rotate pitch horn down and
install hinge bolt at leading-edge side.
NOTE
A bolt may be inserted from trailing-edge side to align spindle and
journal bores (it is pushed out as coning hinge bolt is installed).
6. Install trailing-edge shims (if used) and thrust washer. Apply light coat A257-9
anti-seize to bolt threads and nut face. Install nut finger tight.
NOTE
Do not allow anti-seize to contact journals, shims, or hub bearing
areas. These areas must be clean and dry.
CAUTION
After installing one blade, support blade in a level position until
opposite blade is installed.
7. Install opposite blade per steps 4 thru 6.

8. Tighten nut on coning hinge bolt until journals and thrust washer are firmly seated.
Loosen nut until both thrust washers can be freely rotated.
9. Refer to Figure 26-2. Install MT122 main rotor bolt elongation (stretch) tool on
hinge bolt. Zero dial indicator by rotating dial face and lock dial. Remove tool.
10. Using wrenches with at least 150 ft-lb torque capacity, tighten nut until drilled
holes in nut and bolt align. Install MT122 tool and measure bolt elongation:
WARNING
Do not under-stretch or over-stretch teeter or coning hinge
bolts to obtain proper clamping force. Under-stretching or over-
stretching can cause failure.

10. a. A154-1 hub with NAS630-80 (or MS21250-10080) coning hinge bolts:
i. If bolt elongation is 0.015–0.017 inch, remove tool and install a new
cotter pin wet with epoxy primer.
ii. If bolt elongation is not 0.015–0.017 inch, remove old nut and old bolt
and install a new bolt and a new nut. Stretch new bolt per § 23-33, and
drill new nut and bolt per § 26-34. Install a new cotter pin wet with
epoxy primer.
b. B370-1 hub with NAS632-82 (or MS21250-12082) coning hinge bolts:
i. If bolt elongation is 0.010–0.012 inch, remove tool and install a new
cotter pin wet with epoxy primer.
ii. If bolt elongation is not 0.010–0.012 inch, remove old nut and old bolt
and install a new bolt and a new nut. Stretch new bolt per § 23-33, and
drill new nut and bolt per § 26-34. Install a new cotter pin wet with
epoxy primer.
11. Install hardware securing main rotor pitch link to pitch horn. Standard torque
hardware per § 23-32 and torque stripe per Figure 2-1.
12. Perform steps 8 thru 11 on opposite blade.
13. Track and balance main rotor blades per § 10.230.

26-11 Blade Boots
A. Removal
2. Place a suitable drain container below pitch horn. Remove two B289-2 bolts and
drain fluid.
3. Remove outer boot clamp and hold boot back to expose inner boot clamp. Remove
inner clamp and peel boot from spindle.
B. Installation
1. Visually inspect and verify boot is undamaged. Carefully stretch new boot over
spindle.
2. Solvent-clean surfaces clamped by boot inner lip. Properly position boot inner lip;
install A165-1 (inner) clamp assembly and tighten clamp to 2.330 ± 0.005 inch
outside diameter. Rotate spindle and verify adequate clearance between clamp
assembly and pitch horn.
NOTE
When installing inner clamp, ensure that shoulder of boot inner

lip is not wedged beneath clamp or clamp may loosen in service.
Inspect boot interior and verify no cuts or punctures.
3. Stretch boot outer lip over pitch horn flange. Rotate spindle and align pitch horn
bolt hole with spindle bolt hole per Figure 26-3. Install A165-7 (outer) clamp
assembly and tighten clamp. Verify security.
4. Fill pitch bearing housing per § 26-12.

Intentionally Blank

FIGURE 26-3 FILLING PITCH BEARING HOUSING

26-12 Filling Pitch Bearing Housing
NOTE
MT147-1 Main rotor blade spindle air bleed tool includes supply
container, hose assemblies, and bleed fittings.
WARNING

2. Refer to Figure 26-3. Place a suitable drain container below main rotor pitch horn.
Remove two B289-2 bolts from pitch horn and drain fluid.
3. Install MT147-2 bleed fittings into pitch horn openings. Attach drain hose assembly
to (top) bleed fitting, secure with two wraps of lockwire. Position drain hose into drain
container.
4. Place supply container with sufficient A257-4 fluid approximately 3 feet above spindle.
Route fill hose assembly into drain container and open brass valve. Open supply
container plastic valve and purge air from fill hose. Close valves.
5. Connect brass valve to (bottom) bleed fitting by tightening brass compression sleeve.
6. Open valves and fill spindle housing until no air bubbles are visible in drain hose
assembly. Massage spindle boot, oscillate spindle, and raise blade tip up & down to
remove trapped air.
7. Remove drain hose assembly and (top) bleed fitting, and install B289-2 bolt. Roll the
blade over. After five minutes, inspect the boot for leaks. If no leaks are found, close
valves, remove fill hose assembly brass valve and (bottom) bleed fitting, and install
other bolt.
8. Special torque B289-2 bolts per § 23-33 and torque stripe per Figure 2-1.
9. Repeat steps for opposite blade.

26-20 Main Rotor Hub
A. Removal
2. Refer to Figure 26-5. Mark rotor hub using a grease pencil, tape, or soft marker as
follows:
a. Indicate nut side of teeter bolt.
b. Indicate chord arm side of drive shaft.
3. If same hub will be installed, measure teeter hinge friction per Figure 26-9 and
record value.
4. Remove cotter pin, nut, A152 thrust washers, A117 shims, A106 journals, and
bolt. Rotate hub as required and remove hub. Do not drop thrust washers or
journals.
5. Reinstall bolt, thrust washers, shims, journals, and nut in rotor hub exactly as
removed.
CAUTION
Main rotor chordwise balance is adjusted using A106 journals
and A117 shims. If assembly stack-up is altered, an out-of-
balance condition can occur.
B. Installation
1. Clean and dry teeter hinge hardware using approved solvent per § 23-70. Inspect
journals and thrust washers for chipping of chrome plating, corrosion, and/or wear
grooves extending through chrome plating. Replace journal or thrust washer if any
of these conditions exist.
2. If teeter hinge friction recorded during hub removal was less than 5 ft-lb or more
than 15 ft-lb, if teeter hinge hub bearing(s) was replaced, or if previous installation
information is unavailable, perform teeter hinge journal and shim calculation per
§ 26-31.
3. Refer to Figure 26-5. Line up mark on hub with chord arm on drive shaft. Install
teeter hinge bolt, thrust washers, shims, and journals (if previous installation
information is available, install parts exactly as removed).

26-20 Main Rotor Hub (continued)
4. Coat nut face and bolt threads with A257-9 anti-seize compound, install and
tighten nut, then loosen nut until both thrust washers can be freely rotated. Ensure
journals do not “pinch” droop stops and fully contact drive shaft.
WARNING
Do not allow anti-seize compound to contaminate drive shaft,
journals, shims, or thrust washer inner faces. Contamination
prevents proper joint clamp-up and may cause failure.
5. Refer to Figure 26-2. Install MT122 main rotor bolt elongation (stretch) tool on
teeter bolt. Zero dial indicator by rotating dial face and lock dial. Remove tool.
6. Using wrenches with at least 150 ft-lb torque capacity, tighten nut until drilled
holes in nut and bolt align. Install MT122 tool and measure bolt elongation:
a. If bolt elongation is 0.015–0.017 inch, remove tool and verify correct teeter
hinge friction per § 26-32. Adjust teeter hinge friction as required.
b. If bolt elongation is not 0.015–0.017 inch, remove old nut and old bolt and
install a new bolt and a new nut. Stretch new bolt per § 23-33 and verify
correct teeter hinge friction per § 26-32. Adjust teeter hinge friction as
required. Drill new nut and bolt per § 26-34.
WARNING
Do not under-stretch or over-stretch teeter or coning hinge
bolts to obtain proper clamping force. Under-stretching or over-
stretching can cause failure.
7. Install a new cotter pin wet with epoxy primer.

FIGURE 26-4 MAIN ROTOR HUB BEARING REPLACEMENT
26-21 Bearing Replacement

1. Remove main rotor hub per § 26-20.
2. Refer to Figure 26-4. Verify tooling surfaces are smooth to avoid damaging hub and
bearings. Press A648-1 and/or A648-3 bearing(s) from hub using MT329-1 plug
assembly (Rev H or subsequent) with MT329-10 tube. Press A648-2 bearing(s) from
hub using MT329-11 plug assembly with MT329-10 tube.
3. Visually inspect hub bearing bore(s) per § 2.610 step 3a.
NOTE
Do not allow epoxy primer to contact bearing’s Teflon liner.
4. Verify bearing mating surfaces are smooth and clean and apply light coat of epoxy
primer (refer to § 23-70). If visible, orient coning hinge bearing’s Teflon liner seam
toward top of hub. While primer is wet, press in new A648-1 and/or A648-3 bearing(s)
using MT329-1 plug assembly or A648-2 bearing(s) using MT329-11 plug assembly
(always use MT329-13 or MT329-2 [A154-4 Hub] support when replacing coning
hinge bearing) until bearing flange is completely seated against hub.
5. Using a syringe, seal between bearing’s outboard flange and hub and bearing’s inboard
edge and hub with small fillet of epoxy primer.

Intentionally Blank

FIGURE 26-5 TEETER HINGE (HUB INSTALLATION)
FIGURE 26-6 B370-1 HUB CONING HINGE (BLADE INSTALLATION; VIEW LOOKING DOWN)

26-30 Main Rotor Assembly
26-31 Journal and Shim Calculations
Refer to Table 26-1 and Figures 26-5, 26-6, and 26-7.

A. Teeter Hinge Calculation
1. Measure main rotor hub width across the teeter hinge bearing faces: in.
2. Subtract measured width of A251 driveshaft at teeter hinge bolt hole: – in.
Calculated empty space: = in.
3. Assemble thrust washer, one A117-7 shim (0.020 inch), and one
A106-4 journal (1.300 inches) under the teeter bolt head and insert
bolt thru hub and drive shaft.
Subtract combined measured thickness of A117-7 shim &
A106-4 journal: – in.
Difference: = in.
4. Subtract measured length of nut-side A106-4 or A106-5 journal: – in.
Difference: = in.
CAUTION
Initial teeter hinge hardware stack-up must be adjusted to
0.005/0.008 inch greater than calculated empty space. A
smaller initial stack-up could damage thrust washers and hub
bearings during installation.
5. To accommodate dimensional change due to clamping force, add: + 0.005/

0.008 in.
/
Initial A117 shim stack between nut-side journal & thrust washer: = in.
NOTE
Use as many different size A117 shims as possible to facilitate
head shifting during balancing.
6. Refer to § 26-32. Adjust shim stack as required to meet teeter hinge friction
requirement (less than 15 ft-lb).

FIGURE 26-7 A154-1 HUB CONING HINGE (BLADE INSTALLATION; VIEW LOOKING DOWN)
A106 Journal Lengths

Part No. Length Location
A106-1 1.000 in. Coning hinge, no shims (A154-1 Hub)
A106-4 1.300 in. Teeter hinge (two, or one + A106-5 per hinge), shims
A106-5 1.260 in. Teeter hinge (none, or one + A106-4 per hinge), shims
A106-7 1.005 in. Coning hinge (B370-1 Hub)
A117 Shim Sizes
Part No. Thickness Location (Between thrust washer and journal)
A117-5 0.012 in. Teeter hinge
TABLE 26-1 A106 JOURNAL LENGTHS AND A117 SHIM SIZES

26-31 Journal and Shim Calculations (continued)
B. Coning Hinge Calculation
B370-1 Hub:
1. Measure main rotor hub width across the coning hinge bearing faces: in.
2. Subtract measured width of blade spindle at teeter hinge bolt hole: – in.
3. Subtract combined measured length of two A106-7 journals: – in.
Difference: = in.
CAUTION
Initial teeter hinge hardware stack-up must be adjusted to

0.006 in.
/
Initial A117 shim stack between nut-side journal & thrust washer: = in.
5. Adjust shim stack combination as required to meet coning hinge axial gap
requirement per Figure 26-8 and to maintain teeter friction requirement as follows:
It must be possible to manually cone each blade without teetering the hub when
blades are held up off the droop stops and lifted at tip.

FIGURE 26-8 MEASURING CONING HINGE AXIAL GAP
FIGURE 26-9 MEASURING TEETER HINGE FRICTION

26-31 Journal and Shim Calculations (continued)
B. Coning Hinge Calculation (continued)

A154-1 Hub:
1. Measure main rotor hub width across the coning hinge bearing faces: in.
2. Subtract measured width of blade spindle at coning hinge bolt hole: – in.
CAUTION
Initial coning hinge hardware stack-up must be adjusted to

0.006 in.
/
Sum: = in.
4. Select a combination of A106-1, -2, -3, or -6 journals whose combined measured
lengths equal Sum. The same journal dash number must be used under the head
of both coning hinge bolts to maintain symmetry.
5. Adjust journal combination as required to meet coning hinge axial gap requirement
per Figure 26-8 and to maintain teeter friction requirement as follows: It must be
possible to manually cone each blade without teetering the hub when blades are
held up off the droop stops and lifted at tip.

26-32 Adjusting Hinge Friction
A. Teeter Hinge Friction Adjustment
2. Refer to Figure 26-5 and Table 26-1. Remove cotter pin, nut, thrust washer,
and nut-side A117 shims. Adjust teeter hinge friction by changing nut-side shim
stack thickness in small increments; reducing shim stack thickness increases
friction, increasing shim stack thickness reduces friction. Install shims, thrust
washer, and nut.
3. Refer to Figure 26-9. While torquing teeter hinge bolt per § 23-33, check teeter
hinge friction frequently. To check friction, install MT354 teeter friction tool
into coning hinge bearings on one side of main rotor hub and measure moving
force (not breakaway force) required to teeter main rotor hub with a spring scale.
Teeter friction must be less than 15 ft-lb.
4. Install a new bolt and nut per § 26-20.
B. Coning Hinge Friction Adjustment
1. Refer to Figure 26-6 and Table 26-1. Remove cotter pin, nut, thrust washer, and
cone blade to remove nut-side journal.
a. B370-1 Hub: Adjust coning hinge friction by changing trailing-edge shim
stack thickness in small increments; reducing shim stack thickness increases
friction, increasing shim stack thickness reduces friction. Coning hinge
friction is zero when there is a measurable axial gap per Figure 26-8. Install
shims, thrust washer, and nut.
b. A154-1 Hub: Adjust coning hinge friction by changing trailing-edge journal
length in small increments; using a shorter journal increases friction, using a
longer journal reduces friction. Coning hinge friction is zero when there is a
measurable axial gap per Figure 26-8. Install journal, thrust washer, and nut.
2. Install a new bolt and nut per § 26-20, steps 5 thru 7. Repeat steps for opposite
blade.
3. Check coning hinge friction by lifting blades until spindle tusks clear droop stops.
Hold one blade level and cone opposite blade. Rotor hub must not teeter as blade
is coned. Repeat check on opposite blade.
4. Using a feeler gage, measure gap between thrust washers and bearing faces at
coning hinge bolt head and nut. Verify 0.002-0.006 inch total gap per hinge.
5. Drill nut and bolt per § 26-34. Install a new cotter pin wet with epoxy primer.

26-33 Shifting the Main Rotor Hub
1. Remove cotter pin, nut, thrust washer, and nut-side A117 shims.
2. Have two people cone the main rotor blades. Push out teeter hinge bolt with another
bolt.
3. Move or exchange existing shims from one side of hub to the other as indicated by
main rotor balance chart (refer to § 10.230).
4. Install teeter hinge bolt per § 26-20.
26-34 Drilling Installed Main Rotor Hub Bolts
NOTE
Protect hub from damage due to chuck contact by wrapping
chuck and/or covering hub edge with several layers of tape.
New bolts and nuts must be installed and bolts stretched per § 23-33 prior to drilling.
Using a 0.125-inch diameter Cobalt twist-drill and cutting oil, drill a hole through nut and
bolt using an accessible pre-drilled hole in nut. The MT569-1 and MT569-6 (B370-1
hub coning hinge bolts) drill guide assembly will facilitate drilling a perpendicular hole. If
a pre-drilled hole is inaccessible, completely loosen nut, slightly rotate bolt to favorable
position, then special torque per § 23-33. Protect adjacent area from drilling debris.

FIGURE 26-10 MEASURING MAIN ROTOR BLADE DAMAGE
FIGURE 26-11 SCRATCH LIMITS

26-40 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.
NOTE
The inspection criteria in this section applies to blade damage that
occurs after blade manufacturing (including shipping and handling
and time in service). Damage after blade manufacturing usually
exhibits paint scuffing, scratches, or freshly-exposed metal in
the form of scratches in the finish. If a blade manufacturing
irregularity is suspected, contact RHC Technical Support.
CAUTION
A blade may be repaired more than one time. However, in no
case can more than the maximum material be removed or the
maximum dent depth be exceeded in any one location.
A. Measuring Damage
1. Refer to Figure 26-10. 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. Using a straight edge of excessive length will
cause a false reading due to natural droop of the blade.
B. Measuring Material Removed After Repair
1. Use calipers or micrometers and compare measurements before and after repair to
estimate amount of material removed.
2. Use a straight edge and thickness gage to measure repaired areas less than 2
inches across in the blade skins and spar.
26-41 Scratches and Corrosion on Blade Skins and Doublers
1. Refer to Figure 26-11. Damage may not exceed the following limits after rework:
A016-6 Blades:
a. 0.004 inch maximum depth for scratches more than 15º from spanwise axis.
b. 0.006 inch maximum depth for scratches less than 15º from spanwise axis.
A016-4 Blades:
a. 0.002 inch maximum depth for scratches more than 15º spanwise.
b. 0.003 inch maximum depth for scratches less than 15º spanwise.
2. Refer to § 26-50 for repair procedures for damage within limits. Polish out scratches
and corrosion greater than 0.0005 inch deep using a 0.10 inch blend radius.

FIGURE 26-12 DENTS AND LOCAL DEFORMATIONS

26-42 Dents
CAUTION
Tap-test dented areas in honeycomb using an AN970-4 washer or
1965-or-later U.S. quarter dollar coin in good condition. If any voids
are found associated with dents, contact RHC Technical Support.
CAUTION
Do not repair any dent that has a sharp cut or break in the
skin; dent must have 0.060 inch minimum bottom radius. If
necessary, locally penetrant inspect, keeping penetrant materials
away from bond joints.
1. Refer to Figure 26-12. Damage may not exceed the following limits:
a. Honeycomb:
A016-6 Blades:
i. 0.020 inch maximum bulge on opposite side of blade, opposite dent.
ii. 0.125 inch maximum depth dent between RS 127.0 and RS 151.1.
iii. 0.090 inch maximum depth dent between RS 75.5 and RS 127.0.
iv. 0.030 inch maximum depth dent between RS 10.4 and RS 75.5.
A016-4 Blades:
i. 0.020 inch maximum bulge on opposite side of blade, opposite dent.
ii. 0.125 inch maximum depth dent between RS 130.30 and RS 151.1.
iii. 0.090 inch maximum depth dent between RS 64.00 and RS 130.30.
iv. 0.030 inch maximum depth dent between RS 13.7 and RS 64.00.
b. Leading edge of doublers:
A016-6 Blades: 0.010 inch maximum depth dent.
c. Supported bond joints:
A016-6 Blades: 0.006 inch maximum depth dent.
A016-4 Blades: 0.002 inch maximum depth dent, tip cap only; refer to SB-103A.
d. Local deformations:
A016-6 Blades: Within 0.75 inch forward of trailing edge:
i. 0.060 inch deformation between RS 30.0 and RS 151.0.
ii. 0.015 inch deformation between RS 10.4 and RS 30.0.
A016-4 Blades: Within 0.75 inch forward of trailing edge:
i. 0.060 inch deformation between RS 30.00 and RS 151.00.
ii. 0.015 inch deformation between RS 13.70 and RS 30.00.

FIGURE 26-13 ROOT FITTING BLEND LIMITS
26-42 Dents (continued)

1. e. Spar: Refer to step 2. Blend damaged areas by hand with a minimum 1.0 inch
blend radius. Blending is not allowed within 0.010 inch of spar groove leading
edge.
A016-6 Blades:
i. 0.020 inch maximum depth damage between RS 75.5 and RS 151.0.
ii. 0.010 inch maximum depth damage between RS 21.0 and RS 75.5.
A016-4 Blades:
i. 0.020 inch maximum depth damage between RS 64.0 and RS 151.0.
ii. 0.010 inch maximum depth damage between RS 21.00 and RS 64.00.
2. Refer to § 26-50 for repair procedures for damage within limits. Smooth, round bottom
dents with 0.060 inch minimum radius may be filled and faired to an aerodynamic
shape.

26-43 Root Fitting Damage
1. Refer to Figure 26-13. Damage may not exceed the following limits:
A016-6 Blades:
Refer to step 2. Blend damaged areas by hand with a minimum 0.030 inch blend
radius.
a. 0.002 inch maximum depth blending on flange inboard face.
b. 0.005 inch maximum depth, 0.250 inch maximum diameter blending on flange
outboard machined face (3 blends maximum). 0.10 inch minimum distance
from hole edges.
c. 0.040 inch maximum depth blending on exposed areas of root fitting.
A016-4 Blades:
Refer to step 2. Blend damaged areas by hand with a minimum 0.10 inch blend
radius.
a. 0.010 inch maximum depth blending on flange inboard face.
b. 0.005 inch maximum depth blending on 0.250 inch area outboard of flange.
c. 0.060 inch maximum depth blending on exposed areas of root fitting.
2. Refer to § 26-50 for repair procedures for damage within limits.

FIGURE 26-14 BOND AREAS

26-44 Voids
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.
CAUTION
Tap-test voids and debonds in blades using an AN970-4 washer
or 1965-or-later U.S. quarter dollar coin in good condition.
A. Critical Bond Areas

Refer to Figure 26-14. Critical bond areas are areas less than 0.50 inch spanwise
and less than 0.30 inch chordwise from the edge of any structural bond joint.
Bond areas not defined as semi-critical or non-critical are considered critical.
Voids separated by less than 0.25 inch are considered continuous.
1. Damage may not exceed the following limits:
a. 0.10 square inch maximum void.
b. Area must be at least 90% bonded.
B. Semi-Critical Bond Areas
A016-6 Blades:
A016-6 Blades do not have semi-critical bond areas.
A016-4 Blades:
Refer to Figure 26-14. Semi-critical bond areas are areas more than 0.50 inch
spanwise or more than 0.30 inch chordwise from the edge of the trim tab.
Voids separated by less than 0.25 inch are considered continuous.
1. Damage may not exceed the following limits:
a. 0.80 inch diameter circle maximum void.
b. 0.90 square inch maximum void.
c. 0.10 square inch maximum of a void extending into a critical bond area.
d. Area must be at least 80% bonded.

26-44 Voids (continued)
C. Non-Critical Bond Areas
Refer to Figure 26-14. Non-critical bond areas are areas more than 0.50 inch
spanwise or more than 0.30 inch chordwise from B440 cap (A016-4 blades), from
doubler edges, and from bonded areas between skin and honeycomb.
A016-6 Blades:
1. Voids in doubler bond joints separated by less than 0.25 inch are considered
continuous. Damage in doubler bond joints may not exceed the following limits:
a. Area must be at least 80% bonded.
b. 5.0 square inches, 1.0 inch chordwise, & 6.0 inches spanwise max. void.
c. 0.10 square inch maximum of a void extending into a critical bond area.
d. Voids are permissible within 0.30 inch of doubler leading edge where it
wraps around spar and root fitting.
2. Voids in honeycomb bond joints separated by less than 0.50 inch spanwise
or 1.0 inch chordwise are considered continuous. Damage in honeycomb
bond joints may not exceed the following limits:
a. Area must be at least 80% bonded.
b. 8.0 square inches, 1.0 inches chordwise, & 20.0 inches spanwise
maximum void inboard of RS 92.0.
c. 14.0 square inches, 2.0 inches chordwise, & 20.0 inches spanwise
maximum void outboard of RS 92.0.
A016-4 Blades:
1. Voids in A934 doubler bond joints may not exceed the following limits:
a. 5.0 square inches, 1.10 inches chordwise & 6.0 spanwise max. void.
b. 0.10 square inch maximum void extending into a critical bond area.
c. 2.0 inches maximum void from outboard tips (refer to R22 SL-55).
2. Voids in honeycomb bond joints inboard of RS 106.0 may not exceed 8.00
square inches, 1.00 inches chordwise, & 20.00 inches spanwise maximum.
3. Voids in honeycomb bond joints outboard of RS 106.0 may not exceed 14.00
square inches, 2.00 inches chordwise, & 20.00 inches spanwise maximum.
4. Voids in honeycomb bond joints between RS 120.0 and RS 133.5, and
between RS 150.0 and 166.0, must be at least 1.0 inch forward of
honeycomb trailing edge and the skin over void may not move when trim
tabs are flexed.
5. Voids in A934 doubler bond joints separated by less than 0.25 inch, less
than 0.50 inch spanwise, or less than 1.0 inch chordwise are considered
continuous. Area must be at least 80% bonded.

26-50 Repair of Main Rotor Blades
WARNING
Unauthorized repairs to rotor blades have caused fatal crashes.
CAUTION
Do NOT use power tools or chemical paint strippers to repair
main rotor blades.
NOTE
Refer to § 23-70 for approved materials.
1. Measure damage per § 26-40.

2. Remove damage at trailing edges, trim tab edges, tip cap, and/or tip corner by trimming
per § 26-51 as required.
3. Polish out damage using 220 grit or finer wet-or-dry aluminum-oxide abrasive paper,
and finish with 320 grit or finer wet-or-dry abrasive paper. A fine-toothed file may
be used along the spar and trailing edge, provided the area is finished with 320 grit
or finer wet-or-dry abrasive paper. Sand or file in spanwise direction. Remove only
the material necessary to remove the damage and blend to the radius or dimension
specified. Maintain squareness of trailing edge per Figure 26-16. Visually inspect and
verify damage is removed.
4. Measure material removed per § 26-40. Verify repair does not exceed limit specified.
5. Seal or fill as required per the following:
a. Clean area to be sealed or filled using approved solvent (refer to § 23-70).
b. Apply epoxy primer to bond joints with pin holes or other openings. Mix primer
per manufacturer’s instructions. Allow a minimum of 24 hours cure time.
c. Using 220-grit or finer wet-or-dry aluminum-oxide or silicon-carbide abrasive
paper, hand-sand cured adhesive in spanwise direction to a smooth, aerodynamic
finish, congruent with the blade airfoil. Do not remove metal.
d. Hand-sand surrounding painted surface until 25% primer remains. Keep bare
metal to a minimum.
6. Paint per § 26-52 as required.
7. Track and balance main rotor per § 10.230 as required.

FIGURE 26-15 TRIM LIMITS

FIGURE 26-16 SANDING/FILING SKIN EDGES SQUARE
26-51 Trimming
Refer to Figures 26-15 & 26-16. Trimming may be performed on the trailing edge of main
rotor blade skins and trim tab edges within limits shown. (Alternately, a trailing edge
nick or notch may be blended out 1.0 inch minimum spanwise, each side of nick or notch
within limits shown.) Trimming is not permitted on spar or doublers.
Tip cap and tip corner may be trimmed within limits shown.
Finish repair per § 26-50 steps 2 thru 7. File trailing edge or trim tab edges square with
skins (do not file into a point). Verify minimum chord dimension.
26-52 Painting
Refer to § 23-70 for approved materials. Refer to paint manufacturer’s recommendations.
CAUTION
If force-drying paint, do not exceed 175º F surface temperature
on blade; monitor blade temperature.
1. Remove main rotor blade tip cover(s) as required. Clean the blade(s).
2. Feather edge of paint bordering bare metal by hand-sanding spanwise with 220-grit or
finer wet-or-dry aluminum-oxide or silicon-carbide abrasive paper. Do not remove metal.
3. Mask area to prevent overspray contamination.
4. Clean bare metal to be painted with a lint-free cloth dampened with enamel cleaner.
5. Prime bare metal, including bare metal under tip cover(s) as required, with at least
two coats epoxy primer. Scuff first coat of primer with 320-grit abrasive paper (or
very fine Scotch-Brite), and wipe down with a lint-free cloth dampened with enamel
cleaner prior to applying second coat.

FIGURE 26-17 MAIN ROTOR BLADE PAINT SCHEME (A016-6 BLADE SHOWN)
26-52 Painting (continued)

6. Refer to Figures 26-17. Apply dark gray (root), flat black, white, and/or yellow
polyurethane enamel, as required, to primed area in accordance with paint manufacturer’s
recommendations.
NOTE
Allow Imron paint to cure at least 72 hours before flying in
erosive conditions (such as drizzle, rain, or dust).
7. Install blade tip cover(s) if removed.

8. Remove masking materials.

CHAPTER 27
MAIN ROTOR DRIVE SYSTEM
Section Title Page
27-00 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.1
OCT 2018 Chapter 27 Main Rotor Drive System Page 27.i

Intentionally Blank
Page 27.ii Chapter 27 Main Rotor Drive System OCT 2018

CHAPTER 27
MAIN ROTOR DRIVE SYSTEM
27-00 Description
Reserved.
OCT 2018 Chapter 27 Main Rotor Drive System Page 27.1

Intentionally Blank
Page 27.2 Chapter 27 Main Rotor Drive System OCT 2018

CHAPTER 28
TAIL ROTOR
Section Title Page
28-00 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28.1
OCT 2018 Chapter 28 Tail Rotor Page 28.i

Intentionally Blank
Page 28.ii Chapter 28 Tail Rotor OCT 2018

CHAPTER 28
TAIL ROTOR
28-00 Description
Reserved.
OCT 2018 Chapter 28 Tail Rotor Page 28.1

Intentionally Blank
Page 28.2 Chapter 28 Tail Rotor OCT 2018

CHAPTER 29
TAIL ROTOR DRIVE SYSTEM
Section Title Page
29-00 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.1
OCT 2018 Chapter 29 Tail Rotor Drive System Page 29.i

Intentionally Blank
Page 29.ii Chapter 29 Tail Rotor Drive System OCT 2018

CHAPTER 29
TAIL ROTOR DRIVE SYSTEM
29-00 Description
Reserved.
OCT 2018 Chapter 29 Tail Rotor Drive System Page 29.1

Intentionally Blank
Page 29.2 Chapter 29 Tail Rotor Drive System OCT 2018

CHAPTER 30
ENGINE CONTROLS
Section Title Page
30-00 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30.1
OCT 2018 Chapter 30 Engine Controls Page 30.i

Intentionally Blank
Page 30.ii Chapter 30 Engine Controls OCT 2018

CHAPTER 30
ENGINE CONTROLS
30-00 Description
Reserved.
OCT 2018 Chapter 30 Engine Controls Page 30.1

Intentionally Blank
Page 30.2 Chapter 30 Engine Controls OCT 2018

CHAPTER 31
ENGINE OIL SYSTEM
Section Title Page
31-00 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.1
OCT 2018 Chapter 31 Engine Oil System Page 31.i

Intentionally Blank
Page 31.ii Chapter 31 Engine Oil System OCT 2018

CHAPTER 31
ENGINE OIL SYSTEM
31-00 Description
Reserved.
OCT 2018 Chapter 31 Engine Oil System Page 31.1

Intentionally Blank
Page 31.2 Chapter 31 Engine Oil System OCT 2018

CHAPTER 32
POLICE VERSION
Section Title Page
32-00 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32.1
OCT 2018 Chapter 32 Police Version Page 32.i

Intentionally Blank
Page 32.ii Chapter 32 Police Version OCT 2018

CHAPTER 32
POLICE VERSION
32-00 Description
Reserved.
OCT 2018 Chapter 32 Police Version Page 32.1

Intentionally Blank
Page 32.2 Chapter 32 Police Version OCT 2018

CHAPTER 33
ELECTRICAL SYSTEM
Section Title Page
33-00 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.1

33-10 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.2
33-20 Clutch Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.3
33-30 Lighting System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.3
33-40 Audio System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.4
33-50 Dual Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.5
33-60 Warning and Caution Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.7
33-70 Carbon Monoxide Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.8
33-80 Emergency Locator Transmitter (ELT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.9
33-90 Low Rotor RPM Warning System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.9
33-100 Alternator Output Voltage Adjustment without A942-1 . . . . . . . . . . . . . . . . 33.10
33-110 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.10
33-120 Electrical Load Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.20
OCT 2018 Chapter 33 Electrical System Page 33.i

Intentionally Blank
Page 33.ii Chapter 33 Electrical System OCT 2018

CHAPTER 33
ELECTRICAL SYSTEM
33-00 Description
CAUTION
The installation of electrical devices can affect the accuracy
and reliability of the electronic tachometer.
A 14-volt DC electrical system which includes an alternator and a sealed lead-acid battery
is standard. The battery is located either in the engine compartment or beneath the
instrument console.
The circuit breaker panel is on the ledge just forward of the left seat. Breakers are marked
to indicate function and amperage and are of the push-to-reset type.
The battery switch controls the battery relay which disconnects the battery from the
electrical system. A wire protected by a fuse near the battery bypasses the battery relay
to allow both tachometers and the clock to continue to receive battery power with the
battery switch off.
The alternator control unit protects the electrical system from overvoltage conditions. The
ammeter indicates current to the battery (“—” indicates discharge). An ALT caution light or
ammeter discharge indication in flight indicates low voltage and possible alternator failure.
NOTE
Except for emergency procedures, do not operate alternator
with battery switched off. The battery helps protect electrical
equipment from voltage spikes.
Later aircraft have an avionics master switch which controls power to the avionics bus.
This allows all avionics to be switched on and off by a single switch.
OCT 2018 Chapter 33 Electrical System Page 33.1

33-10 Battery
NOTE
Refer to Concorde Battery Corporation's Owner/Operator's
Manual, and Instruction for Continued Airworthiness for battery
maintenance procedures.
CAUTION
To minimize risk of electrical discharge: When disconnecting
battery, disconnect negative (ground) cable from battery first,
then the positive cable. When connecting battery, connect
positive cable to battery first, then the negative (ground) cable.
A. Disconnecting and Removing Battery

a. Aft Battery: Remove engine left side skirt, as required. Remove cotter
rings and wing nuts to release rods attaching battery box assembly to lower
frames. Remove cover.
b. Nose battery: Open upper console and remove battery box cover.
2. Remove hardware securing negative (ground) cable to battery negative terminal.
3. Remove hardware securing positive cable to battery positive terminal. Carefully
remove battery.
B. Installing and Connecting Battery
2. Position battery in battery box and connect battery cables. Special torque terminal
bolts as noted on battery label and torque stripe per Figure 2-1.
3. Install cover.
a. Aft Battery: Install wing nuts and cotter rings to secure rods attaching
battery box assembly to lower frames. Verify security. Install engine left
side skirt, if removed.
b. Nose battery: Secure upper console.
Page 33.2 Chapter 33 Electrical System OCT 2018

33-20 Clutch Actuator
After the engine is started, it is coupled to the rotor drive system through vee-belts which
are tensioned by raising the upper drive sheave. An electric actuator, located between
the drive sheaves, raises the upper sheave when the pilot engages the clutch switch. The
actuator senses compressive load (belt tension) and switches off when the vee-belts are
properly tensioned. The clutch caution light illuminates whenever the actuator circuit is
energized, either engaging, disengaging, or re-tensioning the belts. The light stays on until
the belts are properly tensioned or completely disengaged.
Belt slack during engine start should be adjusted such that blades begin turning within five
seconds of clutch engagement. Excessive slack may cause belts to jump out of sheave
grooves during start. Periodic readjustment by a mechanic may be required as belts wear
in service.
A fuse located on or near the test switch panel prevents an actuator motor overload from
tripping the circuit breaker. If the fuse blows, the actuator motor will stop but the clutch
caution light will remain illuminated. An open circuit breaker removes power from both the
motor and the light. With an open circuit breaker, no belt tensioning will occur, and the
light will not function to indicate an abnormal condition.
CAUTION
Never take off while clutch caution light is on.
33-30 Lighting System

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. Post and internal lights (earlier aircraft) or a light at the top of the
windshield (later aircraft) illuminate the instruments. Instrument lighting is active when the
nav lights switch is on and lighting is dimmed via the knob above the nav lights switch.
An overhead map light mounted on a swivel is controlled by an adjacent switch. The map
light may be used for emergency lighting of the instrument panel.
Two landing lights are installed in the nose at different vertical angles to increase the lighted
area. One landing light switch controls both lights and is located on the cyclic center post.
NOTE
NOTE
Continuous operation of landing and position lights in flight is
recommended to promote collision avoidance.

33-40 Audio System
A voice-activated intercom/audio system is standard and is controlled by a small control
panel above the avionics stack. The ICS volume knob controls intercom volume but does
not affect radio volume. The VOX squelch knob is used to set the threshold volume at
which the intercom is activated. When the VOX knob is turned fully clockwise, keying
is required to activate the intercom. Later intercom systems include a music input jack
located on the circuit breaker panel. This input is muted when the intercom is active, when
transmitting, and during reception of radio signals.
Headset jacks are located in the ceiling near each seat. The cyclic grips are equipped
with either transmit and intercom buttons or trigger-style intercom/transmit switches. For
the trigger-style switch, the first detent activates the intercom and the second detent
transmits. An additional intercom button is located on the left-hand floor or seat support.
Earlier R22s are equipped with an intercom system that operates in either push-to-talk
(PTT) or hot mic modes. A toggle switch to the left of the cyclic center post is used to
change modes. In PTT mode, the intercom is activated using the intercom buttons.
Audio control panels from several manufacturers are offered as options in place of the
standard intercom system. Pilots should consult the manufacturer’s operating instructions
if an audio panel is installed.

33-50 Dual Tachometer
An electronic engine and rotor dual tachometer is standard. Engine tachometer signal is
provided by magneto breaker points. Rotor tachometer signal is provided by two magnetic
senders at the main gearbox drive yoke. Each tachometer is on a separate circuit with its
own circuit breaker. With battery and alternator switches off, the tachometers continue
to receive power from the battery through a bypass circuit as long as the clutch actuator
switch is in the engage position.
NOTE
Do not stow helicopter with clutch switch engaged. The
tachometers are powered with the clutch engaged and will
discharge the battery.
A. Adjustment
1. The early model A792-1 Dual Tachometer is pre-set at the factory and is not
adjustable in the field. For repair or adjustment, the unit must be returned to
Robinson Helicopter. (No adjustment screw on early models.)
2. The A792-2 Dual Tachometer is pre-set at the factory. Slight variations between
rotorcraft may require readjustment of rotor side of tachometer. To adjust
tachometer:
a. Remove screws that fasten instrument face panel to upper console and
carefully pull panel aft.
b. Ground run helicopter at 104% indication on the engine tachometer. Adjust
the rotor tachometer to read 104%. On back of tachometer, turn the
adjustment screw clockwise to increase and counter-clockwise to decrease
rotor tachometer indication (1/8 turn changes indication approximate 1%).
c. Reinstall instrument panel.
d. If tachometer cannot be adjusted, replace or return to Robinson Helicopter
Company for repair.

FIGURE 33-1 FULL THROTTLE CAUTION LIGHT RIGGING CHECK

33-60 Warning and Caution Lights
Warning and caution lights include clutch, main gearbox over-temperature, main and tail
gearbox chip, starter on (later aircraft), low fuel, low RPM, alternator, low oil pressure,
rotor brake, governor off, carbon monoxide (aircraft with cabin heater), and full throttle
(later aircraft). The clutch light indicates that the clutch actuator is operating. The low
RPM light and horn indicate rotor RPM at 97% or below. The low oil pressure and low fuel
lights are actuated by sensors in those systems and are independent of the gage indicators.
The alternator light warns of a possible alternator failure. The governor-off light indicates
the RPM governor is switched off.
The main and tail gearbox chip detectors are magnetic devices located in the drain plug of
each gearbox. When metallic particles are drawn to the magnets they close an electrical
circuit, illuminating the caution light. Metal particles may be caused by a failing bearing or
gear, thus giving warning of impending gearbox failure. The main gearbox over-temp light
is actuated by a temperature switch located near the input pinion.
The carbon monoxide light is actuated by a sensor above the pilot’s heater outlet and
indicates elevated cab in carbon monoxide levels.
The full throttle light is activated by a switch in the throttle linkage and indicates that the
engine is near full throttle.
A. Full Throttle Caution Light

1. Rigging Check
a. Turn fuel shut-off valve off.
b. Turn battery switch on. Raise collective full up and slowly rotate twist grip
open until full throttle caution light just illuminates.
c. Refer to Figure 33-1. Verify gap from throttle stop to corner of throttle body
full-throttle stop is 0.114–0.148 inch. Adjust as required per step 2.
d. Lower collective & turn battery switch off. Turn fuel shut-off valve on.
2. Switch Adjustment
a. Refer to Figure 33-1. Raise collective full up, rotate (throttle) twist grip
as required, loosen screw, and pivot A607-2 slotted cam (in throttle
linkage, under co-pilot seat) so V3-1 switch activates when throttle stop
is approximately 0.130 inch from corner of throttle body full-throttle stop.
Tighten screw.
b. Perform rigging check per step 1.

33-70 Carbon Monoxide Detector
The carbon monoxide (CO) detector, if installed, indicates elevated cabin CO levels. CO is
an odorless, toxic gas present in engine exhaust which causes headaches, drowsiness, and
possible loss of consciousness. CO levels may become elevated due to an exhaust leak or
exhaust recirculation during prolonged hovering.
The CO detector system consists of a sensor above the pilot’s heater outlet and a caution
light. A system check (light flashes twice) is performed each time power is switched on.
A sensor malfunction is indicated by a continuing flash every four seconds.
If the caution light illuminates, shut off heater and open nose and door vents as required
to ventilate the cabin. If hovering, land or transition to forward flight. If symptoms of CO
poisoning (headache, drowsiness, dizziness) accompany caution light, land immediately.
Have exhaust system inspected before next flight.
Many chemicals can damage the CO sensor. Avoid use of solvents, detergents, or aerosol
sprays near the sensor. Temporarily tape off openings in top and bottom of sensor housing
when cleaning cabin interior.

33-80 Emergency Locator Transmitter (ELT)
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 aft, upper cowl door.
The remote switch/annunciator is located left of the cyclic stick.
The ELT is operated by a switch on the transmitter and a remote switch in the cockpit. The
transmitter switch has been secured in the AUTO or ARM position at installation and should
always be in this position for flight. The remote switch/annunciator is a three position
switch with indicator light. This switch should also be in the AUTO or ARMED (middle)
position for flight. With both switches set to AUTO/ARM, the ELT will begin transmitting
when subjected to a high “G” load. When the unit is transmitting, the red indicator light
illuminates.
Moving the remote switch to ON activates the transmitter. Use the ON position if an
emergency landing is imminent and time permits.
If the ELT is inadvertently activated, use the RESET position of the remote switch to stop
transmission and reset the unit. The red indicator will extinguish when unit is reset.
NOTE
Earlier aircraft may have ELT installations without remote
switch.
For more detailed instructions on ELT operation, maintenance, and required tests, refer to
manufacturer’s instructions supplied with the unit.
33-90 Low Rotor RPM Warning System

A. Horn Adjustment
When the collective is raised 0.2 to 0.4 inches (measured at grip) above fully down, the
low-rotor RPM warning unit must activate the low-rpm warning horn and low-rpm light
at 97% to 96% rotor RPM; horn and light must turn off above 96% to 97% rotor RPM.
The low rotor RPM warning unit is inside the upper console mounted on the left
vertical panel. Some older helicopters may mount the unit on the right side, or
ty‑rapped to upper console’s main wire bundle. Adjustments are made by turning an
exposed screw on warning unit, accessible by removing a black-plastic plug from a
3/8-inch diameter hole on the left vertical panel. The A569-1 warning unit’s (potted
circuit board type) adjustment screw sensitivity is approximately 1/16 turn per 1%
change. The A569‑5 warning unit’s (metal box type) adjustment screw sensitivity is
approximately 2 turns per 1% change. If warning unit cannot be adjusted to above
values it must be replaced.

33-100 Alternator Output Voltage Adjustment without A942-1
To check or adjust the output voltage:
1. Connect a voltmeter to “I” terminal of voltage regulator and ground with helicopter
running and read voltage (13.2 to 13.8 volts).
2. Output voltage may be adjusted using range screw on voltage regulator.
33-110 Troubleshooting
A. A569-5 Low Rotor RPM Warning Unit
Perform following tests prior to replacing A569-5 low rotor-rpm warning unit:
1. Verify:
a. Low RPM light bulb is functional.
b. Master switch off.
c. Full-down collective.
d. Horn circuit breaker in.
2. Access and disconnect both horn and A569-5 low rotor-rpm warning unit from
airframe electrical wiring.
3. Turn Master switch on and verify Horn circuit breaker remains in. If Horn circuit
breaker pops then -70 wire is shorted to ground; repair as required. Turn Master
switch off.
4. On the warning unit’s airframe electrical connector, install a jumper between
wires -70 & -75.
5. Turn Master switch on and verify Horn Start circuit breaker remains in. If Horn
Start circuit breaker pops then a short-to-ground exists in -75 wire and/or collective
activated V3-1 switch; repair as required.
6. Fully raise collective and verify Horn Start circuit breaker remains in and Low
RPM light illuminates. If Horn Start circuit breaker pops then a short-to-ground
exists in -76 wire and/or -78 wire and/or collective-activated V3-1 switch; repair
as required. If Low RPM light does not illuminate then collective-activated V3-1
switch is faulty or mis-adjusted and/or an open exists in -70, -75, or -76 wires.
7. Slowly raise and lower collective fully several times while simultaneously
manipulating throttle. Verify Horn Start circuit breaker remains in and Low RPM
light remains illuminated whenever collective is raised. If Horn Start circuit breaker
pops then a short-to-ground condition is occurring in -70, -75, or -76 wires and/or
collective-activated V3-1 switch due to collective movement. Check for pinched/
rubbing wiring and repair as required.
8. Turn Master switch off. Connect horn to airframe wiring.

33-110 Troubleshooting (continued)
A. A569-5 Low Rotor RPM Warning Unit (continued)
9. Turn Master switch on. Raise collective and verify horn activates and has
consistent tone. If Horn Start circuit breaker pops then horn is faulty and/or -78
wire is shorted to ground; repair as required. If horn fails to activate then -79
wire is open or horn is faulty; repair as required. If tone is inconsistent then horn
is faulty and/or poor connections exist; repair as required.
10. If A569-5 warning unit has starter lockout circuit enabled (warning unit’s 9-pin
connector plugged into airframe harness), also perform following steps:
11. Check A999-1 master radio relay current draw:
a. Master switch off and belt tension actuator fully disengaged.
b. Disconnect A569-5 low-rpm warning unit’s 9-pin connector and place an
ammeter in series (positive lead on pin 7) between pins 7 and 8 on airframe
side of connector.
c. Master switch on, Horn Start and Clutch Start circuit breakers in, avionics
off, rotor brake released, mixture at idle cut-off.
d. Select key switch to Start position and crank engine. Note and record
current draw at ammeter while cranking engine. Select key switch to Off
position.
e. Disconnect 582 wire at tab on starter solenoid and isolate connector (do not
let it ground). Select key switch to Start position. Note and record current
draw at ammeter; current should be 94-156 milliamps and a buzzing sound
should be heard from the starter vibrator. Select key switch to Off position.
12. Check starter circuit:
a. Master switch off and belt tension actuator fully disengaged.
b. Disconnect A569-5 low-rpm warning unit’s 9-pin connector and jump pins 7
and 8 on airframe side of connector.
c. Master switch on, Horn Start and Clutch Start circuit breakers in, rotor brake
released, mixture at idle cut-off.
d. Select key switch to Start position and crank engine. If engine does not
crank there is a problem in the starter circuit. If engine cranks then there is
a problem in either the A569-5 unit or the sense circuit.

A. A569-5 Low Rotor RPM Warning Unit (continued)
13. Check A596-5 sense circuit:
a. Master Switch on.
b. Momentarily engage clutch and verify Clutch light illuminates then disengage
clutch completely.
c. Master switch off.
d. Disconnect A051-1 actuator’s black four-pin connector. Ground airframe-
side plug’s pin 1 thru a #330 (post light type) lamp.
CAUTION
Failure to ground pin 1 thru a #330 lamp (such as direct
grounding) may result in wiring damage.
e. Verify less than 200 ohms (20 ohm nominal) to ground at pin 4 and at pin 5
on ship side of A569-5’s 9-pin connector.
f. Master switch on.
g. With A569-5 unit connected to airframe harness, verify voltage does not
exceed 0.5V from pin 4 to ground and from pin 5 to ground.
h. Master switch on, Horn Start and Clutch Start circuit breakers in, rotor brake
released, mixture at idle cut-off.
i. Select key switch to Start position and crank engine. Failure of engine to
crank indicates problem in A569-5 unit.
14. Upon successful completion of preceding tests the A569-5 low rotor-rpm warning
unit may be replaced and adjusted per § 33-90.

B. General
TROUBLE PROBABLE CAUSE CORRECTION
No electrical Battery terminals corroded Clean terminals.
power
Bad or no ground Clean ground path.
Tripped circuit breaker Check circuit, if circuit checks ok, reset

circuit breaker.
Low battery voltage Check battery. Recharge if necessary.
Low or no alternator output Check alternator belt tension, wiring, and

alternator control unit.
Bad wire or terminal Replace.
Engine cranks Low battery voltage Service or replace battery.

slowly, but will
not start Insufficient drive belt deflection Adjust actuator down-limit screw.
Corroded or dirty battery or starter Clean terminals.

terminals
Bad starter relay, wires or terminals Replace defective parts.
Engine cranks Bad ignition switch Replace switch.

but will not start
Bad starting vibrator Repair or replace vibrator.
Incorrect retard timing Adjust retard magneto internal timing.
Starter fails to Rotor brake engaged Release rotor brake.

operate
Low battery charge Check and recharge if necessary.
Circuit breakers tripped Reset both HORN START and CLUTCH

START circuit breakers.
Actuator not fully disengaged Engage actuator momentarily, then fully

disengage.
Loose connections Check all wiring (refer to wiring diagram).
Defective wiring Check all wiring (refer to wiring diagram).
Starter motor - burned winding or Repair or replace starter.

bad brushes

B. General (continued)
Discharged battery Battery worn out Replace
Charging rate not set correctly Reset
Standing too long Remove and recharge battery
Equipment left on accidentally Remove and recharge battery
Starter - Low cranking speed Same electrical causes as listed Same remedies as listed under
under “starter fails to operate” ”starter fails to operate”
Battery life is short Impurities in electrolyte Replace battery
Low charging rate Adjust voltage regulator
Battery runs out of electrolyte Too much water added to battery Drain and keep battery at proper
and charging rate too high level and adjust voltage regulator
Excessive corrosion inside Spillage from overfilling Use care in adding water
container
Vent lines leaking or clogged Repair or clean
Charging rate too high Adjust voltage regulator
Battery consumes excessive Charging rate too high (if in all Correct charging rate
water cells)
Alternator fails to supply Alternator defective Replace

charging current with engine
operating Voltage regulator defective Replace
Overvoltage relay defective Replace
Alternator switch defective Replace

B. General (continued)
Starter kicks back while Retard breaker contact in engine Measure retard breaker lead con-
cranking; may cause broken left magneto pushed out or no nection. Must be 0.609 in. ±
starter or starter ring gear connection between lead and 0.10 in. There must be a small
magneto contact amount of springback which into
magneto.
Incorrect ignition vibrator wiring Trace ignition vibrator wiring

from ignition switch to magneto.
Correct as required.
Bad ignition switch (See RHC Replace ignition switch

Service Letter R22 SL-29)
Bad ignition vibrator Replace vibrator
Incorrect internal magneto re- Correct as required. Consult

tard breaker timing. Engine left TCM Aircraft Products literature.
magneto
Impulse coupling starting assist Replace impulse coupling with

ignition vibrator starting assist.
RHC KI-4.

C. Clutch Actuator Electrical Troubleshooting
CLUTCH LIGHT
TROUBLE PROBABLE CAUSE
ON OFF
Disengaged actuator will X Motor assembly seized
not engage
X Motor fuse blown (1½-amp)
X Open circuit in motor wiring
X Overtravel switch assembly tripped
X No voltage at circuit breaker
X Circuit breaker tripped
X Spring switch open (normally closed)
X -88 wire not grounded
Engaged actuator will not X Motor assembly seized

disengage
X Motor fuse blown (1½-amp)
X Open circuit in motor wiring
X Overtravel switch assembly tripped
X No voltage at circuit breaker
X Circuit breaker tripped
X Up limit switch stuck (normally closed)
X -88 wire not grounded
Clutch light flickers in flight Actuator column spring uncalibrated
A190 drive belts mismatched
Lower drive sheave improperly torqued
A184 or A181 bearing running rough
Clutch light comes on for 1–6 seconds in flight Normal operation of actuator as it retensions drive belts
Clutch light comes on for more than 6 Drive belts stretched beyond limit of actuator over-
seconds in flight travel switch. Belts must be replaced.
Actuator overtravel switch activated by outside force

D. Electrically Powered Instrument Calibration Values
Using Vibrex 2000 balancing equipment (or similar) capable of displaying ± 1 rpm
resolution and calibrated within one year, verify tachometer accuracy per following
tables. Connect equipment in accordance with §§ 10.221 and 6.240 (use photocell
instead of Strobex per Figure 6-4A). Operate aircraft at noted tachometer indications
and verify engine and rotor rpms as specified. Tachometer needles are 1% wide.
A792-x Dual Tachometer

Tachometer indication Engine RPM Rotor RPM
97% 2471-2476 494-495
100% 2548-2552 509-510
104% 2649-2655 529-530
The rotor tachometer may be adjusted per § 33-50. No other adjustments are
permitted. If tachometer does not meet accuracy tolerance then it must be replaced
or returned to RHC for repair.
A058-5 Carb. Air Temp. Probe A604-2 Carb. Air Temp. Gage at 13.7 Vdc;
0° = 89.68/91.08 ohms 77.40 ohms = -30° ± 2°C
15° = 95.67/98.07 ohms 81.73 ohms = -20° ± 1.75°C
16° = 96.10/98.50 ohms 86.05 ohms = -10° ± 1.5°C
17° = 96.54/98.94 ohms 90.38 ohms = 0° ± 1°C
18° = 96.97/99.37 ohms 94.71 ohms = 10° ± 1.5°C
19° = 97.40/99.80 ohms 99.03 ohms = 20° ± 1.75°C
20° = 97.83/100.23 ohms 103.36 ohms = 30° ± 2°C
21° = 98.27/100.67 ohms
22° = 98.70/101.10 ohms
23° = 99.13/101.53 ohms
24° = 99.56/101.96 ohms
25° = 100.00/102.40 ohms
Example: Replacing the carburetor air temperature probe with a ¼ to 1-watt 100‑ohm
resistor should result in an indication of approximately 21°C (measure exact resistor
value & refer to above). A probe dipped in a Styrofoam cup full of crushed ice
and water should indicate 90.38 ohms resistance per above table. Probe installation
torque is 3 to 4 inch-pounds; over-torquing probe will result in damage.

D. Electrically Powered Instrument Calibration Values (continued)
Following instrument cluster gages are calibrated at 20 to 25 degree angle from horizontal.
Fuel level senders should have 90 ± 2 ohms resistance when fully up (full fuel) and 0
to 0.5 ohm when fully down (no fuel). Perform fuel sender calibration per § 12.410
whenever sender is replaced, or if factory-set fuel gage potentiometers have been
disturbed. On backside of each fuel gage are “Null” and “Gain” potentiometer screws,
covered with aluminum tape pressed against the screw heads to prevent rotation.
“Null” potentiometer is adjusted so gage indicates empty at 0.7 ohm sender circuit
resistance; “Gain” potentiometer is adjusted so gage indicates half at 42 ohms sender
circuit resistance. Calibration values are:
Fuel Quantity Gages 6246-00473 (14V)

0.70 ohm = E (empty) -1, +0 pointer width
21.20 ohms = 1/4 full ± 1 pointer width
90.00 ohms = F (full) ± 1 pointer width
Ammeter 6246-00468 (14V)

-104 mV = -70 amps ± 1 pointer width
-52 mV = -35 amps ± 1 pointer width
0 mV = 0 amps ± ¼ pointer width
+52 mV = +35 amps ± 1 pointer width
+ 104 mV = +70 amps ± 1 pointer width
CHT Probe 3080-38 (14V) CHT Gage 6246-00088 (14V)

200°F = 745 ohms 745 ohms = 200 degrees F ± 1 pointer width
475°F = 38 ohms 110 ohms = 350 degrees F ± 1 pointer width
500°F = 32 ohms 34 ohms = 500 degrees F ±% pointer width
Oil Pressure Sender 115-psi redline Oil Pressure Gage

B308-1 (14V) 6246-00647 (14V)
0 psi = 5-13 ohms 9 ohms = 0 psi ± 1 pointer width

D. Electrically Powered Instrument Calibration Values (continued)
Older, 100-psi red line Oil Pressure Gage

6246-00089 (14V)
0 psi = 10.0 ohms
25 psi = 46.5 ohms
60 psi = 90.0 ohms
90 psi = 125.5 ohms
100 psi = 137.0 ohms
Oil Temperature Sender Oil Temperature Gage

A760-1 (14V) 6246-00090 (14V)
100°F = 497 ohms 903.5 ohms = 75°F ± 1 pointer width
250°F = 34 ohms

33-120 Electrical Load Analysis
To calculate the total electrical load for a specific helicopter, identify all items of equipment
installed on the helicopter from the table below and sum the corresponding continuous and
intermittent loads.
Maximum continuous alternator load is given in the table below:
System Voltage Alternator Rating Maximum Continuous Load

14V 60 amp 54 amps
Intermittent loads are provided for reference.

Alternately, the electrical load may be measured directly at the battery output terminal with
the alternator switched off and all other equipment turned on. The measured load may be
scaled by the ratio of battery voltage to nominal system voltage to obtain a value that is
compared with the alternator load limit.
WARNING
Field (non-factory) installation of electronic equipment can
be hazardous. Due to the compactness of the console and
tunnel containing the controls and wire bundles, installation
of any additional wires can interfere with flight controls.
Electronic tachometers, warning systems, and navigation
equipment essential to flight are sensitive to interference from
other electrical devices. The reliability and accuracy of the
tachometers is essential for safe operation of the helicopter,
and installation of an electrical device not tested and approved
by RHC may result in a hazardous condition.
CONTINUOUS INTERMITTENT CONTINUOUS INTERMITTENT

EQUIPMENT QTY
AMPS EACH AMPS EACH TOTAL TOTAL
MAIN BUS
ESSEX BATTERY RELAY 1 0.75 0.75 0.75 0.75
KISSLING BATTERY RELAY 1 0.35 0.35 0.35 0.35
ALTERNATOR FIELD 1 2.40 2.40 2.40 2.40
AVIONICS RELAY 1 0.13 0.13 0.13 0.13
ENGINE GAGE CLUSTER 1 0.60 0.60 0.60 0.60
HOURMETER 1 0.03 0.03 0.03 0.03
CARB AIR TEMP 1 0.13 0.13 0.13 0.13
AMMETER 1 0.50 0.50 0.50 0.50
DIGITAL OAT GAGE 1 0.15 0.15 0.15 0.15
MAP LIGHT 1 0.00 0.58 0.00 0.58
WARNING LIGHTS 8 0.00 0.08 0.00 0.64
FULL THROTTLE CAUTION LIGHT 1 0.00 0.08 0.00 0.08

33-120 Electrical Load Analysis (continued)

EQUIPMENT QTY
MAIN BUS (continued)

RPM GOVERNOR MOTOR 1 0.00 1.50 0.00 1.50
BELT TENSION ACTUATOR 1 0.00 1.20 0.00 1.20
AUX POWER PLUG (MAX) 1 10.00 10.00 10.00 10.00
HEATER BLOWER 1 7.50 7.50 7.50 7.50

EQUIPMENT QTY
TACH BUS
DUAL TACHOMETER (E) 1 0.10 0.10 0.10 0.10
DUAL TACHOMETER (R) 1 0.10 0.10 0.10 0.10

EQUIPMENT QTY
LIGHTS BUS
POSITION LIGHTS (L, R, & AFT,
3 2.20 2.20 6.60 6.60
INCANDESCENT)
POSITION LIGHTS (L & R, LED) 2 0.25 0.25 0.50 0.50
POSITION LIGHT (AFT, LED) 1 0.30 0.30 0.30 0.30
OVERHEAD PANEL LIGHT 1 1.00 1.00 1.00 1.00
POST LIGHTS 7 0.08 0.08 0.56 0.56
INSTRUMENT LIGHTS 4 0.20 0.20 0.80 0.80
LANDING LIGHT RELAY 1 0.20 0.20 0.20 0.20
LANDING LIGHTS
2 7.70 7.70 15.40 15.40
(INCANDESCENT)
LANDING LIGHTS (HID) 2 2.90 9.52 5.80 19.04
ANTI-COLLISION LIGHT &
1 3.20 3.20 3.20 3.20
POWER SUPPLY
ANTI-COLLISION LIGHT (LED) 1 0.90 4.00 0.90 4.00

EQUIPMENT QTY
AVIONICS
KY197A COM 1 0.80 5.20 0.80 5.20
GTR225B COM 1 0.59 5.31 0.59 5.31
GNS430 COM/NAV/GPS 1 2.44 8.40 2.44 8.40
GTN650 COM/NAV/GPS 1 2.65 6.97 2.65 6.97
KX155 OR KX165 NAV/COM 1 0.70 8.50 0.70 8.50

33-120 Electrical Load Analysis (continued)

EQUIPMENT QTY
AVIONICS (continued)
KR87 ADF 1 1.24 1.24 1.24 1.24
KN63 DME 1 1.21 1.21 1.21 1.21
GARMIN TRANSPONDER 1 1.10 3.10 1.10 3.10
GARMIN RADIO NAVIGATION
1 0.41 0.41 0.41 0.41
INDICATOR
KING RADIO NAVIGATION
1 0.08 0.08 0.08 0.08
INDICATOR
MARKER BEACON 1 0.50 0.50 0.50 0.50
KCS55A HSI 1 3.23 3.23 3.23 3.23
RADAR ALTIMETER 1 1.45 1.45 1.45 1.45
AA12S AUDIO CONTROL 1 1.00 1.00 1.00 1.00
GMA 350H AUDIO CONTROL 1 0.80 1.50 0.80 1.50
ASPEN 1000H EFD 1 4.80 4.80 4.80 4.80
ATTITUDE HORIZON
1 0.54 1.40 0.54 1.40
(MECHANICAL)
ATTITUDE HORIZON (LCD) 1 0.20 0.20 0.20 0.20
TURN COORDINATOR 1 0.70 0.70 0.70 0.70
DIRECTIONAL GYRO 1 0.44 1.40 0.44 1.40
PA/SIREN CONTROL 1 0.05 0.05 0.05 0.05
PA/SIREN SPEAKER 1 7.70 7.70 7.70 7.70
ICOM IC-M412 MARINE
1 1.50 5.50 1.50 5.50
TRANSCIEVER
KENWOOD TK-7160 OR TK8160
1 1.00 8.00 1.00 8.00
FM TRANSCIEVER
KENWOOD TK-7180 OR TK8180
1 1.00 9.00 1.00 9.00
FM TRANSCIEVER
YAESU FT-8800R FM
1 0.50 8.00 0.50 8.00
TRANSCIEVER
VERTEX VX-2200 FM
1 2.50 11.00 2.50 11.00
TRANSCIEVER

EQUIPMENT QTY
OTHER EQUIPMENT
STARTER RELAY 1 0.00 15.00 0.00 15.00
STARTING VIBRATOR 1 0.00 2.50 0.00 2.50
STARTER MOTOR 1 0.00 200.00 0.00 200.00
CLOCK, STANDARD 1 0.02 0.02 0.02 0.02
CLOCK, DIGITAL 1 0.00 0.00 0.00 0.00

CHAPTER 34
AVIONICS
Section Title Page
34-10 Avionics Switch Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34.1

34-20 Transponder Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34.1
34-21 A804-12 Transponder (Garmin GTX 330 ES) Installation . . . . . . . . . . . . . . 34.1
34-30 COM Radio Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34.4
34-31 C802-2 COM Radio (Garmin GTR 225B) Installation . . . . . . . . . . . . . . . . . 34.4
34-40 Audio Control Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34.6
34-41 C822-1 Audio Control (Garmin GMA 350H) Installation . . . . . . . . . . . . . . 34.6
34-50 GPS Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34.8
34-51 C831 GPS (Garmin GTN 600 series) Installation . . . . . . . . . . . . . . . . . . . . 34.8
34-60 Avionics Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34.10
OCT 2018 Chapter 34 Avionics Page 34.i

Intentionally Blank
Page 34.ii Chapter 34 Avionics OCT 2018

CHAPTER 34
AVIONICS
34-10 Avionics Switch Description

R22 Helicopters S/N 4591, 4650, 4651, 4656 & subsequent have a dedicated avionics
switch located on the main switch panel on top of the avionics stack. Earlier R22s have an
avionics bus, but the master radio relay interrupts power to the avionics bus during start-
up, eliminating the need for a switch. The avionics switch controls a relay which interrupts
power to the avionics bus (system is fail-safe ON).
34-20 Transponder Installations
34-21 A804-12 Transponder (Garmin GTX 330 ES) Installation
NOTE
Refer to Garmin GTX 330 ES Maintenance Manual and
Instructions for Continued Airworthiness.
A. Description
Automatic Dependent Surveillance-Broadcast (ADS-B) “Out” equipment transmits aircraft
specific-data and position information to air traffic control via GPS-based surveillance
(rather than radar-based surveillance). ADS-B Out equipment will be required for R22
operation in certain airspace in the United States after January 1, 2020.
ADS-B Out system operates mostly automatically. ADS-B Out equipment is
programmed with aircraft-specific data at installation. ADS-B Out system uses
the primary installed GPS for position information. Additional flight-specific data is
entered by the pilot using transponder controls. ADS-B data is transmitted via the
transponder’s Extended Squitter (ES) on frequency 1090 MHz.
ADS-B Out equipment (transponder and primary GPS) must have power and must
be in normal operating modes for systems to function properly. ADS-B Out system
faults are annunciated on the transponder and primary GPS screens.
Change of aircraft registration may require ADS-B equipment programming by
qualified maintenance personnel.
Refer to R22 Pilot’s Operating Handbook Section 9 for additional information.
B. Schematic
Refer to Figure 14-41 for A804-12 transponder & blind encoder electrical schematic.
OCT 2018 Chapter 34 Avionics Page 34.1

34-21 A804-12 Transponder (Garmin GTX 330 ES) Installation (continued)
C. Removal
1. Turn battery switch off and pull out XPDR circuit breaker (5 amp) at panel.
2. Loosen radio key securing A804-12 transponder to avionics tray.
3. Carefully unplug/remove transponder from tray.
D. Installation
2. Carefully plug-in/install A804-12 transponder in appropriate location in avionics
tray.
3. Tighten radio key securing transponder to tray. Verify equipment security.
4. Push in XPDR circuit breaker (5 amp) at panel. Turn battery & avionics switches
on.
5. Perform appropriate functional checks per Garmin GTX 330 ES Pilot's Guide.
E. Antenna
Refer to § 16-70 for antenna locations and R22 Illustrated Parts Catalog (IPC) Chapter
6.
NOTE
Antenna installation depends on optional equipment installed.
Removal
2. Using plastic scraper, remove B270-1 sealant from around transponder antenna
at corners where it attaches to A794-2 panel.
3. Remove screws securing panel to cabin skin and disconnect antenna cable
from antenna. Remove hardware securing antenna and ground wire to panel
and remove antenna.
Page 34.2 Chapter 34 Avionics OCT 2018

34-21 A804-12 Transponder (Garmin GTX 330 ES) Installation (continued)
E. Antenna (continued)
Installation
2. Remove paint and primer from A794-2 panel where ground wire attaches to
ensure electrical ground.
3. Install hardware securing transponder antenna and ground wire to panel. Verify
security. Connect antenna cable to antenna and install screws securing panel
to cabin skin. Verify security.
corners where it attaches to panel and allow to dry.
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

1. Turn battery and avionics switches off. Open circuit breaker panel and upper
console.
2. 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. Verify no evidence of arcing. Verify equipment security.
D steps 4 and 5.

34-30 COM Radio Installations
34-31 C802-2 COM Radio (Garmin GTR 225B) Installation

A. Description
The C802-2 COM radio (Garmin GTR 225B) includes similar communication features
available in the earlier King KY197A COM radio, but includes an airport frequency
database, ability to monitor the standby frequency, and improved user memory
channel functionality. The Garmin GTR 225B is a dual voltage unit, suitable for use
in 14V and 28V systems.
B. Schematic
Refer to Figure 14-43 for C802-2 COM Radio Installation electrical schematic.
C. Removal
1. Turn battery switch off and pull-out COM radio circuit breaker (10 amp) at panel.
2. Loosen radio key securing C802-2 COM radio to avionics tray.
3. Carefully unplug/remove radio from tray.
D. Installation
1. Turn battery switch off and pull-out COM radio circuit breaker (10 amp) at panel.
2. Carefully plug-in/install C802-2 COM radio in appropriate location in avionics
tray.
3. Tighten radio key securing radio to tray. Verify equipment security.
4. Push-in COM radio circuit breaker (10 amp) at panel. Turn battery and avionics
switches on.
5. Perform appropriate functional checks per Garmin GTR 225B Pilot's Guide. Turn
battery and avionics switches off.
E. Antenna
6.
NOTE
Antenna installation depends on number of COM installations
and additional equipment installed.

34-31 C802-2 COM Radio (Garmin GTR 225B) Installation (continued)
Removal
1. Turn battery switch off and pull out COM radio circuit breaker (10 amp) at panel.
2. Using plastic scraper, remove B270-1 sealant from around COM antenna at
3. Disconnect antenna cable from antenna. As required, remove B270-13 sealant from
fastener holes. Remove screws securing antenna to tailcone and remove antenna.
Installation
1. Turn battery switch off and pull out COM radio circuit breaker (10 amp) at panel.
2. Remove paint & primer from antenna mating surfaces to ensure electrical ground.
3. As required, apply light coat B270-13 sealant to screw threads and install
screws securing antenna to tailcone. As required, seal around screw heads and
fill fastener holes using B270-13 sealant and allow to dry. Verify security.
5. Connect antenna cable to antenna. Verify security.
NOTE
NOTE

1. Turn battery and avionics switches off. Open circuit breaker panel and upper console.
2. Inspect condition of and verify no obvious damage to COM radio, radio tray,
D steps 4 and 5.

34-40 Audio Control Installations
34-41 C822-1 Audio Control (Garmin GMA 350H) Installation
NOTE
Refer to Garmin GMA 350H series Maintenance Manual and

A. Description
The Garmin GMA 350H audio control includes improved squelch and background
noise suppression, 3D audio (if stereo headsets are used) which allows inputs from
separate radios to sound as if they are coming from separate locations around the
listener, and some control functions via voice command when a momentary push-
button switch is depressed on the pilot's cyclic grip.
B. Schematic
Refer to Figure 14-44 for C822-1 Audio Control Installation electrical schematic.
C. Removal
1. Turn battery switch off and pull out AUDIO PANEL circuit breaker (5 amp) at
panel.
2. Loosen radio key securing Garmin GMA 350H audio control to avionics tray.
3. Carefully unplug/remove audio control from tray.
D. Installation
1. Turn battery switch off and pull out AUDIO PANEL circuit breaker (5 amp) at
panel.
2. Carefully plug-in/install Garmin GMA 350H audio control in appropriate location
in avionics tray.
3. Tighten radio key securing audio control to tray. Verify equipment security.
4. Push in AUDIO PANEL circuit breaker (5 amp) at panel. Turn battery & avionics
switches on.
5. Perform appropriate functional checks per Garmin GMA 350H series Pilot's Guide.
Turn battery & avionics switches off.
E. Antenna
6.

34-41 C822-1 Audio Control (Garmin GMA 350H) Installation (continued)
Removal
1. Turn battery switch off & pull out AUDIO PANEL circuit breaker (5 amp) at panel.
2. Using plastic scraper, remove B270-1 sealant from around CI 102 marker
beacon antenna at corners where it attaches to A794-2 panel.
3. Remove hardware securing panel to belly and disconnect A850-210 antenna cable
from antenna. Carefully remove screws (they are installed with threadlocker)
securing antenna to panel and remove antenna.
Installation
1. Turn battery switch off & pull out AUDIO PANEL circuit breaker (5 amp) at panel.
3. Apply light coat B270-11 adhesive to new screw threads and install screws
securing CI 102 marker beacon antenna to A794-2 panel. Verify security.
4. Connect A850-210 antenna cable to antenna. Install screws securing forward
belly panel to belly. Verify security.
corners where it attaches to belly panel and allow to dry.
NOTE
NOTE

1. Turn battery & avionics switches off. Open circuit breaker panel and upper console.
2. Inspect condition of and verify no obvious damage to audio control, radio tray,
D steps 4 and 5.

34-50 GPS Installations
34-51 C831 GPS (Garmin GTN 600 series) Installation
NOTE
Refer to Garmin GTN 600 series Maintenance Manual and
A. Description
The C831 GPS (Garmin GTN 600 series) includes similar navigation features available
in the earlier Garmin GNS 400 series GPS, but the interface offers a combination of
touch screen technology with traditional buttons and knobs.
One GTN 600 series GPS may be installed in the pilot-side console location only.
Note: R22 ADS-B Out system requires Garmin GTN 600-series GPS. Refer to §
14.1230.
B. Schematic
Refer to Figure 14-45 for C831 GPS (Garmin GTN 600 series) installation electrical
schematic.
C. Removal
1. Turn battery switch off and pull out COM circuit breakers(s) (10 amp) and GPS
circuit breaker(s) (7.5 amp) as required at panel.
2. Loosen radio key securing C831 GPS to tray in pilot's side console.
3. Carefully unplug/remove GPS from tray.
D. Installation
1. Turn battery switch off and pull out COM circuit breakers(s) (10 amp) and GPS
2. Carefully plug-in/install C831 GPS in tray in pilot's side console.
3. Tighten radio key securing GPS to tray. Verify equipment security.
4. Push in COM circuit breaker(s) (10 amp) and GPS circuit breaker(s) (7.5 amp) as
required at panel. Turn battery and avionics switches on.
5. Perform appropriate functional checks per Garmin GTN 600 series Pilot's Guide.

34-51 C831 GPS (Garmin GTN 600 series) Installation (continued)
E. Antenna
Refer to § 16-70 for antenna locations and R22 Illustrated Parts Catalog (IPC) Chapter 6.
NOTE
Antenna installation depends on number COM installations and
additional equipment installed.
Removal
1. Turn battery switch off and pull out COM circuit breaker(s) (10 amp) and GPS
2. Using plastic scraper, remove B270-1 sealant from around GPS antenna at
3. Disconnect antenna cable from antenna. As required, remove B270-13 sealant
from fastener holes. Remove screws securing antenna to tailcone and remove
antenna.
Installation
1. Turn battery switch off and pull out COM circuit breaker(s) (10 amp) and GPS
3. As required, apply light coat B270-13 sealant to screw threads and install
screws securing antenna to tailcone. As required, seal around screw heads
and fill fastener holes using B270-13 sealant and allow to dry. Verify security.
5. Connect antenna cable to antenna. Verify security.
NOTE
NOTE

34-51 C831 GPS (Garmin GTN 600 series) Installation (continued)
1. Turn battery and avionics switches off. Open circuit breaker panel. Remove
hardware securing pilot's side console shell assembly to tray and carefully pivot
shell assembly upward (GPS and faceplate may be also be removed).
2. Inspect condition of and verify no obvious damage to GPS, tray, copper bus bars,
circuit breaker, and wiring. Verify no loose, chafed, or broken wires or terminals.
Verify no evidence of arcing. Verify equipment security.
3. Secure circuit breaker panel and pilot's side console. Perform ground checks per
Part D steps 4 and 5.
34-60 Avionics Software

Modern avionics software is complex and subject to rigorous testing by RHC to assure proper
function and integration in the aircraft. Only specified software versions and software
configurations have been FAA-approved for installation in Robinson helicopters. Software
updates should not be attempted without a thorough understanding of approval status and
compatibility. Technical support from either RHC or the avionics manufacturer will likely be
required. In some cases, updating software for one item of avionics may require additional
avionics to be updated to assure compatibility.
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.
Consult www.robinsonheli.com > Customer Support > Avionics Support > Avionics
Software page for approved software configurations.
NOTE
The above statements apply to avionics operating software.
Databases (e.g. charts, terrain, etc.) may be updated regularly
using avionics manufacturer’s recommended procedures.

CHAPTER 35
WIRING DIAGRAMS
Section Title Page
35-00 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.1
OCT 2018 Chapter 35 Wiring Diagrams Page 35.i

Intentionally Blank
Page 35.ii Chapter 35 Wiring Diagrams OCT 2018

CHAPTER 35
WIRING DIAGRAMS
35-00 Description
Reserved.
OCT 2018 Chapter 35 Wiring Diagrams Page 35.1

Intentionally Blank
Page 35.2 Chapter 35 Wiring Diagrams OCT 2018

CHAPTER 36
SPECIAL TOOLS
Section Title Page
36-10 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36.1

36-20 Illustrations and Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36.2
OCT 2018 Chapter 36 Special Tools Page 36.i

Intentionally Blank
Page 36.ii Chapter 36 Special Tools OCT 2018

CHAPTER 36
SPECIAL TOOLS
36-10 Special Tools
The following is a list of Robinson R22-series special tools.

R22-series special tools are to be used in conjunction with the applicable instructions for
continued airworthiness, for their designated maintenance task.
OCT 2018 Chapter 36 Special Tools Page 36.1

36-20 Illustrations and Tasks
Item Part Number Description

1 MT016-1 Engine Hoist
2 MT050-1 Main Rotor Rigging Fixture
3 MT050-2 Tail Rotor Rigging Fixture
4 MT053-1 Main Gearbox Drain Assembly – Thread Type Chip Detector
5 MT054-1 Main Gearbox Drain Assembly – Quick Disconnect Chip Detector
6 MT068-1 Horizontal Stabilizer Rigging Tool
7 MT091-1 Holder – Engine Ring Gear (includes MT091-3 decal)
8 MT091-3 Decal (torquing instructions)
FIGURE 36-1 SPECIAL TOOLS
Page 36.2 Chapter 36 Special Tools OCT 2018

36-20 Illustrations and Tasks (continued)

1 MT092-1 Fan Puller (includes MT092-3 spacer)
2 MT092-3 Spacer – Fan Puller
3 MT122-1 Main Rotor Hub, Bolt Elongation (teeter hinges & A154-1 hub coning hinges)
4 MT122-15 Main Rotor Hub, Bolt Elongation (B370-1 hub coning hinges)
5 MT146-1 Blocks – Swashplate Rigging (set of 2)
6 MT147-1 Bleed Tool – Main Rotor Blade Spindle
7 MT173-4 Socket – 1-11/16 (3/4-inch drive, 12-point)
8 MT173-5 Torque Wrench Extension – Tool Set (no longer available)
9 MT173-6 Tube Weldment (no longer available)
10 MT173-7 Socket – 1-1/2-inch (3/4-inch drive, 12-point)
11 MT173-8 Socket – 2-inch (3/4-inch drive, 12-point)


1 MT179-4 Balancing Bar – Tail Rotor Assembly Static Balance
2 MT200-1 Dial Indicator
3 MT201-1 Pressing Fixture – Tail Rotor Hub Bearing
4 MT234-1 Helicopter Lifting Fixture
5 MT260-6 Tail Rotor Drive Shaft Runout Attachments Kit
6 MT294-1 Collective Spring Retainer


1 MT295-1 Tail Rotor Gearbox Output Shaft Seal Replacement Tools (includes items 2, 3, 4,
and Figure 36-9 item 5)
2 MT295-3 Punch
3 MT295-6 Screw
4 MT295-10 Mandrel
5 MT303-1 Clutch Bearing (A184) Removal and Installation Tools
6 MT303-3 Clutch Bearing (A184) Removal and Installation Tools (use with MT303-1 tools
when hydraulic press is unavailable)


1 MT329-1 Plug Assembly (A648-1 or A648-3 Bearings)
2 MT329-2 Support Weldment (A154-1 Hub)
3 MT329-8 Plug – Main Rotor Hub Bearing Installation
4 MT329-10 Tube
5 MT329-11 Plug Assembly (A648-2 Bearings)
6 MT329-13 Support Weldment
7 MT331-4 Sheave Alignment Bar
8 MT352-1 Main Rotor Blade Trim Tab Gage (includes MT200-1 dial indicator)
9 MT354-1 Teeter Moment Tool (no longer available; replaced by MT354-7)
10 MT354-7 Teeter Moment Tool (R22, R44, R66)


1 MT357-1 0.125-inch dia. Cobalt Drill Bit
2 MT357-2 0.375-inch diameter Reamer
3 MT357-4 Hex Driver (Snap-On Part No. FABL8)
4 MT357-5 Torque Adapter (Snap-On Part No. FRDH101)
5 MT357-6 Wrench (Open end; Snap-On Part No. LTA1214)
6 MT357-7 Wrench (Box end; Snap-On Part No. XDH78A)
7 MT357-8 Nipple Chuck
8 MT357-9 Taper Gage


1 MT358-1 0.750-inch dia. Spot-Facing Tool
2 MT359-1 Spring Scale (0-30 lb)
3 MT376-1 Blocks – Main Rotor Rigging (set; holds cyclic in neutral position)
4 MT526-1 Main Rotor Blade Trim Tab Bender (stainless steel skin)
5 MT526-8 Main Rotor Blade Trim Tab Bender (aluminum skin)


1 MT556-1 Tail Rotor Elastomeric Bearing Replacement Tools (includes items 2 thru 4, and 7)
2 MT556-2 Mandrel Assembly
3 MT556-5 Support
4 MT556-6 Cap
5 MT569-1 Main Rotor Bolt Drilling Fixture (teeter hinge & A154-1 hub coning hinge bolts)
6 MT569-6 Main Rotor Bolt Drilling Fixture (B370-1 hub coning hinge bolts)
7 AN4-25A Bolt
8 AN970-4* Washer – Tap Test Tool
* Or 1965 or later U.S. quarter dollar coin in good condition.


1 2020HR ACES Probalancer Analyzer (or equivalent dynamic balancer)
2 60297-12 Engine Operator’s Manual (O-360 engine; refer to Lycoming Service Letter No. L114)
3 60297-30 Engine Operator’s Manual (O-320 engine; refer to Lycoming Service Letter No. L114)
4 9HT4441 Extension Bar (3/4 square drive x 8 inch)
5 92470A113 Screws (#4 x 0.75 inch)

CHAPTER 37
REVISION LOG
Section Title Page
37-00 Revision Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37.1
OCT 2018 Chapter 37 Revision Log Page 37.i

Intentionally Blank
Page 37.ii Chapter 37 Revision Log OCT 2018

REVISION LOG
OCT 2018
The R22 Maintenance Manual (MM) list of effective pages and effective dates are given
below. If a previously issued page is not listed below, it is no longer an effective page and
must be discarded. The issue or revision date is in bold at the top of each revision log page.
Please visit www.robinsonheli.com, and click on the Publications tab, to verify the issue or
revision date is current. A subscription service form is included in the front of this manual.
Page Date Page Date Page Date
i............... OCT 2018 2.3 . . . . . . . . . . . . . OCT 2018 2.35 . . . . . . . . . . . . OCT 2018

ii . . . . . . . . . . . . . . . OCT 2018 2.4 . . . . . . . . . . . . . OCT 2018 2.36 . . . . . . . . . . . . OCT 2018
iii . . . . . . . . . . . . . . . OCT 2018 2.5 . . . . . . . . . . . . . OCT 2018 2.37 . . . . . . . . . . . . OCT 2018
iv . . . . . . . . . . . . . . OCT 2018 2.6 . . . . . . . . . . . . . OCT 2018 2.38 . . . . . . . . . . . . OCT 2018
v............... OCT 2018 2.7 . . . . . . . . . . . . . OCT 2018 2.39 . . . . . . . . . . . . OCT 2018
vi . . . . . . . . . . . . . . . OCT 2018 2.8 . . . . . . . . . . . . . OCT 2018 2.40 . . . . . . . . . . . . OCT 2018
2.9 . . . . . . . . . . . . . APR 2007 2.41 . . . . . . . . . . . . OCT 2018
1.i . . . . . . . . . . . . . . OCT 2018 2.10 . . . . . . . . . . . . JUN 2006 2.42 . . . . . . . . . . . . OCT 2018
1.ii . . . . . . . . . . . . . . OCT 2018 2.11 . . . . . . . . . . . . JUN 2006 2.43 . . . . . . . . . . . . JUN 2006
1.1 . . . . . . . . . . . . . OCT 2018 2.12 . . . . . . . . . . . . JUN 2006 2.44 . . . . . . . . . . . . JUN 2006
1.2 . . . . . . . . . . . . . OCT 2018 2.13 . . . . . . . . . . . . OCT 2018 2.45 . . . . . . . . . . . . JUN 2006
1.3 . . . . . . . . . . . . . OCT 2018 2.14 . . . . . . . . . . . . OCT 2018 2.46 . . . . . . . . . . . . APR 2007
1.4 . . . . . . . . . . . . . OCT 2018 2.15 . . . . . . . . . . . . JUN 2006 2.47 . . . . . . . . . . . . JUN 2006
1.5 . . . . . . . . . . . . . OCT 2018 2.16 . . . . . . . . . . . . JUN 2006 2.48 . . . . . . . . . . . . JUN 2006
1.6 . . . . . . . . . . . . . OCT 2018 2.17 . . . . . . . . . . . . OCT 2018 2.49 . . . . . . . . . . . . JUN 2006
1.7 . . . . . . . . . . . . . OCT 2018 2.18 . . . . . . . . . . . . OCT 2018 2.50 . . . . . . . . . . . . APR 2007
1.8 . . . . . . . . . . . . . OCT 2018 2.19 . . . . . . . . . . . . OCT 2018 2.51 . . . . . . . . . . . . JUN 2006
1.9 . . . . . . . . . . . . . OCT 2018 2.20 . . . . . . . . . . . . OCT 2018 2.52 . . . . . . . . . . . . JUN 2006
1.10 . . . . . . . . . . . . OCT 2018 2.21 . . . . . . . . . . . . OCT 2018 2.53 . . . . . . . . . . . . JUN 2006
1.11 . . . . . . . . . . . . OCT 2018 2.22 . . . . . . . . . . . . OCT 2018 2.54 . . . . . . . . . . . . JUN 2006
1.12 . . . . . . . . . . . . OCT 2018 2.23 . . . . . . . . . . . . OCT 2018 2.55 . . . . . . . . . . . . JUN 2006
1.13 . . . . . . . . . . . . OCT 2018 2.24 . . . . . . . . . . . . OCT 2018 2.56 . . . . . . . . . . . . JUN 2006
1.14 . . . . . . . . . . . . OCT 2018 2.25 . . . . . . . . . . . . OCT 2018 2.57 . . . . . . . . . . . . JUN 2006
1.15 . . . . . . . . . . . . OCT 2018 2.26 . . . . . . . . . . . . OCT 2018 2.58 . . . . . . . . . . . . JUN 2006
1.16 . . . . . . . . . . . . OCT 2018 2.27 . . . . . . . . . . . . OCT 2018 2.59 . . . . . . . . . . . . OCT 2018
1.17 . . . . . . . . . . . . OCT 2018 2.28 . . . . . . . . . . . . OCT 2018 2.60 . . . . . . . . . . . . OCT 2018
1.18 . . . . . . . . . . . . OCT 2018 2.29 . . . . . . . . . . . . OCT 2018 2.61 . . . . . . . . . . . . OCT 2018
2.30 . . . . . . . . . . . . OCT 2018 2.62 . . . . . . . . . . . . OCT 2018
2.i . . . . . . . . . . . . . . OCT 2018 2.31 . . . . . . . . . . . . OCT 2018 2.63 . . . . . . . . . . . . OCT 2018
2.ii . . . . . . . . . . . . . . OCT 2018 2.32 . . . . . . . . . . . . OCT 2018 2.64 . . . . . . . . . . . . OCT 2018
2.1 . . . . . . . . . . . . . OCT 2018 2.33 . . . . . . . . . . . . OCT 2018 2.65 . . . . . . . . . . . . OCT 2018
2.2 . . . . . . . . . . . . . OCT 2018 2.34 . . . . . . . . . . . . OCT 2018 2.66 . . . . . . . . . . . . OCT 2018
OCT 2018 Chapter 37 Revision Log Page 37.1

REVISION LOG
OCT 2018
2.67 . . . . . . . . . . . . OCT 2018 4.19 . . . . . . . . . . . . 26 JUL 96 6.13 . . . . . . . . . . . . 19 SEP 97

2.68 . . . . . . . . . . . . OCT 2018 4.20 . . . . . . . . . . . . 30 JUN 99 6.14 . . . . . . . . . . . . 19 SEP 97
2.69 . . . . . . . . . . . . OCT 2018 4.21 . . . . . . . . . . . . JUN 2006 6.15 . . . . . . . . . . . . JAN 2005
2.70 . . . . . . . . . . . . OCT 2018 4.22 . . . . . . . . . . . . JUN 2006 6.16 . . . . . . . . . . . . 26 JUL 96
4.23 . . . . . . . . . . . . 7 AUG 92 6.16A . . . . . . . . . . . 7 AUG 92
3.i . . . . . . . . . . . . . . OCT 2018 4.24 . . . . . . . . . . . . 7 AUG 92 6.16B . . . . . . . . . . . JAN 2005
3.ii . . . . . . . . . . . . . OCT 2018 4.25 . . . . . . . . . . . . 7 AUG 92 6.16C . . . . . . . . . . . 7 AUG 92
3.1 . . . . . . . . . . . . . OCT 2018 6.16D . . . . . . . . . . . 7 AUG 92
3.2 . . . . . . . . . . . . . OCT 2018 5.i . . . . . . . . . . . . . . OCT 2018 6.17 . . . . . . . . . . . . APR 2007
3.3 . . . . . . . . . . . . . OCT 2018 5.ii . . . . . . . . . . . . . OCT 2018 6.18 . . . . . . . . . . . . APR 2007
3.4 . . . . . . . . . . . . . OCT 2018 5.1 . . . . . . . . . . . . . OCT 2018 6.19 . . . . . . . . . . . . APR 2007
3.5 . . . . . . . . . . . . . OCT 2018 5.2 . . . . . . . . . . . . . OCT 2018 6.20 . . . . . . . . . . . . APR 2007
3.6 . . . . . . . . . . . . . OCT 2018 5.3 . . . . . . . . . . . . . OCT 2018 6.21 . . . . . . . . . . . . OCT 2014
3.7 . . . . . . . . . . . . . OCT 2018 5.4 . . . . . . . . . . . . . OCT 2018 6.22 . . . . . . . . . . . . OCT 2014
3.8 . . . . . . . . . . . . . OCT 2018 5.5 . . . . . . . . . . . . . OCT 2018 6.23 . . . . . . . . . . . . MAR 2004
3.9 . . . . . . . . . . . . . OCT 2018 5.6 . . . . . . . . . . . . . OCT 2018 6.24 . . . . . . . . . . . . MAR 2004
3.10 . . . . . . . . . . . . OCT 2018 5.7 . . . . . . . . . . . . . 5/22/87 6.25 . . . . . . . . . . . . APR 2007
5.8 . . . . . . . . . . . . . 28 JUL 89 6.26 . . . . . . . . . . . . APR 2007
4.i . . . . . . . . . . . . . . OCT 2018 5.9 . . . . . . . . . . . . . 28 JUL 89 6.27 . . . . . . . . . . . . APR 2007
4.ii . . . . . . . . . . . . . . OCT 2018 5.10 . . . . . . . . . . . . 28 JUL 89 6.28 . . . . . . . . . . . . APR 2007
4.1 . . . . . . . . . . . . . OCT 2018 5.11 . . . . . . . . . . . . 28 JUL 89 6.29 . . . . . . . . . . . . APR 2007
4.2 . . . . . . . . . . . . . OCT 2018 5.12 . . . . . . . . . . . . JUN 2000 6.30 . . . . . . . . . . . . APR 2007
4.3 . . . . . . . . . . . . . OCT 2018 5.13 . . . . . . . . . . . . 28 JUL 89
4.4 . . . . . . . . . . . . . OCT 2018 7.i . . . . . . . . . . . . . . OCT 2018
4.5 . . . . . . . . . . . . . 31 JAN 89 6.i . . . . . . . . . . . . . . OCT 2014 7.ii . . . . . . . . . . . . . . OCT 2018
4.6 . . . . . . . . . . . . . APR 2005 6.ii . . . . . . . . . . . . . OCT 2014 7.1 . . . . . . . . . . . . . OCT 2014
4.7 . . . . . . . . . . . . . 5/22/87 6.1 . . . . . . . . . . . . . OCT 2014 7.2 . . . . . . . . . . . . . OCT 2014
4.8 . . . . . . . . . . . . . 5/22/87 6.2 . . . . . . . . . . . . . OCT 2014 7.3 . . . . . . . . . . . . . JUN 2006
4.9 . . . . . . . . . . . . . 5/22/87 6.3 . . . . . . . . . . . . . APR 2007 7.4 . . . . . . . . . . . . . 5/22/87
4.10 . . . . . . . . . . . . JAN 2005 6.4 . . . . . . . . . . . . . APR 2007 7.5 . . . . . . . . . . . . . JUN 2006
4.11 . . . . . . . . . . . . 5/22/87 6.5 . . . . . . . . . . . . . JUN 2006 7.6 . . . . . . . . . . . . . JUN 2006
4.12 . . . . . . . . . . . . APR 2007 6.6 . . . . . . . . . . . . . JUN 2006 7.7 . . . . . . . . . . . . . OCT 2018
4.13 . . . . . . . . . . . . 5/22/87 6.7 . . . . . . . . . . . . . APR 2005 7.8 . . . . . . . . . . . . . OCT 2018
4.14 . . . . . . . . . . . . 29 MAR 93 6.8 . . . . . . . . . . . . . APR 2005 7.9 . . . . . . . . . . . . . 19 SEP 97
4.15 . . . . . . . . . . . . JAN 2005 6.9 . . . . . . . . . . . . . OCT 2018 7.9A . . . . . . . . . . . . 19 SEP 97
4.16 . . . . . . . . . . . . JAN 2005 6.10 . . . . . . . . . . . . OCT 2018 7.9B . . . . . . . . . . . . 19 SEP 97
4.17 . . . . . . . . . . . . JUN 2000 6.11 . . . . . . . . . . . . 26 JUL 96 7.10 . . . . . . . . . . . . JUN 2000
4.18 . . . . . . . . . . . . 30 JUN 99 6.12 . . . . . . . . . . . . 30 JUN 99 7.11 . . . . . . . . . . . . 5/22/87
Page 37.2 Chapter 37 Revision Log OCT 2018

REVISION LOG
OCT 2018
7.12 . . . . . . . . . . . . 3 MAR 99 7.44 . . . . . . . . . . . . 19 SEP 97 8.14 . . . . . . . . . . . . 4/15/88

7.13 . . . . . . . . . . . . 3 MAR 99 7.44A . . . . . . . . . . . 4/15/88 8.15 . . . . . . . . . . . . 5/22/87
7.14 . . . . . . . . . . . . JUN 2000 7.44B . . . . . . . . . . . 5 JUL 90 8.16 . . . . . . . . . . . . 5/22/87
7.15 . . . . . . . . . . . . OCT 2018 7.44C . . . . . . . . . . . 26 JUL 96 8.17 . . . . . . . . . . . . 5/22/87
7.16 . . . . . . . . . . . . OCT 2018 7.44D . . . . . . . . . . . 7 AUG 92 8.18 . . . . . . . . . . . . 7 AUG 92
7.17 . . . . . . . . . . . . APR 2005 7.45 . . . . . . . . . . . . OCT 2018 8.19 . . . . . . . . . . . . 12 JAN 90
7.18 . . . . . . . . . . . . MAR 2004 7.46 . . . . . . . . . . . . OCT 2018 8.20 . . . . . . . . . . . . 12 JAN 90
7.19 . . . . . . . . . . . . OCT 2018 7.47 . . . . . . . . . . . . JUN 2000 8.21 . . . . . . . . . . . . 5/22/87
7.20 . . . . . . . . . . . . OCT 2018 7.48 . . . . . . . . . . . . JUN 2000 8.22 . . . . . . . . . . . . 5/22/87
7.21 . . . . . . . . . . . . OCT 2018 7.48A . . . . . . . . . . . 31 DEC 98 8.23 . . . . . . . . . . . . 5/22/87
7.22 . . . . . . . . . . . . OCT 2018 7.48B . . . . . . . . . . . MAR 2004 8.24 . . . . . . . . . . . . 5/22/87
7.23 . . . . . . . . . . . . OCT 2018 7.49 . . . . . . . . . . . . OCT 2018 8.25 . . . . . . . . . . . . 5/22/87
7.24 . . . . . . . . . . . . OCT 2018 7.50 . . . . . . . . . . . . OCT 2018 8.26 . . . . . . . . . . . . MAR 2004
7.25 . . . . . . . . . . . . OCT 2018 7.51 . . . . . . . . . . . . OCT 2018 8.27 . . . . . . . . . . . . 26 JUL 96
7.26 . . . . . . . . . . . . OCT 2018 7.52 . . . . . . . . . . . . OCT 2018 8.28 . . . . . . . . . . . . MAR 2004
7.27 . . . . . . . . . . . . OCT 2018 7.53 . . . . . . . . . . . . OCT 2018 8.29 . . . . . . . . . . . . 5/22/87
7.28 . . . . . . . . . . . . OCT 2018 7.54 . . . . . . . . . . . . OCT 2018 8.30 . . . . . . . . . . . . MAR 2004
7.29 . . . . . . . . . . . . OCT 2018 7.55 . . . . . . . . . . . . OCT 2018 8.31 . . . . . . . . . . . . 19 SEP 97
7.29A . . . . . . . . . . OCT 2018 7.56 . . . . . . . . . . . . OCT 2018 8.32 . . . . . . . . . . . . 5 JUL 90
7.29B . . . . . . . . . . OCT 2018 7.57 . . . . . . . . . . . . 31 JAN 89 8.33 . . . . . . . . . . . . OCT 2018
7.30 . . . . . . . . . . . . OCT 2018 8.34 . . . . . . . . . . . . OCT 2018
7.31 . . . . . . . . . . . . OCT 2018 8.i . . . . . . . . . . . . . . OCT 2014 8.34A . . . . . . . . . . . MAR 2004
7.32 . . . . . . . . . . . . OCT 2018 8.ii . . . . . . . . . . . . . OCT 2014 8.34B . . . . . . . . . . . 26 JUL 96
7.33 . . . . . . . . . . . . OCT 2014 8.iii . . . . . . . . . . . . . OCT 2014 8.34C . . . . . . . . . . . MAR 2004
7.33A . . . . . . . . . . . OCT 2014 8.iv . . . . . . . . . . . . . OCT 2014 8.34D . . . . . . . . . . . MAR 2004
7.33B . . . . . . . . . . . MAR 2004 8.1 . . . . . . . . . . . . . OCT 2014 8.35 . . . . . . . . . . . . 5/22/87
7.34 . . . . . . . . . . . . 5/22/87 8.2 . . . . . . . . . . . . . OCT 2014 8.36 . . . . . . . . . . . . 5/22/87
7.35 . . . . . . . . . . . . 26 JUL 96 8.3 . . . . . . . . . . . . . 5/22/87 8.37 . . . . . . . . . . . . JUN 2006
7.36 . . . . . . . . . . . . MAR 2004 8.4 . . . . . . . . . . . . . 5/22/87 8.38 . . . . . . . . . . . . JUN 2006
7.37 . . . . . . . . . . . . 26 JUL 96 8.5 . . . . . . . . . . . . . 5/22/87 8.39 . . . . . . . . . . . . OCT 2018
7.38 . . . . . . . . . . . . 26 JUL 96 8.6 . . . . . . . . . . . . . 5/22/87 8.40 . . . . . . . . . . . . OCT 2018
7.38A . . . . . . . . . . . 26 JUL 96 8.7 . . . . . . . . . . . . . 5/22/87 8.41 . . . . . . . . . . . . OCT 2018
7.38B . . . . . . . . . . . 26 JUL 96 8.8 . . . . . . . . . . . . . 5/22/87 8.42 . . . . . . . . . . . . OCT 2018
7.39 . . . . . . . . . . . . 19 SEP 97 8.9 . . . . . . . . . . . . . 5/22/87 8.43 . . . . . . . . . . . . OCT 2018
7.40 . . . . . . . . . . . . 19 SEP 97 8.10 . . . . . . . . . . . . 5/22/87 8.44 . . . . . . . . . . . . OCT 2018
7.41 . . . . . . . . . . . . 19 SEP 97 8.11 . . . . . . . . . . . . 5/22/87 8.45 . . . . . . . . . . . . OCT 2018
7.42 . . . . . . . . . . . . 19 SEP 97 8.12 . . . . . . . . . . . . 5/22/87 8.46 . . . . . . . . . . . . OCT 2018
7.43 . . . . . . . . . . . . 19 SEP 97 8.13 . . . . . . . . . . . . 5/22/87 8.47 . . . . . . . . . . . . 19 SEP 97

REVISION LOG
OCT 2018
8.48 . . . . . . . . . . . . 26 JUL 96 10.i . . . . . . . . . . . . . OCT 2018 10.32A . . . . . . . . . . OCT 2014

8.49 . . . . . . . . . . . . MAR 2004 10.ii . . . . . . . . . . . . . OCT 2018 10.32B . . . . . . . . . . OCT 2014
8.50 . . . . . . . . . . . . 5/22/87 10.1 . . . . . . . . . . . . OCT 2014 10.33 . . . . . . . . . . . 5/22/87
8.51 . . . . . . . . . . . . 5/22/87 10.2 . . . . . . . . . . . . OCT 2014 10.34 . . . . . . . . . . . 5/22/87
8.52 . . . . . . . . . . . . 5/22/87 10.3 . . . . . . . . . . . . 5/22/87 10.35 . . . . . . . . . . . JAN 2005
8.53 . . . . . . . . . . . . 5/22/87 10.4 . . . . . . . . . . . . 5/22/87 10.36 . . . . . . . . . . . JAN 2005
8.54 . . . . . . . . . . . . 5/22/87 10.5 . . . . . . . . . . . . APR 2005 10.37 . . . . . . . . . . . JAN 2005
8.55 . . . . . . . . . . . . JAN 2005 10.6 . . . . . . . . . . . . APR 2007 10.38 . . . . . . . . . . . JAN 2005
8.56 . . . . . . . . . . . . JAN 2005 10.7 . . . . . . . . . . . . APR 2005 10.39 . . . . . . . . . . . JAN 2005
8.57 . . . . . . . . . . . . 5/22/87 10.8 . . . . . . . . . . . . 5/22/87 10.40 . . . . . . . . . . . JAN 2005
8.58 . . . . . . . . . . . . 5/22/87 10.9 . . . . . . . . . . . . 5/22/87
8.59 . . . . . . . . . . . . JUN 2006 10.10 . . . . . . . . . . . 5/22/87 11.i . . . . . . . . . . . . . OCT 2018
8.60 . . . . . . . . . . . . JUN 2006 10.11 . . . . . . . . . . . 5/22/87 11.ii . . . . . . . . . . . . . OCT 2018
8.61 . . . . . . . . . . . . 22 JAN 93 10.12 . . . . . . . . . . . 5/22/87 11.1 . . . . . . . . . . . . OCT 2018
8.62 . . . . . . . . . . . . 22 JAN 93 10.13 . . . . . . . . . . . 5/22/87 11.2 . . . . . . . . . . . . OCT 2018
8.63 . . . . . . . . . . . . APR 2005 10.14 . . . . . . . . . . . 5/22/87 11.3 . . . . . . . . . . . . OCT 2018
8.64 . . . . . . . . . . . . APR 2005 10.15 . . . . . . . . . . . APR 2007 11.4 . . . . . . . . . . . . OCT 2018
10.16 . . . . . . . . . . . APR 2007 11.5 . . . . . . . . . . . . OCT 2018
9.i . . . . . . . . . . . . . . OCT 2018 10.17 . . . . . . . . . . . 5/22/87 11.6 . . . . . . . . . . . . OCT 2018
9.ii . . . . . . . . . . . . . OCT 2018 10.18 . . . . . . . . . . . 5/22/87
9.1 . . . . . . . . . . . . . OCT 2018 10.19 . . . . . . . . . . . 5/22/87 12.i . . . . . . . . . . . . . OCT 2018
9.2 . . . . . . . . . . . . . OCT 2018 10.20 . . . . . . . . . . . MAR 2004 12.ii . . . . . . . . . . . . . OCT 2018
9.26C . . . . . . . . . . . OCT 2014 10.21 . . . . . . . . . . . OCT 2018 12.1 . . . . . . . . . . . . OCT 2018
9.26D . . . . . . . . . . . OCT 2014 10.22 . . . . . . . . . . . OCT 2018 12.2 . . . . . . . . . . . . OCT 2018
9.27 . . . . . . . . . . . . JUN 2000 10.23 . . . . . . . . . . . 28 JUL 89 12.3 . . . . . . . . . . . . OCT 2014
9.28 . . . . . . . . . . . . JUN 2000 10.24 . . . . . . . . . . . 30 JUN 99 12.4 . . . . . . . . . . . . OCT 2014
9.29 . . . . . . . . . . . . JUN 2006 10.25 . . . . . . . . . . . 5/22/87 12.5 . . . . . . . . . . . . OCT 2014
9.30 . . . . . . . . . . . . JUN 2006 10.25A . . . . . . . . . . 28 JUL 89 12.6 . . . . . . . . . . . . OCT 2014
9.31 . . . . . . . . . . . . 31 DEC 98 10.25B . . . . . . . . . . 28 JUL 89 12.7 . . . . . . . . . . . . OCT 2014
9.32 . . . . . . . . . . . . 31 DEC 98 10.26 . . . . . . . . . . . 28 JUL 89 12.8 . . . . . . . . . . . . OCT 2014
9.32A . . . . . . . . . . . JUN 2000 10.26A . . . . . . . . . . JUN 2006 12.9 . . . . . . . . . . . . OCT 2018
9.32B . . . . . . . . . . . JUN 2000 10.26B . . . . . . . . . . JUN 2006 12.9A . . . . . . . . . . . OCT 2018
9.32C . . . . . . . . . . . MAR 2004 10.27 . . . . . . . . . . . JUN 2006 12.9B . . . . . . . . . . . OCT 2018
9.32D . . . . . . . . . . . JUN 2000 10.28 . . . . . . . . . . . MAR 2004 12.10 . . . . . . . . . . . OCT 2018
9.33 . . . . . . . . . . . . 5/22/87 10.29 . . . . . . . . . . . 19 SEP 97 12.11 . . . . . . . . . . . OCT 2014
9.34 . . . . . . . . . . . . 5/22/87 10.30 . . . . . . . . . . . 5/22/87 12.12 . . . . . . . . . . . OCT 2014
9.35 . . . . . . . . . . . . 19 SEP 97 10.31 . . . . . . . . . . . OCT 2014 12.13 . . . . . . . . . . . OCT 2018
10.32 . . . . . . . . . . . OCT 2014 12.14 . . . . . . . . . . . OCT 2018

REVISION LOG
OCT 2018
12.15 . . . . . . . . . . . OCT 2014 14.13 . . . . . . . . . . . 5/22/87 14.26E . . . . . . . . . . JUN 2000

12.16 . . . . . . . . . . . OCT 2014 14.14 . . . . . . . . . . . 5/22/87 14.26F . . . . . . . . . . JUN 2000
12.17 . . . . . . . . . . . OCT 2014 14.15 . . . . . . . . . . . 5/22/87 14.26G . . . . . . . . . . JUN 2000
12.18 . . . . . . . . . . . OCT 2014 14.16 . . . . . . . . . . . 12 JAN 90 14.26H . . . . . . . . . . JUN 2000
14.16A . . . . . . . . . . 12 JAN 90 14.26I . . . . . . . . . . . JUN 2000
13.i . . . . . . . . . . . . . OCT 2018 14.16B . . . . . . . . . . 12 JAN 90 14.26J . . . . . . . . . . JUN 2000
13.ii . . . . . . . . . . . . . OCT 2018 14.17 . . . . . . . . . . . 12 JAN 90 14.26K . . . . . . . . . . MAR 2004
13.1 . . . . . . . . . . . . OCT 2018 14.17A . . . . . . . . . . 12 JAN 90 14.26L . . . . . . . . . . MAR 2004
13.2 . . . . . . . . . . . . OCT 2018 14.17B . . . . . . . . . . 12 JAN 90 14.27 . . . . . . . . . . . 5 JUL 90
13.3 . . . . . . . . . . . . OCT 2018 14.17C . . . . . . . . . . 12 JAN 90 14.28 . . . . . . . . . . . 5/22/87
13.4 . . . . . . . . . . . . OCT 2018 14.17D . . . . . . . . . . 12 JAN 90 14.28A . . . . . . . . . . 5 JUL 90
13.5 . . . . . . . . . . . . OCT 2018 14.18 . . . . . . . . . . . 5/22/87 14.28B . . . . . . . . . . 5 JUL 90
13.6 . . . . . . . . . . . . OCT 2018 14.18A . . . . . . . . . . 30 JUN 99 14.29 . . . . . . . . . . . 5/22/87
13.7 . . . . . . . . . . . . OCT 2018 14.18B . . . . . . . . . . 30 JUN 99 14.30 . . . . . . . . . . . 5/22/87
13.8 . . . . . . . . . . . . OCT 2018 14.19 . . . . . . . . . . . OCT 2018 14.31 . . . . . . . . . . . 5/22/87
13.9 . . . . . . . . . . . . OCT 2018 14.20 . . . . . . . . . . . OCT 2018 14.32 . . . . . . . . . . . 5/22/87
13.10 . . . . . . . . . . . OCT 2018 14.20A . . . . . . . . . OCT 2018 14.33 . . . . . . . . . . . 5/22/87
13.11 . . . . . . . . . . . OCT 2018 14.20B . . . . . . . . . OCT 2018 14.34 . . . . . . . . . . . 5/22/87
13.12 . . . . . . . . . . . OCT 2018 14.21 . . . . . . . . . . . 30 JUN 99 14.35 . . . . . . . . . . . 5/22/87
13.13 . . . . . . . . . . . OCT 2018 14.21A . . . . . . . . . . 30 JUN 99 14.36 . . . . . . . . . . . 5/22/87
13.14 . . . . . . . . . . . OCT 2018 14.21B . . . . . . . . . . 30 JUN 99 14.37 . . . . . . . . . . . 5/22/87
13.15 . . . . . . . . . . . OCT 2018 14.22 . . . . . . . . . . . 5/22/87 14.38 . . . . . . . . . . . 5/22/87
13.16 . . . . . . . . . . . OCT 2018 14.23 . . . . . . . . . . . OCT 2018 14.39 . . . . . . . . . . . 28 JUL 89
13.17 . . . . . . . . . . . OCT 2018 14.23A . . . . . . . . . . OCT 2018 14.40 . . . . . . . . . . . 5/22/87
13.18 . . . . . . . . . . . OCT 2018 14.23B . . . . . . . . . . OCT 2018 14.40A . . . . . . . . . . JUN 2000
13.19 . . . . . . . . . . . OCT 2018 14.23C . . . . . . . . . . OCT 2018 14.40B . . . . . . . . . . JUN 2000
13.20 . . . . . . . . . . . OCT 2018 14.23D . . . . . . . . . . OCT 2018 14.40C . . . . . . . . . . JUN 2000
13.21 . . . . . . . . . . . OCT 2018 14.23E . . . . . . . . . . OCT 2018 14.40D . . . . . . . . . . JUN 2000
13.22 . . . . . . . . . . . OCT 2018 14.23F . . . . . . . . . . OCT 2018 14.41 . . . . . . . . . . . 9/25/87
13.23 . . . . . . . . . . . OCT 2018 14.23G . . . . . . . . . . OCT 2018 14.42 . . . . . . . . . . . 9/25/87
13.24 . . . . . . . . . . . OCT 2018 14.23H . . . . . . . . . . OCT 2018 14.43 . . . . . . . . . . . 5/22/87
14.24 . . . . . . . . . . . OCT 2018 14.44 . . . . . . . . . . . 5/22/87
14.i . . . . . . . . . . . . . OCT 2018 14.25 . . . . . . . . . . . 26 JUL 96 14.45 . . . . . . . . . . . 5/22/87
14.ii . . . . . . . . . . . . . OCT 2018 14.26 . . . . . . . . . . . 5/22/87 14.46 . . . . . . . . . . . 5/22/87
14.1 . . . . . . . . . . . . OCT 2018 14.26A . . . . . . . . . . 7 AUG 92 14.47 . . . . . . . . . . . 5/22/87
14.2 . . . . . . . . . . . . OCT 2018 14.26B . . . . . . . . . . 30 JUN 99 14.48 . . . . . . . . . . . 5/22/87
14.11B . . . . . . . . . . OCT 2018 14.26C . . . . . . . . . . JUN 2000 14.49 . . . . . . . . . . . 9/25/87
14.12 . . . . . . . . . . . OCT 2018 14.26D . . . . . . . . . . JUN 2000 14.50 . . . . . . . . . . . 5/22/87

REVISION LOG
OCT 2018
14.51 . . . . . . . . . . . 7 AUG 92 15.8 . . . . . . . . . . . . OCT 2018 19.2 . . . . . . . . . . . . OCT 2018

14.52 . . . . . . . . . . . 5/22/87 19.3 . . . . . . . . . . . . OCT 2018
14.53 . . . . . . . . . . . 5/22/87 16.i . . . . . . . . . . . . . OCT 2018 19.4 . . . . . . . . . . . . OCT 2018
14.54 . . . . . . . . . . . 4/22/87 16.ii . . . . . . . . . . . . . OCT 2018 19.5 . . . . . . . . . . . . OCT 2018
14.55 . . . . . . . . . . . 5/22/87 16.1 . . . . . . . . . . . . OCT 2018 19.6 . . . . . . . . . . . . OCT 2018
14.56 . . . . . . . . . . . 5/22/87 16.2 . . . . . . . . . . . . OCT 2018 19.7 . . . . . . . . . . . . OCT 2018
14.57 . . . . . . . . . . . 5/22/87 16.3 . . . . . . . . . . . . OCT 2018 19.8 . . . . . . . . . . . . OCT 2018
14.58 . . . . . . . . . . . 5/22/87 16.4 . . . . . . . . . . . . OCT 2018
14.59 . . . . . . . . . . . 5/22/87 16.5 . . . . . . . . . . . . OCT 2018 20.i . . . . . . . . . . . . . OCT 2018
14.60 . . . . . . . . . . . 5/22/87 16.6 . . . . . . . . . . . . OCT 2018 20.ii . . . . . . . . . . . . . OCT 2018
14.61 . . . . . . . . . . . 5/22/87 16.7 . . . . . . . . . . . . OCT 2018 20.1 . . . . . . . . . . . . OCT 2018
14.62 . . . . . . . . . . . 5/22/87 16.8 . . . . . . . . . . . . OCT 2018 20.2 . . . . . . . . . . . . OCT 2018
14.63 . . . . . . . . . . . 5/22/87 20.3 . . . . . . . . . . . . OCT 2018
14.64 . . . . . . . . . . . 19 SEP 97 17.i . . . . . . . . . . . . . OCT 2018 20.4 . . . . . . . . . . . . OCT 2018
14.65 . . . . . . . . . . . OCT 2018 17.ii . . . . . . . . . . . . . OCT 2018
14.66 . . . . . . . . . . . OCT 2018 17.1 . . . . . . . . . . . . OCT 2018 21.i . . . . . . . . . . . . . OCT 2018
14.67 . . . . . . . . . . . OCT 2018 17.2 . . . . . . . . . . . . OCT 2018 21.ii . . . . . . . . . . . . . OCT 2018
14.68 . . . . . . . . . . . OCT 2018 17.3 . . . . . . . . . . . . OCT 2018 21.1 . . . . . . . . . . . . OCT 2018
14.69 . . . . . . . . . . . OCT 2018 17.4 . . . . . . . . . . . . OCT 2018 21.2 . . . . . . . . . . . . OCT 2018
14.70 . . . . . . . . . . . OCT 2018 17.5 . . . . . . . . . . . . OCT 2018
14.71 . . . . . . . . . . . OCT 2018 17.6 . . . . . . . . . . . . OCT 2018 22.i . . . . . . . . . . . . . OCT 2018
14.72 . . . . . . . . . . . OCT 2018 22.ii . . . . . . . . . . . . . OCT 2018
14.73 . . . . . . . . . . . OCT 2018 18.i . . . . . . . . . . . . . OCT 2018 22.1 . . . . . . . . . . . . OCT 2018
14.74 . . . . . . . . . . . OCT 2018 18.ii . . . . . . . . . . . . . OCT 2018 22.2 . . . . . . . . . . . . OCT 2018
14.75 . . . . . . . . . . . OCT 2018 18.1 . . . . . . . . . . . . OCT 2018 22.3 . . . . . . . . . . . . OCT 2018
14.76 . . . . . . . . . . . OCT 2018 18.2 . . . . . . . . . . . . OCT 2018 22.4 . . . . . . . . . . . . OCT 2018
14.77 . . . . . . . . . . . OCT 2018 18.3 . . . . . . . . . . . . OCT 2018 22.5 . . . . . . . . . . . . OCT 2018
14.78 . . . . . . . . . . . OCT 2018 18.4 . . . . . . . . . . . . OCT 2018 22.6 . . . . . . . . . . . . OCT 2018
18.5 . . . . . . . . . . . . OCT 2018 22.7 . . . . . . . . . . . . OCT 2018
15.i . . . . . . . . . . . . . OCT 2018 18.6 . . . . . . . . . . . . OCT 2018 22.8 . . . . . . . . . . . . OCT 2018
15.ii . . . . . . . . . . . . . OCT 2018 18.7 . . . . . . . . . . . . OCT 2018 22.9 . . . . . . . . . . . . OCT 2018
15.1 . . . . . . . . . . . . OCT 2018 18.8 . . . . . . . . . . . . OCT 2018 22.10 . . . . . . . . . . . OCT 2018
15.2 . . . . . . . . . . . . OCT 2018 18.9 . . . . . . . . . . . . OCT 2018 22.11 . . . . . . . . . . . OCT 2018
15.3 . . . . . . . . . . . . OCT 2018 18.10 . . . . . . . . . . . OCT 2018 22.12 . . . . . . . . . . . OCT 2018
15.4 . . . . . . . . . . . . OCT 2018 22.13 . . . . . . . . . . . OCT 2018
15.5 . . . . . . . . . . . . OCT 2018 19.i . . . . . . . . . . . . . OCT 2018 22.14 . . . . . . . . . . . OCT 2018
15.6 . . . . . . . . . . . . OCT 2018 19.ii . . . . . . . . . . . . . OCT 2018
15.7 . . . . . . . . . . . . OCT 2018 19.1 . . . . . . . . . . . . OCT 2018 23.i . . . . . . . . . . . . . OCT 2018

REVISION LOG
OCT 2018
23.ii . . . . . . . . . . . . . OCT 2018 26.29 . . . . . . . . . . . OCT 2018

23.1 . . . . . . . . . . . . OCT 2018 25.i . . . . . . . . . . . . . OCT 2018 26.30 . . . . . . . . . . . OCT 2018
23.2 . . . . . . . . . . . . OCT 2018 25.ii . . . . . . . . . . . . . OCT 2018 26.31 . . . . . . . . . . . OCT 2018
23.3 . . . . . . . . . . . . OCT 2018 25.1 . . . . . . . . . . . . OCT 2018 26.32 . . . . . . . . . . . OCT 2018
23.4 . . . . . . . . . . . . OCT 2018 25.2 . . . . . . . . . . . . OCT 2018 26.33 . . . . . . . . . . . OCT 2018
23.5 . . . . . . . . . . . . OCT 2018 25.3 . . . . . . . . . . . . OCT 2018 26.34 . . . . . . . . . . . OCT 2018
23.6 . . . . . . . . . . . . OCT 2018 25.4 . . . . . . . . . . . . OCT 2018
23.7 . . . . . . . . . . . . OCT 2018 27.i . . . . . . . . . . . . . OCT 2018
23.8 . . . . . . . . . . . . OCT 2018 26.i . . . . . . . . . . . . . OCT 2018 27.ii . . . . . . . . . . . . . OCT 2018
23.9 . . . . . . . . . . . . OCT 2018 26.ii . . . . . . . . . . . . . OCT 2018 27.1 . . . . . . . . . . . . OCT 2018
23.10 . . . . . . . . . . . OCT 2018 26.1 . . . . . . . . . . . . OCT 2018 27.2 . . . . . . . . . . . . OCT 2018
23.11 . . . . . . . . . . . OCT 2018 26.2 . . . . . . . . . . . . OCT 2018
23.12 . . . . . . . . . . . OCT 2018 26.3 . . . . . . . . . . . . OCT 2018 28.i . . . . . . . . . . . . . OCT 2018
23.13 . . . . . . . . . . . OCT 2018 26.4 . . . . . . . . . . . . OCT 2018 28.ii . . . . . . . . . . . . . OCT 2018
23.14 . . . . . . . . . . . OCT 2018 26.5 . . . . . . . . . . . . OCT 2018 28.1 . . . . . . . . . . . . OCT 2018
23.15 . . . . . . . . . . . OCT 2018 26.6 . . . . . . . . . . . . OCT 2018 28.2 . . . . . . . . . . . . OCT 2018
23.16 . . . . . . . . . . . OCT 2018 26.7 . . . . . . . . . . . . OCT 2018
23.17 . . . . . . . . . . . OCT 2018 26.8 . . . . . . . . . . . . OCT 2018 29.i . . . . . . . . . . . . . OCT 2018
23.18 . . . . . . . . . . . OCT 2018 26.9 . . . . . . . . . . . . OCT 2018 29.ii . . . . . . . . . . . . . OCT 2018
23.19 . . . . . . . . . . . OCT 2018 26.10 . . . . . . . . . . . OCT 2018 29.1 . . . . . . . . . . . . OCT 2018
23.20 . . . . . . . . . . . OCT 2018 26.11 . . . . . . . . . . . OCT 2018 29.2 . . . . . . . . . . . . OCT 2018
23.21 . . . . . . . . . . . OCT 2018 26.12 . . . . . . . . . . . OCT 2018
23.22 . . . . . . . . . . . OCT 2018 26.13 . . . . . . . . . . . OCT 2018 30.i . . . . . . . . . . . . . OCT 2018
23.23 . . . . . . . . . . . OCT 2018 26.14 . . . . . . . . . . . OCT 2018 30.ii . . . . . . . . . . . . . OCT 2018
23.24 . . . . . . . . . . . OCT 2018 26.15 . . . . . . . . . . . OCT 2018 30.1 . . . . . . . . . . . . OCT 2018
23.25 . . . . . . . . . . . OCT 2018 26.16 . . . . . . . . . . . OCT 2018 30.2 . . . . . . . . . . . . OCT 2018
23.26 . . . . . . . . . . . OCT 2018 26.17 . . . . . . . . . . . OCT 2018
23.27 . . . . . . . . . . . OCT 2018 26.18 . . . . . . . . . . . OCT 2018 31.i . . . . . . . . . . . . . OCT 2018
23.28 . . . . . . . . . . . OCT 2018 26.19 . . . . . . . . . . . OCT 2018 31.ii . . . . . . . . . . . . . OCT 2018
23.29 . . . . . . . . . . . OCT 2018 26.20 . . . . . . . . . . . OCT 2018 31.1 . . . . . . . . . . . . OCT 2018
23.30 . . . . . . . . . . . OCT 2018 26.21 . . . . . . . . . . . OCT 2018 31.2 . . . . . . . . . . . . OCT 2018
26.22 . . . . . . . . . . . OCT 2018
24.i . . . . . . . . . . . . . OCT 2018 26.23 . . . . . . . . . . . OCT 2018 32.i . . . . . . . . . . . . . OCT 2018
24.ii . . . . . . . . . . . . . OCT 2018 26.24 . . . . . . . . . . . OCT 2018 32.ii . . . . . . . . . . . . . OCT 2018
24.1 . . . . . . . . . . . . OCT 2018 26.25 . . . . . . . . . . . OCT 2018 32.1 . . . . . . . . . . . . OCT 2018
24.2 . . . . . . . . . . . . OCT 2018 26.26 . . . . . . . . . . . OCT 2018 32.2 . . . . . . . . . . . . OCT 2018
24.3 . . . . . . . . . . . . OCT 2018 26.27 . . . . . . . . . . . OCT 2018
24.4 . . . . . . . . . . . . OCT 2018 26.28 . . . . . . . . . . . OCT 2018 33.i . . . . . . . . . . . . . OCT 2018

REVISION LOG
OCT 2018
33.ii . . . . . . . . . . . . . OCT 2018 35.1 . . . . . . . . . . . . OCT 2018

33.1 . . . . . . . . . . . . OCT 2018 35.2 . . . . . . . . . . . . OCT 2018
33.2 . . . . . . . . . . . . OCT 2018
33.3 . . . . . . . . . . . . OCT 2018 36.i . . . . . . . . . . . . . OCT 2018
33.4 . . . . . . . . . . . . OCT 2018 36.ii . . . . . . . . . . . . . OCT 2018
33.5 . . . . . . . . . . . . OCT 2018 36.1 . . . . . . . . . . . . OCT 2018
33.6 . . . . . . . . . . . . OCT 2018 36.2 . . . . . . . . . . . . OCT 2018
33.7 . . . . . . . . . . . . OCT 2018 36.3 . . . . . . . . . . . . OCT 2018
33.8 . . . . . . . . . . . . OCT 2018 36.4 . . . . . . . . . . . . OCT 2018
33.9 . . . . . . . . . . . . OCT 2018 36.5 . . . . . . . . . . . . OCT 2018
33.10 . . . . . . . . . . . OCT 2018 36.6 . . . . . . . . . . . . OCT 2018
33.11 . . . . . . . . . . . OCT 2018 36.7 . . . . . . . . . . . . OCT 2018
33.12 . . . . . . . . . . . OCT 2018 36.8 . . . . . . . . . . . . OCT 2018
33.13 . . . . . . . . . . . OCT 2018 36.9 . . . . . . . . . . . . OCT 2018
33.14 . . . . . . . . . . . OCT 2018 36.10 . . . . . . . . . . . OCT 2018
33.15 . . . . . . . . . . . OCT 2018
33.16 . . . . . . . . . . . OCT 2018 37.i . . . . . . . . . . . . . OCT 2018
33.17 . . . . . . . . . . . OCT 2018 37.ii . . . . . . . . . . . . . OCT 2018
33.18 . . . . . . . . . . . OCT 2018 37.1 . . . . . . . . . . . . OCT 2018
33.19 . . . . . . . . . . . OCT 2018 37.2 . . . . . . . . . . . . OCT 2018
33.20 . . . . . . . . . . . OCT 2018 37.3 . . . . . . . . . . . . OCT 2018
33.21 . . . . . . . . . . . OCT 2018 37.4 . . . . . . . . . . . . OCT 2018
33.22 . . . . . . . . . . . OCT 2018 37.5 . . . . . . . . . . . . OCT 2018
37.6 . . . . . . . . . . . . OCT 2018
34.ii . . . . . . . . . . . . . OCT 2018 37.7 . . . . . . . . . . . . OCT 2018
34.1 . . . . . . . . . . . . OCT 2018 37.8 . . . . . . . . . . . . OCT 2018
34.2 . . . . . . . . . . . . OCT 2018
34.3 . . . . . . . . . . . . OCT 2018
34.4 . . . . . . . . . . . . OCT 2018
34.5 . . . . . . . . . . . . OCT 2018
34.6 . . . . . . . . . . . . OCT 2018
34.7 . . . . . . . . . . . . OCT 2018
34.8 . . . . . . . . . . . . OCT 2018
34.9 . . . . . . . . . . . . OCT 2018
34.10 . . . . . . . . . . . OCT 2018
35.i . . . . . . . . . . . . . OCT 2018

35.ii . . . . . . . . . . . . . OCT 2018

r22 MM Full Book PDF

Uploaded by

Copyright:

Available Formats

r22 MM Full Book PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

r22 MM Full Book PDF

Uploaded by

Copyright:

Available Formats

R22 MAINTENANCE MANUAL

AND INSTRUCTIONS FOR CONTINUED AIRWORTHINESS

Production Certificate Number 424WE

Robinson Helicopter Company Phone: (310) 539-0508

CUSTOMER SUPPORT AND SPARES ORDERS

OCT 2018 Introduction Page i

Subscription order and renewal forms are located at www.robinsonheli.com.

Helicopter and parts warranty information is located at www.robinsonheli.com.

Page ii Introduction OCT 2018

OCT 2018 Introduction Page iii

Page iv Introduction OCT 2018

RECOMMENDED CHANGE REPORT

OCT 2018 Introduction Page v

Page vi Introduction OCT 2018

1.000 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1

OCT 2018 Chapter 1 General Page 1.i

Page 1.ii Chapter 1 General OCT 2018

1.001 R22 Maintenance Manual Revisions

OCT 2018 Chapter 1 General Page 1.1

1.003 R22 Component Maintenance Authorization

1.004 Maintenance Record

Page 1.2 Chapter 1 General OCT 2018

1.006 Maintenance Manual and Illustrated Parts Catalog References

OCT 2018 Chapter 1 General Page 1.3

Page 1.4 Chapter 1 General OCT 2018

14 CFR: Title 14 of the Code of Federal Regulations. The Federal Aviation

OCT 2018 Chapter 1 General Page 1.5

Page 1.6 Chapter 1 General OCT 2018

OCT 2018 Chapter 1 General Page 1.7

c. Connect straight multi-pin connector to directional gyro and/or angled connector

Page 1.8 Chapter 1 General OCT 2018

OCT 2018 Chapter 1 General Page 1.9

Perform inspection per Lycoming Operator’s Manual.* • • • •

* Shorter interval than published on referenced document.

Page 1.10 Chapter 1 General OCT 2018

1.101 Scheduled Maintenance and Inspections

OCT 2018 Chapter 1 General Page 1.11

Part Number Description Action

Page 1.12 Chapter 1 General OCT 2018

Part Number Description Action

OCT 2018 Chapter 1 General Page 1.13

Part Number Description Action

Page 1.14 Chapter 1 General OCT 2018

Part Number Description Action

OCT 2018 Chapter 1 General Page 1.15

Part Number Description Action

Page 1.16 Chapter 1 General OCT 2018

Part Number Description Action

OCT 2018 Chapter 1 General Page 1.17

Page 1.18 Chapter 1 General OCT 2018

2.000 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1

OCT 2018 Chapter 2 Inspection Page 2.i

2.610 Main Rotor Hub Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . 2.62

Page 2.ii Chapter 2 Inspection OCT 2018

2.100 General Procedures

2.110 Ball and Roller Bearings

OCT 2018 Chapter 2 Inspection Page 2.1

FIGURE 2-1A ROD END CENTERING

Page 2.2 Chapter 2 Inspection OCT 2018