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AEROSPACE
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www.dartaerospace.com
INSTRUCTIONS FOR CONTINUED

AIRWORTHINESS
FOR
EMERGENCY FLOAT KITS
ROBINSON MODEL R44 & R44 II HELICOPTERS
P/N 644.7001 R44 EMERGENCY FLOAT KIT W/

EXTENSIONS
P/N 644.7002 R44 EMERGENCY FLOAT KIT
P/N 644.7004 R44 EMERGENCY FLOAT KIT W/
EXTENSIONS HIGH GEAR
P/N 644.7005 R44 EMERGENCY FLOAT KIT HIGH
GEAR
Document No.: ICA44-1 Rev. J
Name Title Date
Prepared by R. Takahashi Project Engineer II 10/28/19
Approved by J. Gardiner Senior Engineer 10/28/19
This technical data package being provided to the Federal Aviation Administration (FAA).
It includes, but is not limited to drawings, specifications and other technical data attached hereto and are the Property of
APICAL Industries, Inc., dba DART Aerospace (DA) and constitute trade secrets for the purpose of the Trade Secrets and
Freedom of Information Act. Disclosures to any party for any reason without the permission of DA is prohibited, except that
disclosures may be made within the FAA’s organization consistent with the need to evaluate DA’s technical data.
SUBJECT: DOCUMENT No:

INSTRUCTIONS FOR CONTINUED REF DWG. No. ICA44-1
AIRWORTHINESS; EMERGENCY FLOAT 644.7000 Rev. J
KIT FOR ROBINSON R44 & R44 II HELICOPTERS 10/28/19
LOG OF REVISIONS
Revision Date Pages Description Approval
N/C 01/02/07 All Initial Release S. Joseph
A 05/01/07 4 Updated List of Effective Pages P. Bravo
12 Revised Table II Operating Press.
15 Revised section 3.1.2d
16 Update section 3.1.3d and section 3.2, added note
17 Revised Section 4.0 Towing
25 Revised Parts List Figure number
43 Revised Fig. 15 & Fig. 16
45 Revised Fig. 19, Fig. 20, Section 6.5.1c
58 Revised Fig. 32
B 10/29/08 4 Updated List of Effective pages P. Bravo
16 Revised 3.1.3.b.
18 Updated Figure 2
54 Revised Figure 29 and 29a Parts List
59 Revised Figure 31 and 32 Parts List
60 Revised 9.4.b.
62 Revised Figure 34 Parts List
C 01/14/10 4 Updated List of Effective pages P. Bravo
39 Revised Figure 11 and 12 Parts List
D 02/26/10 All Updated List of Effective pages P. Bravo
Revised Figure 11 and 12 Parts List
E 12/19/11 13 Revised Table 1 P. Bravo
17 Revised Section 3.1.3.b
28 Revised Section 6.3.a.1 and 6.3.a.2
29 Revised Section 6.3.a.6, 6.3.b and 6.3.c
54 Removed Section 7.3
55 Renamed Section 7.4 to be Section 7.3
F 06/20/12 7 Revised List of Figures P. Bravo
19 Added Figure 3
20 Added Figures 4 and 5
Revised Section 5.2
G 08/02/12 66-68 Revised Table XI P. Bravo
Added Lateral Weight & Balance
H 07/22/15 All Reformatted to current document standard P. Bravo
43 Revised Section 6.5.1, G-J
J 10/28/19 All Updated table numbering FORJ. Gardiner
1 Revised Title Page
4 Added to Record of Service Bulletins
5 Added List of Effective Pages
11, 12 Revised Sections 1.1, 1.2, and 1.10
24 Revised Figure 10, Table 5, and Section 6.1
25 Revised Figure 11
26 Revised Table 6
Copyright 2007-2019 Apical Industries, Inc. dba DART Aerospace See the Non-Disclosure Notice on the cover page.
All Rights Reserved 2 of 68

Revision Date Pages Description Approval

29-30 Revised Section 6.3.3, Table 9, and Note
34 Revised Section 6.4.3
37 Revised Table 15
39 Revised Figures 16
40 Updated Figure 17 and Table 18
49 Revised Section 6.6
50 Revised Figure 34
51 Revised Section 7.3
52 Revised Table 20
61 Revised Table 24
62 Revised Table 25 and Table 26
65 Revised Table 29
66 Revised Table 30 and Table 31
67 Added Table 32
68 Added Table 33

RECORD OF SERVICE BULLETINS

Number Date Description
Reinforcement strips shall be installed on R44 EFS float assemblies
SB2017-05 08/15/18
within a specified serial number range.

LIST OF EFFECTIVE PAGES

Title Page Revision No
Cover 1 J
Log of Revisions 2-3 J
Record of Service Bulletins (SBs) 4 J
List of Effective Pages 5 J
Table of Contents 6-7 J
List of Figures 8-9 J
List of Tables 10 J
1.0 INTRODUCTION 11-13 J
2.0 Airworthiness Limitations 14 N/C
3.0 Inspection Requirements and Overhaul Schedule 15-16 J
4.0 Towing 17 J
5.0 Placards and Labels 18-19 J
6.0 Float and Cover Removal, Clean, Test, Overhaul, and Reinstall 20-48 J
7.0 Hose Removal, Overhaul, and Reinstall 49-51 J
8.0 Skid Extension Removal, Inspection, and Installation 52-53 J
9.0 Pull Cable and Reservoir Removal, Test, Overhaul, and Rigging 54-58 J
10.0 Weight and Balance 59-66 J

TABLE OF CONTENTS
LOG OF REVISIONS ................................................................................................................. 2
RECORD OF SERVICE BULLETINS ......................................................................................... 4
LIST OF EFFECTIVE PAGES.................................................................................................... 5
TABLE OF CONTENTS ............................................................................................................. 6
TABLE OF FIGURES ................................................................................................................. 8
LIST OF TABLES..................................................................................................................... 10
1.0 INTRODUCTION ........................................................................................................... 11
1.1 SCOPE ................................................................................................................. 11
1.2 PURPOSE ............................................................................................................ 11
1.3 REVISION CONTROL PROCEDURE ................................................................... 11
1.4 SERVICE DIFFICULTY REPORTING ................................................................... 11
1.5 APPLICABILITY .................................................................................................... 11
1.6 ABBREVIATIONS ................................................................................................. 11
1.7 GENERAL PRECAUTIONS .................................................................................. 12
1.8 UNITS OF MEASURE ........................................................................................... 12
1.9 DISTRIBUTION..................................................................................................... 12
1.10 DESCRIPTION ..................................................................................................... 12
2.0 AIRWORTHINESS LIMITATIONS ................................................................................. 14
3.0 INSPECTION REQUIREMENTS AND OVERHAUL SCHEDULE .................................. 15
3.1 INSPECTION REQUIREMENTS........................................................................... 15
3.2 COMPONENT OVERHAUL SCHEDULE .............................................................. 16
4.0 TOWING ........................................................................................................................ 17
5.0 PLACARDS AND LABELS............................................................................................. 18
5.1 PLACARD INFORMATION ................................................................................... 18
5.2 PLACARD LOCATION .......................................................................................... 19
5.3 APPLICATION ...................................................................................................... 19
6.0 FLOAT AND COVER REMOVAL, CLEAN, TEST, OVERHAUL, AND REINSTALL ....... 20
6.1 FLOAT REMOVAL ................................................................................................ 20
6.2 FLOAT CLEANING ............................................................................................... 27
6.3 FLOAT TESTING .................................................................................................. 28
6.4 FLOAT REPAIRS – FABRIC AND SEAM REPAIRS ............................................. 30
6.5 FLOAT REPACKING INSTRUCTIONS ................................................................. 41
6.6 FLOAT REINSTALLATION ................................................................................... 47
7.0 HOSE REMOVAL, OVERHAUL AND REINSTALL ........................................................ 50
7.1 HOSE REMOVAL ................................................................................................. 50
7.2 HOSE INSPECTION ............................................................................................. 51

7.3 HOSE REINSTALLATION..................................................................................... 51

8.0 SKID EXTENSION REMOVAL, INSPECTION, AND INSTALLATION............................ 53
8.1 SKID EXTENSION REMOVAL .............................................................................. 53
8.2 SKID EXTENSION INSTALLATION ...................................................................... 54
9.0 PULL CABLE AND RESERVOIR REMOVAL, TEST, OVERHAUL, AND RIGGING....... 55
9.1 PULL CABLE REMOVAL ...................................................................................... 55
9.2 PULL CABLE INSPECTION AND TESTING ......................................................... 57
9.3 PULL CABLE INSTALLATION .............................................................................. 58
9.4 RESERVOIR REMOVAL....................................................................................... 58
9.5 RESERVOIR INSTALLATION............................................................................... 60
10.0 WEIGHT AND BALANCE .............................................................................................. 61

TABLE OF FIGURES
Figure 1: Float Cylinder Pressure Limits................................................................................... 15
Figure 2: Placard F/N 48 .......................................................................................................... 18
Figure 3: Label Baggage F/N 57 .............................................................................................. 18
Figure 4: Label Baggage Limit F/N 58 ...................................................................................... 19
Figure 5: Label Articles F/N 59 ................................................................................................. 19
Figure 6: FWD Fairing Removal ............................................................................................... 20
Figure 7: Float Removal / Installation – Float Positioning (1) .................................................... 21
Figure 8: Float Removal / Installation – Float Positioning (2) .................................................... 22
Figure 9: Float Removal / Installation – FWD Float .................................................................. 23
Figure 10: Float Removal / Installation – Aft Float .................................................................... 24
Figure 11: Float Removal / Installation – Hose Routing ............................................................ 25
Figure 12: Opening Float Covers ............................................................................................. 26
Figure 13: Float Repairs – Special Tool ................................................................................... 35
Figure 14: PRV/Inlet Check Valve Assembly (Typ. 4Pl.) .......................................................... 36
Figure 15: Inlet Check Valve Assembly (Typ. 4 Pl.) .................................................................. 37
Figure 16: Cover Inspection (1) ................................................................................................ 39
Figure 17: Cover Inspection (2) ................................................................................................ 40
Figure 18: Float Packing – Inflated Float .................................................................................. 41
Figure 19: Float Packing – Deflated Float ................................................................................ 41
Figure 20: Float Packing – Manipulating (1) ............................................................................. 42
Figure 24: Float Packing – Folding (1) ..................................................................................... 44
Figure 25: Float Packing – Folding (2) ..................................................................................... 44
Figure 26: Float Packing – Rolling (1) ...................................................................................... 45
Figure 27: Float Packing – Rolling (2) ...................................................................................... 45
Figure 28: Float Packing – Snap Cover .................................................................................... 46
Figure 29: Lacing ..................................................................................................................... 46
Figure 30: Secured Lacing Panel ............................................................................................. 47
Figure 31: Float Packing – Endcaps......................................................................................... 47
Figure 32: Float Packing – Completed ..................................................................................... 47
Figure 33: Float Reinstallation – Rivnuts .................................................................................. 48

Figure 34: Hose Removal – Hose Routing ............................................................................... 50

Figure 35: Hose Removal – Details .......................................................................................... 51
Figure 36: Skid Extension Removal & Installation .................................................................... 53
Figure 37: Valve Pull Cable Removal and Installation .............................................................. 56
Figure 38: Lever Assembly Pull Cable Removal and Installation .............................................. 56
Figure 39: Float Reservoir Assembly Installation...................................................................... 59
Figure 40: Reservoir Installation / Removal .............................................................................. 59

LIST OF TABLES
Table 1: Float Characteristics................................................................................................... 13
Table 2: Inflation Cylinder Characteristics ................................................................................ 13
Table 3: Cover Characteristics ................................................................................................. 13
Table 4: Parts List for Figure 7 and Figure 8 ............................................................................ 22
Table 5: Parts list for Figure 9 and Figure 10 ........................................................................... 24
Table 6: Parts List for Figure 11 ............................................................................................... 26
Table 7: Consumable Cleaning Material Required ................................................................... 26
Table 8: Visual Check of Assemblies and Components ........................................................... 27
Table 9: Testing Equipment/Materials Required ....................................................................... 29
Table 10: Helicopter Float Repair Kit 644.4204 ........................................................................ 30
Table 11: Cement Bonding Parts List ....................................................................................... 30
Table 12: Minimum Patch Sizes ............................................................................................... 31
Table 13: Adhesive Pot Life and Cure Times ........................................................................... 32
Table 14: Parts List for Figure 14 and Figure 15 ...................................................................... 37
Table 15: Float Will Not Maintain Operating Pressure .............................................................. 37
Table 16: Special Tools............................................................................................................ 38
Table 17: Repair Materials Required ........................................................................................ 38
Table 18: Parts list for Figure 16 and Figure 17........................................................................ 40
Table 19: Parts List for Figure 33 ............................................................................................. 48
Table 20: Parts List for Figure 34 and Figure 35 ...................................................................... 52
Table 22: Parts List for Figure 37 & Figure 38 .......................................................................... 57
Table 24: 644.7001 Longitudinal Weight and Balance.............................................................. 61
Table 29: 644.7001 Lateral Weight and Balance ...................................................................... 65

1.0 INTRODUCTION
1.1 SCOPE
This manual provides description, operation, disassembly, inspection, assembly, repair, and
testing instructions as well as an illustrated parts list for:
 P/N 644.7001 R44 Emergency Float Kit w/Extensions
 P/N 644.7002 R44 Emergency Float Kit
 P/N 644.7004 R44 Emergency Float Kit w/Extensions High Gear
 P/N 644.7005 R44 Emergency Float Kit High Gear
1.2 PURPOSE
The purpose of this manual is to maintain the following:
 Robinson Model R44 Emergency Float Kit w/Extensions
 R44 Emergency Float Kit
 R44 Emergency Float Kit w/Extensions High Gear
 R44 Emergency Float Kit High Gear
1.3 REVISION CONTROL PROCEDURE
All revisions to this document shall be identified in the Details of Revisions. All pages are
summarized on the “List of Effective Pages.”
1.4 SERVICE DIFFICULTY REPORTING
A record of kit sales shall be maintained by DART. Any changes to these instructions resulting
from service difficulties shall be distributed to all previous recipients.
1.5 APPLICABILITY
This manual shall be used to maintain the Emergency Float Kit w/Extensions for Robinson
Model R44 & R44II Helicopters.
1.6 ABBREVIATIONS
 psi = pounds per square inch
 ft. lbs. = foot pounds
 in. lbs. = inch pounds
 ºF = degrees Fahrenheit
 ºC = degrees Celsius
 PRV = pressure relief valve
 P/N = part number
 F/N = find number
 cu.in. = cubic inch
 LH = left hand
 RH = right hand

1.7 GENERAL PRECAUTIONS

 Personal Protective Equipment (PPE) shall be worn when exposed to flying particles, liquid
chemicals, or other potential hazards to the skin, eyes, ears, or respiratory system.
 Ensure that the work area is free from dirt and foreign matter and contaminants that could
otherwise damage functionality.
 Failure to comply with or deviate from the procedure may negatively affect the equipment. It
is the operator’s responsibility to comply with these procedures.
1.8 UNITS OF MEASURE
 psi = pounds per square inch
 ft. lbs. = foot pounds of torque
 in. lbs. = inch pounds of torque
 ºF = degrees Fahrenheit
 ºC = degrees Celsius
1.9 DISTRIBUTION
This manual will be distributed to float kit end users (or their mechanics or maintenance
departments). Repair Stations and other companies may request a manual for a fee to be
determined by DART.
DART shall provide a copy of this ICA with each kit that is sold.
1.10 DESCRIPTION
The DART R44 Emergency Float Kit w/Extensions, P/N 644.7001, consists of:
 Four emergency floats which are attached to the skid gear
 A pair of skid extensions for the aft floats
 A float inflation reservoir with a mechanical activation system
The DART R44 Emergency Float Kit, P/N 644.7002, consists of:
The DART R44 Emergency Float Kit w/Extensions High Gear, P/N 644.7004, consists of:
 A pair of skid extensions for the aft floats
The DART R44 Emergency Float Kit High Gear (P/N 644.7005) consists of:
The Emergency Floatation Assembly includes the following:
 Four floats (forward and aft on the left hand side and forward and aft on the right hand side)

Each float consists of three separate air-holding chambers. The chambers are separated by
bulkheads made of the same urethane-coated nylon as the tube, to minimize the loss of
buoyancy in the event of puncture or tear. Each chamber contains an inlet check valve for
inflation by the reservoir/valve assembly and a topping/PRV for manual inflation and to
prevent over-pressurization.
 A cover for each float
 One float reservoir assembly with hoses that lead to each chamber of the four floats
 A mechanical float inflation system (a collective-mounted lever handle initiates inflation of
the floats via pull cable connected to the float reservoir assembly)
Table 1: Float Characteristics

Material Urethane Coated Nylon
Ship set inflated volume 60.06 Cubic Feet
Ship set inflated buoyancy 3844.16 lbs.
Operating pressure 1.75 psi
Type of inflation Compressed helium or nitrogen
Total float ship set weight See Table 24
Table 2: Inflation Cylinder Characteristics

Cylinder Volume Operating Pressure System
601.1104 416 cu. in. 4945 psi Float
Table 3: Cover Characteristics

Material Chloroprene or vinyl chloride polymer coated nylon

AIRWORTHINESS; EMERGENCY FLOAT 644.7000 Rev. N/C
2.0 AIRWORTHINESS LIMITATIONS

A. Float Inflation Reservoir has a 15-year retirement life from the date of manufacture.
B. The Airworthiness Limitations section is FAA approved and specifies the
maintenance required under FAR 43.16 and 91.403 of the Federal Aviation
Regulations unless an alternative program has been FAA approved.

3.0 INSPECTION REQUIREMENTS AND OVERHAUL SCHEDULE

3.1 INSPECTION REQUIREMENTS
WARNING: PRIOR TO ANY INSPECTION INSTALL SAFETY PINS INTO CYLINDER
VALVES
3.1.1 PREFLIGHT – REFERENCE RFMS44-1
1. Check the LH and RH float assemblies and inspect for damaged areas.
Any break or hole in the coated fabric covers must be inspected for internal damage
and should be investigated. If damaged, refer to Section 6.4.5.
2. Check all exposed hoses for cuts or kinks. If damaged, refer to Section 7.0.
3. Check the pressure gauge mounted on the cylinder valve. Verify that the pressure
indicated on the cylinder falls within the acceptable range shown on the pressure and
temperature chart located on the cylinder and in Figure 1. Charge the cylinder to the
proper operating pressure per the pressure and temperature chart. If leaking
persists, the valve assembly is not field replaceable, return it to DART (or an
approved service center) for repair/replacement.
MAX
Float Cylinder Pressure Limits (He) NOM
Ambient Temperature ( °F) MIN
-40 -20 0 20 40 60 80 100 120 140

5500
5250
5000
Pressure (psig)
4750
4500
4250
4000
3750
-40 -29 -18 -7 4 16 27 38 49 60
601.2431
Ambient Temperature ( °C) REV N/C
Figure 1: Float Cylinder Pressure Limits

3.1.2 18-MONTH INSPECTION

1. Unsnap the float covers.
2. Inspect the covers for any cuts or tears.
If the cover is damaged in any way, remove and replace it. (Refer to Section 6.4.5.)
3. Conduct the 18-month float leak test in accordance with Section 6.3.
4. Inspect the cylinder and valve for surface damage and visible corrosion.
5. Inspect pull cables for corrosion and check for full range of motion at the valve, in
accordance with Section 9.2.
3.1.3 3-YEAR INSPECTION
1. Use the float activation lever and initiate the float inflation. Clear an area of at least
15 feet from either side of the floats.
2. After inflation, measure the pressure in each float chamber.
Pressure shall be a minimum of 1.75 psi at 70º F after 10 minutes.
3. Conduct a float leak test in accordance with Section 6.3 and inspect for chafing or
damaged areas.
4. Disconnect the pull cable per Section 9.1
5. Inspect the pull cable and activation lever for ease of movement and corrosion in
accordance with Section 9.2.
The pull cables have an unlimited service life from the date of installation.
6. Install the pull cable as shown in Section 9.3.
If the pull cable is damaged in any way, remove it and return it to DART (or an
approved service center).
7. Inspect the hoses in accordance with Section 7.2.
8. Inspect the covers for any cuts or tears, in accordance with Section 6.4.5.
3.2 COMPONENT OVERHAUL SCHEDULE
Component P/N Component Nomenclature Time Between Overhaul Section
(TBO)
644.7701 Reservoir Assembly 3 years (see Note) 8.1
NOTE: The TBO of three years is from the date of installation. The DOT cylinder hydrotest
requirement is five years from the date of manufacture or the last test.

4.0 TOWING
The DART R44 Emergency Float Kit includes a ground handling lever kit (R44), P/N 644.8101.
The ground handling lever kit replaces the Robinson OEM bar attached to the ground handling
wheel on the LH side of the helicopter. When replaced, the ground handling lever kit will clear
the LH aft DART float.
Only one replacement lever bar is needed per kit.

5.0 PLACARDS AND LABELS

5.1 PLACARD INFORMATION
Figure 2: Placard F/N 48
Figure 3: Label Baggage F/N 57

Figure 4: Label Baggage Limit F/N 58
Figure 5: Label Articles F/N 59
5.2 PLACARD LOCATION

1. Install the placard (F/N 48) on the instrument panel, in the plain view of the pilot.
2. Install the label baggage, label baggage limit, and label articles (F/N 57, 58, 59) on the
inboard wall of the under-seat compartment.
5.3 APPLICATION
Placards and labels contain an air curing pressure sensitive adhesive. To remove placards and
labels:
1. Pry them off.
To install placards and labels:
1. Remove the paper backing, place them where they belong, and apply pressure.
2. Leave them undisturbed for 12 hours.

6.0 FLOAT AND COVER REMOVAL, CLEAN, TEST, OVERHAUL,

AND REINSTALL
WARNING: BEFORE DOING ANY MAINTENANCE WORK ON OR AROUND THE
HELICOPTER, ENSURE THAT THE SAFETY PIN IS IN THE RESERVOIR
ASSEMBLY. THE SAFETY PIN SHOULD ONLY BE REMOVED PRIOR TO
FLIGHT.
6.1 FLOAT REMOVAL
NOTE: Removal is typical for all four floats.
1. Turn off all helicopter power, in accordance with the Flight Manual.
2. Remove FWD fairings as per Figure 6.
Figure 6: FWD Fairing Removal

Figure 7: Float Removal / Installation – Float Positioning (1)

Figure 8: Float Removal / Installation – Float Positioning (2)
Table 4: Parts List for Figure 7 and Figure 8

F/N QTY Part Number Description
REF 1 - OEM FWD LH Fairing
REF 1 - OEM FWD RH Fairing
REF 7 - OEM Button Head Screw
REF 8 - OEM Rivet
1 1 644.7301 SKID Extension Assembly LH (R44)
2 1 644.7302 SKID Extension Assembly RH (R44)
8 1 644.7202 FWD LH Float Assembly
9 1 644.7203 FWD RH Float Assembly
10 1 644.7204 AFT LH Float Assembly
11 1 644.7205 AFT RH Float Assembly
3. Remove the bolts (F/N 12 or 13), washers (F/N 14), and nuts (F/N 15) that attach the float
girt to the skidtube (12 PL total), as shown in Figure 9 and Figure 10.
4. Discard and replace the hardware.

Figure 9: Float Removal / Installation – FWD Float

Figure 10: Float Removal / Installation – Aft Float
Table 5: Parts list for Figure 9 and Figure 10

12 6 601.2404 Bolt (AN3-32A)
13 6 601.2462 Bolt (AN3C-31A)
14 24 601.0774 Washer (NAS1149C0363R)
15 12 600.0733 Locknut (MS21044C3)
16 REF 602.2615 Hose Assembly
5. Disconnect the float hoses (F/N 16) from FWD floats and aft floats (Figure 11).
6. Disconnect the float hoses (F/N 22 or F/N 56) from the tee connector at the FWD floats
(Figure 11).

Figure 11: Float Removal / Installation – Hose Routing
NOTE: Protect open pneumatic fittings with applicable caps or plugs to prevent line
contamination.

Table 6: Parts List for Figure 11

16 2 602.2615 Hose Assembly
23 4 600.0646 Ty-wrap
7. Carefully place floats in a padded and clean work area. The work area should be well lit and
well ventilated.
8. Undo the VELCRO® and snaps on the float covers (Figure 12).
Figure 12: Opening Float Covers
Table 7: Consumable Cleaning Material Required

Description Availability
Cleaning Solvent - Methyl Ethyl Ketone (MEK) Commercially available
Stiff bristle nylon brush ½ or 1” Commercially available
Soft bristle nylon brush ½ or 1” Commercially available
Detergent Commercially available
Activating agent - Methyl Ethyl Ketone (MEK) Commercially available
Brush - solvent resistant - 1” Commercially available
Spatula - 2 ¼” x 4” DART
Cotton cloth Commercially available

Table 8: Visual Check of Assemblies and Components

Component Check Procedure Disposition
See Repair Section 6.4. If beyond limits, it
Cuts, tears, punctures, abrasions is not field replaceable, return to DART (or
Fabric/Seams
(mark with chalk if discrepant) an approved service center) for repair or
replacement.
If valve leaks, replace it. If the flange leaks,
Leaks, opening and closing
PRV / Topping it is not field replaceable, return to DART
pressure only - see Testing Section
Valve (or an approved service center) for repair
6.3.2
or replacement.
Leaks only – see Testing If valve leaks, it is not field replaceable,

Inlet Check Valve return to DART (or an approved service
Section 6.3.3 center) for repair or replacement.
Not field replaceable; return to DART (or an
Girt Assembly Condition, function, and security approved service center) for repair or
replacement.
CAUTION: THE WORKING AREA FOR REPAIR SHOULD BE COVERED WITH A CLEAN
TARPAULIN OR CARPETING PROTECTION, AND BE FREE OF HARDWARE,
TOOLS, AND OTHER SHARP OBJECTS.
6.2 FLOAT CLEANING
Use good shop safety precautions and practices at all times when using solvents.
WARNING: USE FLAMMABLE SOLVENTS ONLY IN WELL-VENTILATED AREAS. DO
NOT INHALE FUMES.
NOTE: Do not apply cleaning solvent to float decals or stencil markings. It will remove them.
1. If necessary, clean the float assembly fabric surfaces using detergent soap and water
solution or a cleaning solvent. (Detergent soap and water solution is the preferred method.)
See Table 7.
2. Apply a cleaning solvent (Table 7) with a clean, soft cloth (or a soft bristle brush) to areas of
oil, dust, or dirt.
3. Immediately remove excess solvent with a clean, soft cloth and dry using compressed air
(shop air).
The compressed air source should be oil and moisture free and should be equipped with a
20-micron filter for best results.

6.3 FLOAT TESTING

Use the following procedures for the leak test.
Following the overhaul of float assemblies, perform a float pressure test before returning the
equipment to service. The pressure relief/topping valve tests may be performed in conjunction
with troubleshooting information (Table 15) in the case of the annual inspection or as part of the
float pressure test, if replacement or repair of those components was accomplished during
overhaul.
6.3.1 FLOAT PRESSURE TEST (TABLE 9)
1. Using shop air, inflate all chambers of the assembly to 1.75 psig, inflate in
increments of 0.5 psig. Measure the pressure in each compartment with a mercury
manometer or pressure gauge (calibrated in increments not greater than 0.1 psig),
connected to the topping valve.
2. Allow the inflated float to stand for one hour after initial inflation. Then, check and
readjust pressure in each compartment, if necessary, to 1.75 psig.
3. Record the temperature and barometric pressure.
4. Allow the float to remain undisturbed for eight hours.
After correcting for temperature and barometric variations, the maximum allowable
pressure drop is 0.50 psig (or, allow the float to stand for 24 hours and the maximum
allowable pressure drop is 1.0 psig).
5. Record the compartment pressures, the temperature, and the barometric reading at
the end of the pressure test.
6. Correct for temperature variations by subtracting 0.1 psig for every 3° F rise in
temperature, or adding 0.1 psig for every 3° F drop.
7. Correct for barometric conditions by adding 0.1 psig to the final gauge reading for
every 0.2 inches of mercury that the barometric pressure had increased, or subtract
0.1 psig from final reading for every 0.2 inches of mercury that the barometer has
fallen.
8. If the corrected pressure falls below specified limits, inflate the float to 1.75 psig and
check for leaks by swabbing the tubes with leak solution (Table 9), using a soft
bristle brush (Table 7).
6.3.2 PRV /TOPPING VALVE LEAKAGE TEST
This valve may be checked as part of the float pressure test while it is inflated to 1.75
psig.
1. Using a soft nylon bristle brush (Table 7), apply leak solution (Table 9) at the
mounting patch to the float attachment location.
If bubbles indicate a leak, the float assembly must be returned to DART (or an
approved service center) for replacement of the valve flange/base.

2. If leakage is due to the valve not seating properly, remove and replace the valve
(Figure 14).
3. Fill the relief valve aperture with clean water.
4. Slowly raise the compartment pressure and watch for bubbles indicating that the
valve opens.
5. Then, reduce pressure while watching for the elimination of bubbles.
The valve should open at 4.0 psig ± 0.25 psig and should close by 3.5 psig ± 0.25.
6. If the valve operates improperly, apply leak solution (Table 9) in the valve aperture.
7. If bubbles indicate a leak at this location, remove the valve from the base flange and
check the threads in the flange base and on the valve.
8. It is not field replaceable, so if threads in the flange are damaged, return it to DART
(or an approved service center) for repair or replacement.
9. If the valve threads are damaged, replace as specified (Figure 14).
6.3.3 INLET CHECK VALVE TEST
This valve may be checked as part of the float pressure test while it is inflated to 1.75
psig.
1. With a soft nylon bristle brush (Table 7), apply leak solution (Table 9) at the mounting
patch to the float location.
2. If bubbles indicate a leak, it is not field replaceable, return to it DART (or an
approved service center) for repair or replacement.
Table 9: Testing Equipment/Materials Required

Equipment Description/Function Supplier
Scale increments no more than 0.10 psi.
Manometer Note 3)
Range: 0-120 in. Hg.
Pressure Gauge Increments not greater than 0.1 psi Note 3)
Barometer Scale increments not more than 0.10 in. Hg. Note 3)
Stopwatch Plain timer, 0.10 second graduations Note 3)
Thermometer Scale increments not more than 1° F Note 3)
Leak Test Solution Leak test; Detergent soap and water solution Note 4)
NOTES: Test set up information:

1) The testing of components is accomplished on the float assembly with all components
assembled as an operational system. Special fixtures and test benches are not required.
2) Attachment of an inflation shop air source (or manometer testing equipment) to the float
assembly is accomplished using the topping-off valves and adapters.

3) The equipment supplier is optional. However, the equipment must be able to be calibrated
for accuracy.
4) The equipment supplier is optional.
6.4 FLOAT REPAIRS – FABRIC AND SEAM REPAIRS
The following repairs will be confined to the patching of punctures, tears, and holes no greater
than either three inches in diameter or two inches by 10 inches in length. Replacement of a
complete section or bulkheads shall not be attempted in the field since operating integrity and
the air retaining capabilities of the float shall be affected.
All major repairs shall be accomplished at a certified repair station or by DART. Repair kit items
are listed in Table 10.
Table 10: Helicopter Float Repair Kit 644.4204

QTY Item Part Number
4 5 inch diameter repair patch 644.4210
2 4 x 12 inch rectangular patches 644.4211
2 6 x 14 inch rectangular patches 644.4212
1 8 ounce tube of adhesive 600.0902
1 1/2” soft bristle brush 601.2210
1 MSDS for adhesive LA-4123
1 Dual-slotted wrench 645.3210
1 PRV/topping valve 601.1447
1 Instruction sheet ARIS-001
1 Test adapter 600.0209
6.4.1 CEMENT BONDING

Table 11: Cement Bonding Parts List
Part Number Material Washing Activating Adhesive
600.0008
Urethane Coated
Or MEK 100% MEK 100% 600.0902
Fabric
600.0110
All mixing containers, cans, stirrers and mixing equipment shall be clean and free of any
dirt, contamination, and dried adhesive.
Supplies:
 Cloth, lint-free, dye-free or white cotton, cut to about 8”x 8” square.
 Stiff nylon bristle brush, utility, size suited to the bond area.

 Solvent containers:
 Safety storage can for solvent
 Pump (plunger) can
 Brush container with cover
 Rag can with cover
 Solvent waste can
 Spent rag can
 Hand tools:
 Pusher, plastic or metal
 Roller
To ensure a proper bond, use the chart below to determine the minimum patch size to
use, if applicable.
Table 12: Minimum Patch Sizes

Tear Size Minimum Overlap on all Sides of Damaged Area
up to 1/8 inch 1 inch
1/8 inch to 2 inches 2 inches
Inside patch 1 inch
2 inches to 10 inches
Outside patch 2 inches
6.4.2 HOLES, CUTS, TEARS, AND PUNCTURES UP TO 3 INCHES

1. Using a clean cloth, dry the surface to which the patch is to be applied.
2. If the surface cannot be cleaned due to a buildup of chemicals, use 100-grit
sandpaper to abrade the area to be bonded, until achieving a dull appearance.
3. Check for dryness by touching with the back of the hand or knuckles only; do not
touch or handle the cemented areas because oils on the fingers can contaminate the
adhesive.
Adhesives have a limited pot life, meaning that they “go bad” after a specified length of
time. Adhesives may not be used after their pot life has expired, as indicated on the
container label. Dispose of expired cement appropriately. See the adhesive pot life and
cure time below.
CAUTION: THE ADHESIVE BOND DEVELOPS INCREASING STRENGTH OVER A
PERIOD OF DAYS.
Cemented components should not be tested or inflated prior to reaching the initial cure
period specified in Table 13. Products should not be packed until reaching the final cure
period, also specified in Table 13.

Table 13: Adhesive Pot Life and Cure Times

Supplier Grade Pot Life Hours Initial Cure Final Cure
DART 600.0902 6 Overnight 2 days
The adhesive bonding process is affected by environmental conditions of temperature

and humidity. Low temperatures will slow drying and cure times. Adhesive bonding
cannot be performed at temperatures lower than 55° F. High humidity may cause
moisture to condense on the bond area, as indicated by a foggy white appearance on
the cement or component. Before applying additional cement or before activating, flash
(evaporate) the moisture by wiping lightly with additional solvent.
4. Clean the bond area as follows:
1. Fold a clean cloth in half, then fold in half again to form a square.
2. Dampen the cloth with solvent. Squeeze any excess solvent from the cloth, back
into the pump can screen.
3. Wash the bond area by wiping in only one direction to remove all visible
contamination and release agents.
 Wiping back and forth only smears contaminants.
 When washing coated fabric, do not allow excess solvent to collect at the
edges of seams.
 Do not apply solvent to decals or stencil markings because the solvent can
remove them.
4. Refold the cloth as necessary to keep a clean wiping surface. Each cloth should
give eight wiping surfaces.
5. When the cloth is soiled, properly dispose of it.
5. Allow the cleaning solvent to evaporate completely before applying the adhesive.
6. To apply the first coat of adhesive to the bond area:
1. Brush (Table 7) a uniform coat of adhesive onto the bond area, rubbing the
adhesive firmly into the fabric or component.
2. Allow the first coat to air dry completely before proceeding; check dryness with
the back of your knuckle.
3. Close the adhesive container when not in active use.
7. To apply the second coat of adhesive to the bond area:
1. Brush (Table 7) a second uniform coat of adhesive onto the bond area, painting
the adhesive lightly over the first coat.
2. Allow the second coat to air dry completely before proceeding. Check dryness
with the back of your knuckle.
8. Activate the adhesive by one of the following methods:
 To solvent activate:
1. Dampen a clean cloth with solvent.

2. Wipe both cemented surfaces lightly but thoroughly with the dampened cloth.
3. Within 15 seconds of activating, join the components as per the next step.
 To heat activate:
1. Direct the flow from a hot air gun over both cemented surfaces.
Avoid applying too much heat, which may melt the coating or component.
2. When the adhesive feels tacky, immediately proceed to join the components
as per the next step.
9. To join the components:
1. When activated, align the two mating surfaces and press them together in a
wallpapering fashion. Use a roller to expel any trapped air.
2. Press with a pusher or roller over the entire activated area to ensure complete
contact.
3. When a component is bonded over a seam, tape or other uneven base, first
press firmly at the edge of the step-off to avoid bridging. Then bond the
remainder of the component.
4. Apply the patch gradually from the center to the edges, to minimize the possibility
of air bubbles being trapped beneath the patch.
5. Using a smooth edge putty knife and starting at the center of the patch, apply
pressure and move toward the edge of the patch, pushing out any air bubbles or
wrinkles. Take special care when pushing the edge of the patch to prevent the
edges from lifting.
6. When all wrinkles and air bubbles have been eliminated, uniformly roll the joined
area using a hand roller.
10. After the patch has dried for approximately two hours, the repaired area may be
inflated to a maximum of 1.0 psi. After the repair has dried for 24 hours, the product
may be inflated to working pressure and tested in accordance with testing
instructions in this manual (Section 6.3).
11. To clean and inspect the bonded area:
1. Clean any adhesive drops and adhesive outside the required bond area by
wiping with a cloth dampened with solvent. (Table 7)
2. Inspect for location, overlap, lifts, wrinkles, and air bubbles. Reactivate and join
to repair these defects.
12. Allow the bonded components to cure, undisturbed.

6.4.3 HOLES, CUTS, TEARS, AND PUNCTURES UP TO 2 X 10 INCHES

These instructions are for repairing fabric tears that are limited to a 2x10 inch maximum
tear (either curved or straight).
CAUTION: REPAIR TEARS BY PATCHING BOTH THE INSIDE AND THE OUTSIDE
SURFACES OF THE FABRIC PRIOR TO INFLATING THE FLOAT.
1. Use scissors to trim loose threads.
2. To prevent joining the inside surfaces of the fabric together, sprinkle a handful of
powdered soapstone or talc inside the float opposite the tear area.
3. Using a clean cloth, dry all surfaces where the patches will be applied.
4. Using a cloth dampened with solvent, thoroughly clean both the inside surface of the
fabric around the tear and the underside of one of the patches (Table 7).
5. Apply adhesive and activate surfaces as instructed in 6.4.2, Steps 5, 6, 7, & 8.
6. Fold the patch in half lengthwise and pass the patch through the tear and install it
cement side up on the inside surface of the float fabric directly under the tear.
7. Immediately apply pressure with a hand roller to bond the patch to the inside of the
fabric. Pressure is important for a good bond.
8. If the surface cannot be cleaned due to a buildup of chemicals, use 100-grit
sandpaper to abrade the outside surface of the area to be bonded until achieving a
dull appearance.
9. Thoroughly clean the outside surface of the fabric around the tear and the underside
of the other patch using a cloth dampened with solvent.
10. Apply adhesive and activate surfaces as instructed in 6.4.2 Steps 5, 6, 7, & 8.
11. Apply the patch gradually, from the center, as instructed in 6.4.2 Steps 9, 10, 11, &
12.
6.4.4 REPAIRING AND REPLACING VALVES
Inlet check valves and pressure relief (PRV) inflate-deflate valves used in the float
assemblies shall be inspected for leaks, cleaned as required, and if faulty, inlet check
valves and PRV/inflate-deflate valves should be replaced. PRV valves may be replaced
in field while inlet check valve repair/replacement requires depot-level servicing. Return
to DART (or an approved service center) for repair or replacement.
Inlet check valves and PRV/inflate-deflate valves may be removed and reinstalled using
a dual slotted wrench (P/N 645.3210) (Table 16 and Figure 13). Refer to Figure 14 and
the following instructions for valve removal and replacement.
1. Using a special tool (dual slotted wrench P/N 645.3210) remove PRV/ inflate-deflate
valve by inserting wrench into molded flange and turn counter-clockwise to remove

valves. Insert wrench slot over molded tab of topping off valve and turn counter-
clockwise. (Figure 13)
Figure 13: Float Repairs – Special Tool
2. Check threads in the recessed molded fitting that is bonded in the float and clean it if
necessary. If it is damaged, it is not field replaceable, so return it to DART (or an
3. Insert the valve into the threads of the recessed molded fitting and turn clockwise by
hand to ensure that the threads are not crossed.
4. Continue to turn by hand until the valve is seated.
5. Attach the wrench, turn clockwise, and torque to 30-40 in. lbs.

Figure 14: PRV/Inlet Check Valve Assembly (Typ. 4Pl.)
6. To remove the inlet check valve, use the dual-slotted wrench (P/N 645.3210), turning
it counter-clockwise (Figure 15).
7. Check threads in the recessed molded fitting that is bonded in the float and clean it if
necessary. If it is damaged, it is not field replaceable, so return it to DART (or an
8. Insert the inlet check valve into the threads of the recessed molded fitting and turn
clockwise by hand. Continue to turn by hand until the valve is seated. (Depot level
task only.)
9. Attach the wrench, turn clockwise, and torque to 30-40 in. lbs. (Depot level task
only.)

Figure 15: Inlet Check Valve Assembly (Typ. 4 Pl.)

D 12 601.1447 PRV/Topping Valve
E 8 645.1701/647.0601 -4 Dual Inlet Check Valve
F 4 645.1601/647.0501 -4 Single Inlet Check Valve
Table 15: Float Will Not Maintain Operating Pressure

Probable Cause Remedy
Hole in Fabric, up to 3” Patch Hole (Section 6.4.2)
Tear in Fabric, up to 10” Patch Tear (Section 6.4.3)
Leaking PRV/Topping Valve ** Check Threaded Fixtures (Section 6.4.4)
Leaking Inlet Check Valve Return assembly to DART (or an approved service center)
for repair/replacement
** If the valve leaks at the mounting base, it is not field replaceable, so return the float to DART (or
an approved service center) for repair or replacement.

Table 16: Special Tools

DART Part Number Nomenclature Application
Removal and Installation of PRV/Topping
645.3210 Dual Slotted Wrench
Valves and Inlet Check Valves
600.0209 Test Adapter Accepts Gauge to Test Float Pressure
600.0210 Deflate Adapter Exhaust Air from Chambers
600.0234 Bleed Fitting Bleed down over charged cylinder
Fill Fitting Adapter Quick Attach fill hose to valve when charging
600.0235 or 601.1425
Disconnect cylinder
Table 17: Repair Materials Required

Material/Equipment Specification and Vendor Designation
Float Material 600.0008; DART
Adhesive 600.0902; DART
Activating Agent Methyl Ethyl Ketone (MEK)
Nylon Brush, 1” Wide Commercial - Solvent Resistant
Spatula (pusher) or Dull Putty Knife 2 1/4” x 4”; DART
Mastinox 600.0927;DART
Moly-Lube Anti-seize in Accordance with
Commercially Available
MIL-M-7866
6.4.5 COVER INSPECTION

Inspect the exterior of all the float covers for and cuts or tears. If a cover is torn in any
way, it must be replaced. Minor scuffs and abrasions are acceptable.
Floats suspected of damage must be returned to DART (or an approved service center)
for inspection and repair.
To inspect covers:
1. Unsnap the FWD and aft covers.
2. Inspect the cover interiors for any cuts, tears, or loose threads. Look for any missing
or damaged snaps. If any defects are found on the FWD and aft float covers, remove
the covers and replace them (Figure 16 and Figure 17).
3. In order to remove the cover, first remove the float from the skid (Section 6.1).
4. Detach the covers from the floats by removing nuts, bolts, and washers. Discard and
replace the removed hardware (Figure 16 and Figure 17).
5. Attach new covers with new hardware, and torque fasteners to 35-45 in. lbs.

6. Repack the floats per Section 6.5.

7. Reattach the floats as shown in Section 6.6.
Figure 16: Cover Inspection (1)

Figure 17: Cover Inspection (2)
NOTE: The Table 18 parts list only reflects parts on Figure 16 and Figure 17.
Table 18: Parts list for Figure 16 and Figure 17

F/N Qty. Part Number Description
A 2 644.8012 Inside FWD Channel (short)
B 2 644.8011 Inside FWD Channel (long)
C 6 644.8010 Channel
D 1 644.7901 FWD LH Float Cover Assembly
E 1 644.7902 FWD RH Float Cover Assembly
F 1 644.7903 Aft LH Float Cover Assembly
G 1 644.7202 FWD LH Float Assembly
H 1 644.7203 FWD RH Float Assembly
J 1 644.7204 AFT LH Float Assembly
K 1 644.7205 AFT RH Float Assembly
L 42 601.0757 Bolt (AN3C4A)
M 42 601.2381 Washer (NAS620C-10L)
N 42 601.0789 Nut (MS21043-3)
P 42 601.2421 Washer (NAS1149C0332R)
R 1 644.7904 Aft RH Float Cover Assembly

6.5 FLOAT REPACKING INSTRUCTIONS

6.5.1 FWD FLOAT REPACKING INSTRUCTIONS
Figure 18: Float Packing – Inflated Float
1. Remove approximately 90% of the air from the float by attaching a vacuum source to
the PRV/topping valve. Leave just enough air so that the bag can still be
manipulated. (Figure 19)
Figure 19: Float Packing – Deflated Float
2. Move the float material into a three-sided pattern, so that it has two sides and a
flattened center top and fold the three-sided pattern flat. (Figure 20 to Figure 23)

Figure 20: Float Packing – Manipulating (1)

3. Start with the float laid out as shown in Figure 23. Fold the center cone and entire aft
end on to the top of the float.
4. Pull these two ends toward the middle to ensure that the entire float is inside the
cover area.
5. Attach the male VELCRO® strap to the female VELCRO® strap.
NOTE: Failure to attach VELCRO® straps properly may result in improper inflation.
6. Remove the remaining air from the float. This should prevent the float from unfolding
(Figure 24).

Figure 24: Float Packing – Folding (1)
7. Create one more fold at the nose to evenly space the float material.
Figure 25: Float Packing – Folding (2)

8. Roll both sides of the float in an underhand fashion toward the girt.
Figure 26: Float Packing – Rolling (1)
Figure 27: Float Packing – Rolling (2)
9. Pull the girt cover over the rolled material and fasten the snap buttons.

Figure 28: Float Packing – Snap Cover
10. Tighten the lacing panel from aft to front using the packing tool (PN: 601.3701).
This step may need to be repeated to fully tighten lacing (Figure 29).
Figure 29: Lacing
11. Tie the parachute cord and secure the access.

Figure 30: Secured Lacing Panel
12. Close and VELCRO® the closing flap and the two end caps.
Figure 31: Float Packing – Endcaps
Figure 32: Float Packing – Completed
6.6 FLOAT REINSTALLATION

WARNING: ENSURE THAT THE SAFETY PIN IS IN THE RESERVOIR ASSEMBLY.
Before installing floats:
1. Inspect the area of the skidtube for damage or corrosion. Refer to Maintenance Manual for
repair and treatment procedures.

2. Connect the hoses to the inlet check valves on the bottom of the floats. Torque the -4 hoses
to 140 ± 10 in. lbs. (Figure 34).
3. Check the Rivnuts F/N 17 and loop clamps F/N 20 for corrosion or damage. If corrosion has
occurred, replace the Rivnuts or loop clamps.
4. Replace all bolts (F/N 19) and washers (F/N 14) (Figure 33).
Figure 33: Float Reinstallation – Rivnuts

F/N Qty. Part Number Description
3 2 601.0720 Bolt (AN3C5A)
14 16 601.0774 Washer (NAS1149C0363R)
17 8 601.2473 Rivnut (NAS1329A3-130)
19 8 601.0757 Bolt (AN3C4A)
20 10 601.2472 Loop Clamp (MS21919WDG5)
49 2 624.2203 Loop Clamp Extension Bracket

5. Before positioning the floats, and before installing the bolts, washers, and locknuts, attach
each hose end of the hose (F/N 16) onto a FWD float inlet check valve fitting, and onto an
aft float inlet check valve fitting. Then torque each fitting to 140 ± 10 in. lbs. Do this for both
LH and RH sides (Figure 34).
6. Attach the hose ends of F/N 22 or F/N 56 onto the FWD float -4 tee fitting (Ref P/N
601.2370). If needed, loosen the hose fitting and the -4 tee fitting to position Tee to match
the crosstube angle.
7. Torque each Fitting to 140 ± 10 in. lbs. Do this for both LH and RH sides (Figure 34).
8. Position and install the FWD floats using bolts (F/N 12), washers (F/N 14), and locknuts (F/N
15) (
9. Figure 7 to Figure 9 ).
10. Position and install the aft floats using bolts (F/N 13), washers (F/N 14), and locknuts (F/N
15 (
11. Figure 7, Figure 8, and Figure 10).
12. Route the hose (F/N 16), onto the helicopter crosstube. Install the hose clamp sub-assembly
using F/N 14, F/N 17, F/N 19 and F/N 20 onto the hose (F/N 16) and skidtube.
13. Install the loop clamp bracket sub-assembly using F/N 14, F/N 17, F/N 19, F/N 20 and F/N
49 (loop clamp extension bracket) (Figure 33).
14. Attach the hoses (F/N 22 or F/N 56) onto each end of a -4 bulkhead branch tee w/nut (F/N
27).
15. Attach a -4 bulkhead branch tee w/nut onto the helicopter bulkhead.
16. Attach a washer (F/N 28) and nut (comes with bulkhead tee) from the interior of the
helicopter hull (Figure 35).
17. Attach Ty-wraps (F/N 23), onto the hose (F/N 22 or F/N 56) (Figure 34).
18. Attach the hose (F/N 22 or F/N 56) to the helicopter bulkhead using screws (F/N 24),
washers (F/N 21), spacers (F/N 26), loop clamps (F/N 20), and locknuts (F/N 25) (Figure
35).

7.0 HOSE REMOVAL, OVERHAUL AND REINSTALL

7.1 HOSE REMOVAL
1. Disconnect the reservoir feed hose from the respective valve assembly, and immediately
attach a diffuser cap on the outlet port of the valve assembly (P/N 601.2382 -4 diffuser cap).
2. All remaining hoses may be removed in any order by removing their attaching nuts, bolts,
and loop clamps.
3. Remove all hoses from the floats, reservoirs, and helicopter crosstubes.
Figure 34: Hose Removal – Hose Routing

Figure 35: Hose Removal – Details
7.2 HOSE INSPECTION

1. Inspect the internal surfaces of each hose for a loose or missing liner. If one is found,
discard the hose and contact DART for a replacement.
2. Inspect external hose surfaces for abrasions, cuts, or signs of corrosion. If any are found,
discard the hose and contact DART for a replacement.
7.3 HOSE REINSTALLATION
1. Refer to Section 6.6 for hose reinstallation information that is associated with float
installation.
2. Route the float hose (F/N 22 or F/N 56) along each side of FWD crosstube and attach the
hoses to opposite sides of a -4 bulkhead branch tee w/nut, F/N 27 (Figure 34).
3. Attach the float reservoir hose, F/N 36, to the center of the -4 bulkhead branch tee w/nut,
F/N 27, and route the hose forward to the float cylinder (Figure 34).


14 4 601.0774 Washer (NAS1149C0363R)
15 2 600.0733 Locknut (MS21044C3)
20 2 601.2472 Loop Clamp (MS21919WDG5)
23 4 600.0646 Ty-wrap
24 2 601.0785 Bolt (AN3C6A)
26 2 601.2476 Spacer (NAS43DD3-12N)
27 1 601.2460 -4 Bulkhead Branch Tee w/Nut
28 2 601.1885 Washer (NAS1149C0763R)
REF 602.2612 Hose Assembly

8.0 SKID EXTENSION REMOVAL, INSPECTION, AND INSTALLATION

WARNING: THE SAFETY PIN MUST BE INSTALLED IN THE RESERVOIR VALVE
ASSEMBLY PRIOR TO WORKING ON OR AROUND CYLINDERS OR
CABLES.
8.1 SKID EXTENSION REMOVAL
Remove and inspect skid extensions every three years.
1. Remove the LH and RH aft floats (Section 6.1).
2. Remove the LH and RH float hoses (F/N 16), P/N 602.2615 (Section 7.1).
3. Remove the bolts and washers from the OEM crosstube and OEM skidshoe.
Save the OEM skidshoe and OEM hardware for reuse.
4. If there is significant corrosion or damage on any of these parts, replace them with new
parts.
Figure 36: Skid Extension Removal & Installation


1 1 644.7301 Skid Extension Assembly LH (R44)
2 1 644.7302 Skid Extension Assembly RH (R44)
4 8 601.0775 Socket Head Button Screw
7 A/R 601.2045 RTV
50 1 601.1150 Sealant (MIL-S-8802 CLASS B)
REF 8 OEM Bolt (NAS6606-4 CS)
REF 8 OEM Washer (NAS1149F0663P)
REF 2 OEM Skidshoe
REF 8 OEM Socket Head Button Screw
5. Remove the skid extension assembly LH (F/N 1), and skid extension assembly RH (F/N 2).
6. Inspect mating surfaces for corrosion.
8.2 SKID EXTENSION INSTALLATION
1. Place the OEM skidshoe back into position.
2. Slide the skid extension into the skidtube until the skid extension pre-drilled holes align with
the OEM crosstube and skidshoe mounting holes.
3. Open or slot any of the existing crosstube and skidtube holes that do not line up with the
DART skid extension.
4. Remove the skid extension.
5. To fill any gaps between the skid extension and the skidtube mating surfaces, apply sealant
(F/N 50) onto the skid extension and skidtube mating surface.
6. Install the skid extension assembly using OEM bolts and washers.
7. Seal all skid extension holes, openings, and gaps with RTV (F/N 7).

9.0 PULL CABLE AND RESERVOIR REMOVAL, TEST, OVERHAUL,

AND RIGGING
WARNING: A SAFETY PIN MUST BE INSTALLED IN THE RESERVOIR VALVE
ASSEMBLY PRIOR TO WORKING ON OR AROUND CYLINDERS OR
CABLES
9.1 PULL CABLE REMOVAL
1. Ensure that the safety pin is in place on the reservoir assembly (F/N 37) (Figure 37).
2. Remove the reservoir valve cover (Ref P/N 644.7113) by removing screws (Ref P/N
601.2383), washers (Ref P/N 601.1869), and nuts (Ref P/N 601.2384) (Figure 37).
3. Cut and remove the Ty-wrap (F/N 45) that is holding the pull cable adapter (Ref P/N
644.7112) to the pull cable assembly, F/N 38 (Figure 37).
4. Remove the bolts (F/N 39), washers (F/N 6), spacers (F/N 41), cable clamps (F/N 40), and
nuts (F/N 42) from the valve cover (Ref P/N 644.7113). If any hardware is worn, damaged,
or corroded, replace it (Figure 37).
5. Go to the lever assembly (F/N 43) and remove the hardware holding the loop clamp (Ref
P/N 601.2399) to the collective and cable clamps (Ref P/N 601.2390) holding cable (Figure
38).

.
Figure 37: Valve Pull Cable Removal and Installation
Figure 38: Lever Assembly Pull Cable Removal and Installation

Table 22: Parts List for Figure 37 & Figure 38

6 5 601.1869 Washer (NAS1149CN832R)
29 2 601.2487 Grommet (MS35489-17)
38 1 644.7501 Pull Cable Assembly (R44)
39 2 601.2490 Screw (MS27039C0811)
40 3 601.2390 Cable Clamp (AN742-D3)
41 2 601.2514 Spacer (NAS43DD3-10N)
42 2 601.1868 Nut (MS21043-08)
43 1 644.7401 Lever Assembly (R44)
44 1 601.2489 Grommet (MS35489-6)
45 2 600.0648 Ty-wrap
46 1 601.2263 Screw (MIL-5197-44)
REF 4 601.0774 Washer (NAS1149C0363R)
REF 4 601.0789 Nut (MS21043-3)
REF 4 601.1869 Washer (NAS1149CN832R)
REF 2 601.2383 Screw (MIL-51957-44)
REF 2 601.2384 Nut (MS35649)
REF 2 601.2388 Screw (MS51958-64)
REF 2 601.2390 Cable Clamp (AN742-D3)
REF 2 601.2399 Tube Clamp
REF 4 601.2421 Washer (NAS1149C0332R)
REF 2 601.2554 Screw (MS27039C1-11)
REF 1 601.7110 Valve Cover
REF 1 601.7112 Pull Cable Adaptor
9.2 PULL CABLE INSPECTION AND TESTING

1. After the pull cable is removed, lay the cable out straight and flat in a clean work area.
2. Check all pull cables for ease of movement. Discard any that show corrosion, kinks, or sharp
bends that could cause friction.
3. Bulges in the black outer coating may be a sign of corrosion. If the cable has cuts, tears, or
bulging in the outer coating, it must be replaced.

9.3 PULL CABLE INSTALLATION

1. Attach the ball terminal of the pull cable assembly (F/N 38) onto the pull cable adapter (Ref
P/N 644.7112). The pull cable adapter should already be over the dual ball pull cable (Ref
P/N 601.0991). If not, place the pull cable adapter over the ball end of the dual ball pull
cable.
2. Wrap Ty-wraps (F/N 45) over the pull cable adapter so that the ball terminals are set in
place within the pull cable adapter (Figure 37).
3. Attach the cable clamp sub-assembly with screws (F/N 39), washers (F/N 6), spacers (F/N
41), cable clamp (F/N 40), and locknut (F/N 42) (Figure 37).
4. Attach the pull cable housing (Ref P/N 644.7113) using screws (Ref P/N 601.2383),
washers (Ref P/N 601.1869), and nuts (Ref P/N 601.2384).
5. Go to the lever assembly (F/N 43) and attach the ball terminal of the pull cable assembly
(F/N 38) to the lever assembly handle.
6. Re-install hardware such as loop clamps, screws, washers, and nuts onto the collective
lever (Figure 38).
9.4 RESERVOIR REMOVAL
NOTE: The reservoir assembly is installed within the passenger side under-seat
compartment.
Figure 39 references the position of the reservoir assembly, F/N 37.
1. Remove the cylinder support cover assembly, F/N 31, from the cylinder neck support
assembly, F/N 30, by removing screws (F/N 46), washers (F/N 6), and nuts (F/N 42).
2. Lift the reservoir assembly (F/N 37) and slide it out of the cylinder mounting brackets.
3. Return the reservoir assembly to DART (or an approved service center) for overhaul and
testing. Before returning the helicopter to service, and during pre-flight, always verify that the
pressures indicated on the valve assembly fall within the acceptable range as shown on the
pressure chart located on the bottle (and in Figure 1).

Figure 39: Float Reservoir Assembly Installation
Figure 40: Reservoir Installation / Removal
NOTE: Δ = Underseat Bulkhead


6 4 601.1869 Washer (NAS1149CN832R)
30 1 644.7601 Cylinder Neck Support Assembly
31 1 644.7602 Cylinder Support Cover Assembly
32 1 644.7603 Cylinder Strap Support Assembly
33 2 644.7604 Cylinder Floor Support ASSY
34 4 601.0790 Rivet (CR3213-4-3)
35 12 601.1039 Rivet (CR3213-4-2)
37 1 644.7701 Reservoir Assembly (R44)
42 2 601.1868 Nut (MS21043-08)
46 2 601.2263 Screw (MIL-51957-44)
9.5 RESERVOIR INSTALLATION

1. Slide the reservoir assembly, (F/N 37), back into position as shown in Figure 40.
2. Refer to Section 9.3 for information about the installation of the pull cable assembly, F/N 38,
onto the reservoir assembly, F/N 37.

10.0 WEIGHT AND BALANCE

Table 24: 644.7001 Longitudinal Weight and Balance
644.7001 R44 Emergency Float Kit w/Extensions
Longitudinal Weight and Balance
Total
Weight Arm Moment
P/N Description QTY WT
(lbs) (in) (lb-in)
(lbs)
644.7301 Skid Extension Assembly LH 1 4.39 4.39 146.19 641.77
644.7302 Skid Extension Assembly RH 1 4.39 4.39 146.19 641.77
644.7202 FWD LH Float Assembly 1 7.02 7.02 60.44 424.29
644.7203 FWD RH Float Assembly 1 7.02 7.02 60.44 424.29
644.7204 Aft LH Float Assembly 1 6.97 6.97 146.85 1023.54
644.7205 Aft RH Float Assembly 1 6.97 6.97 146.85 1023.54
602.2615 Hose Assembly 2 0.51 1.02 107.07 109.21
602.2611 Hose Assembly 2 0.41 0.82 69.73 57.18
602.2610 Hose Assembly 1 0.34 0.34 56.56 19.23
644.7701 Reservoir Assembly 1 11.28 11.28 44.74 504.67
644.8201 Pull Cable Assembly 1 0.16 0.16 54.11 8.66
644.7401 Lever Assembly 1 0.16 0.16 48.82 7.81
N/A Miscellaneous Hardware 1 0.96 0.96 146.85 140.98
Weight Arm Moment
644.7001 Configuration Total 51.50 97.61 5026.92


Total
Weight Arm Moment
(lbs) (in) (lb-in)
(lbs)
602.2615 Hose Assembly 2 0.51 1.02 107.07 109.21
602.2611 Hose Assembly 2 0.41 0.82 69.73 57.18
602.2610 Hose Assembly 1 0.34 0.34 56.56 19.23
644.7401 Lever Assembly 1 0.16 0.16 48.82 7.81
Weight Arm Moment

644.7003 Alternate Reservoir Kit
Total
Weight Moment
P/N Description QTY WT Arm (in)
(lbs) (lb-in)
(lbs)
Weight Arm Moment
Total 0.24 48.79 11.71


644.7004 R44 Emergency Float Kit w/Extensions High Gear
Total
Weight Arm Moment
(lbs) (in) (lb-in)
(lbs)
644.7302 Skid Extension Assembly RH 1 4.39 4.39 146.19 641.77
602.2615 Hose Assembly 2 0.51 1.02 107.07 109.21
602.2617 Hose Assembly 2 0.51 1.02 69.73 71.12
602.2610 Hose Assembly 1 0.34 0.34 56.56 19.23
644.7401 Lever Assembly 1 0.16 0.16 48.82 7.81
Weight Arm Moment


644.7005 R44 Emergency Float Kit High Gear
Total
Weight Arm Moment
(lbs) (in) (lb-in)
(lbs)
602.2615 Hose Assembly 2 0.51 1.02 107.07 109.21
602.2617 Hose Assembly 2 0.51 1.02 69.73 71.12
602.2610 Hose Assembly 1 0.34 0.34 56.56 19.23
644.7401 Lever Assembly 1 0.16 0.16 48.82 7.81
Weight Arm Moment

Table 29: 644.7001 Lateral Weight and Balance

Lateral Weight and Balance
Total
Weight Moment
(lbs) (lb-in)
(lbs)
644.7302 Skid Extension Assembly RH 1 4.39 4.39 -41.65 -182.84
644.7203 FWD RH Float Assembly 1 7.02 7.02 -42.04 -295.12
644.7205 Aft RH Float Assembly 1 6.97 6.97 -41.78 -291.21
602.2615 Hose Assembly (LH) 1 0.51 0.51 39.67 20.23
602.2615 Hose Assembly (RH) 1 0.51 0.51 -39.67 -20.23
602.2611 Hose Assembly (LH) 1 0.41 0.41 20.32 8.33
602.2611 Hose Assembly (RH) 1 0.41 0.41 -20.32 -8.33
602.2610 Hose Assembly 1 0.34 0.34 6.69 2.27
644.7401 Lever Assembly 1 0.16 0.16 0 0.00
Weight Arm Moment


644.7002 R44 Emergency Float Kit
Total
Weight Moment
(lbs) (lb-in)
(lbs)
602.2615 Hose Assembly (LH) 1 0.51 0.51 39.67 20.23
602.2615 Hose Assembly (RH) 1 0.51 0.51 -39.67 -20.23
602.2611 Hose Assembly (LH) 1 0.41 0.41 20.32 8.33
602.2611 Hose Assembly (RH) 1 0.41 0.41 -20.32 -8.33
602.261 Hose Assembly 1 0.34 0.34 6.69 2.27
644.7401 Lever Assembly 1 0.16 0.16 0 0.00
Weight Arm Moment

644.7003 Alternate Reservoir Kit
Total
Weight Moment
(lbs) (lb-in)
(lbs)
644.7502 Pull Cable Assembly 1 0.21 0.21 -1.79 -0.38
N/A Miscellaneous Hardware 1 0.03 0.03 -5.56 -0.17
Weight Arm Moment
Total 0.24 -2.26 -0.54


644.7004 R44 Emergency Float Kit w/Extensions High Gear
Total
Weight Arm Moment
(lbs) (in) (lb-in)
(lbs)
644.7302 Skid Extension Assembly RH 1 4.39 4.39 -41.65 -182.84
602.2615 Hose Assembly (LH) 1 0.51 0.51 39.67 20.23
602.2615 Hose Assembly (RH) 1 0.51 0.51 -39.67 -20.23
602.2617 Hose Assembly (LH) 1 0.51 0.51 20.32 10.36
602.2617 Hose Assembly (RH) 1 0.51 0.51 -20.32 -10.36
602.261 Hose Assembly 1 0.34 0.34 6.69 2.27
644.7401 Lever Assembly 1 0.16 0.16 0 0.00
Weight Arm Moment


644.7005 R44 Emergency Float Kit High Gear
Total
Weight Arm Moment
(lbs) (in) (lb-in)
(lbs)
602.2615 Hose Assembly (LH) 1 0.51 0.51 39.67 20.23
602.2615 Hose Assembly (RH) 1 0.51 0.51 -39.67 -20.23
602.2617 Hose Assembly (LH) 1 0.51 0.51 20.32 10.36
602.2617 Hose Assembly (RH) 1 0.51 0.51 -20.32 -10.36
602.261 Hose Assembly 1 0.34 0.34 6.69 2.27
644.7401 Lever Assembly 1 0.16 0.16 0 0.00
Weight Arm Moment

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Released on 11/21/2019

PRINTED COPY OF THIS DOCUMENT IS FOR REFERENCE ONLY AND IS UNCONTROLLED

INSTRUCTIONS FOR CONTINUED

P/N 644.7001 R44 EMERGENCY FLOAT KIT W/

Document No.: ICA44-1 Rev. J

Name Title Date

Prepared by R. Takahashi Project Engineer II 10/28/19

Approved by J. Gardiner Senior Engineer 10/28/19

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Revision Date Pages Description Approval

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RECORD OF SERVICE BULLETINS

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LIST OF EFFECTIVE PAGES

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7.3 HOSE REINSTALLATION..................................................................................... 51

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Figure 34: Hose Removal – Hose Routing ............................................................................... 50

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1.7 GENERAL PRECAUTIONS

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Table 1: Float Characteristics

Table 2: Inflation Cylinder Characteristics

Table 3: Cover Characteristics

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2.0 AIRWORTHINESS LIMITATIONS

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3.0 INSPECTION REQUIREMENTS AND OVERHAUL SCHEDULE

-40 -20 0 20 40 60 80 100 120 140

Figure 1: Float Cylinder Pressure Limits

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3.1.2 18-MONTH INSPECTION

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5.0 PLACARDS AND LABELS

Figure 2: Placard F/N 48

Figure 3: Label Baggage F/N 57

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Figure 4: Label Baggage Limit F/N 58

Figure 5: Label Articles F/N 59

5.2 PLACARD LOCATION

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6.0 FLOAT AND COVER REMOVAL, CLEAN, TEST, OVERHAUL,

Figure 6: FWD Fairing Removal

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Figure 7: Float Removal / Installation – Float Positioning (1)

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Figure 8: Float Removal / Installation – Float Positioning (2)

Table 4: Parts List for Figure 7 and Figure 8

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