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Robinson R66 Helicopter Maintenance Manual

The R66 Maintenance Manual provides essential instructions for the maintenance, servicing, and handling of the R66 helicopter, including compliance with Service Bulletins and technical publications. It outlines authorization requirements for maintenance personnel and includes a comprehensive list of chapters covering various aspects of helicopter maintenance. Additionally, it emphasizes the importance of using current effective pages and provides contact information for customer support and technical publications.

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DANIEL EDUARDO MANNS SOSSA

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0% found this document useful (0 votes)

33 views950 pages

Robinson R66 Helicopter Maintenance Manual

Uploaded by

DANIEL EDUARDO MANNS SOSSA

We take content rights seriously. If you suspect this is your content, claim it here.

Available Formats

Download as PDF, TXT or read online on Scribd

R66 MAINTENANCE MANUAL

AND INSTRUCTIONS FOR CONTINUED AIRWORTHINESS

RTR 660 VOLUME I

Production Certificate Number 424WE

Type Certificate Number R00015LA

Robinson Helicopter Company Phone: (310) 539-0508

2901 Airport Drive Fax: (310) 539-5198
Torrance, California 90505-6115 Web: www.robinsonheli.com
United States 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 service directory.
Procure parts from any R66 Dealer or Service Center,
or order directly from RHC Customer Service via email, fax, or phone.

PUBLICATIONS
Please visit www.robinsonheli.com to view our publications electronically.

APR 2019 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 APR 2019

CHAPTER LIST

Introduction
Chapter 1 General
Chapter 4 Airworthiness Limitations
Chapter 5 Inspections
Chapter 6 Dimensions and Descriptions
Chapter 7 Jacking and Hoisting
Chapter 8 Weight and Balance
Chapter 9 Ground Handling
Chapter 10 Parking and Storage
Chapter 11 Placards and Markings
Chapter 12 Servicing
Chapter 18 Track and Balance
Chapter 20 Standard Practices
Chapter 21 Environment Control
Chapter 22 Autopilot
Chapter 25 Furnishings
Chapter 28 Fuel System
Chapter 29 Hydraulics
Chapter 32 Landing Gear
Chapter 33 Lights
Chapter 52 Doors and Windows
Chapter 53 Fuselage
Chapter 62 Main Rotor
Chapter 63 Main Rotor Drive System
Chapter 64 Tail Rotor
Chapter 65 Tail Rotor Drive System
Chapter 67 Flight Controls
Chapter 71 Powerplant
Chapter 75 Engine Air Systems
Chapter 76 Engine Controls
Chapter 79 Engine Oil System
Chapter 90 Police Version
Chapter 92 E.N.G. Version
Chapter 95 Instrument System
Chapter 96 Electrical System
Chapter 97 Avionics
Chapter 98 Wiring Diagrams
Chapter 99 Special Tools
Chapter 100 Revision Log

JUL 2020 Introduction Page iii

Intentionally Blank

Page iv Introduction JUL 2020

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

Date: Publication:
Name: Chapter:
Company: Section:
Helicopter Model: Page:
Serial Number: Revision:
Phone:
Email:

COMMENTS:

APR 2017 Introduction Page v

Intentionally Blank

Page vi Introduction APR 2017

CHAPTER 1

GENERAL

Section Title Page

1-00 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1

1-10 R66 Maintenance Manual Revisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1
1-20 R66 Maintenance Authorization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
1-30 Component Maintenance Authorization . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
1-40 Maintenance Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
1-50 Notations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
1-55 Maintenance Manual and Illustrated Parts Catalog References . . . . . . . . . . . . 1.3
1-60 Definitions and Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
1-70 Service Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4B
1-71 Part Designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4B
1-72 Returning Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4B
1-73 Ordering and Shipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4B
1-74 Warranty Claims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4B
1-75 Customer Service Directory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4B
1-80 Assembly Instructions for R66 Helicopter Crated for Export . . . . . . . . . . . . . 1.5
1-90 Helicopter Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11
1-91 Scheduled Maintenance and Inspections . . . . . . . . . . . . . . . . . . . . . . . . 1.11
1-92 Additional Component Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12

JUL 2020 Chapter 1 General Page 1.i

Intentionally Blank

Page 1.ii Chapter 1 General JUL 2020

CHAPTER 1

GENERAL

1-00 Introduction
The R66 Maintenance Manual contains instructions necessary for proper maintenance,
servicing, and handling of the R66 helicopter. The R66 Instructions for Continued
Airworthiness (ICA) includes the R66 Maintenance Manual (MM), R66 Illustrated Parts Catalog
(IPC), R66 Service Bulletins (SB), R66 Service Letters (SL), RR300 Series Operation and
Maintenance Manual (OMM), applicable Rolls-Royce technical publications, and applicable
component manufacturer technical publications.
Service Bulletins are issued by Robinson Helicopter Company (RHC), Rolls-Royce, 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. Rolls-Royce technical publications are available online at
https://fast.aeromanager-online.com.
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
instructions issued by RHC either implement approved type design data, or are approved
as type design data.
The R66 Maintenance Manual is formatted in Air Transport Association of America
Specification No. 100 (ATA-100). Style, content, and structure deviates from ATA-100
when necessary for clarity, and for logic of presentation. A list of chapters and a complete
list of contents is located in the Introduction. Chapters are separated by tab dividers and
chapter contents are listed in the chapter front pages.

CAUTION
Always read instructions completely before performing a task.

1-10 R66 Maintenance Manual Revisions

Before using the R66 Maintenance Manual, verify it consists of current effective pages.
The list of effective pages is located in the Revision Log in Chapter 100. When a new
manual is purchased, complete and submit the Subscription Order 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.

APR 2019 Chapter 1 General Page 1.1

1-20 R66 Maintenance Authorization
Only appropriately certificated mechanics who have successfully completed an R66
factory-sponsored maintenance course, or are under direct supervision of the above-
stated mechanic, are authorized to perform maintenance, repairs, or inspections on the
R66 helicopter. Annual inspections of U.S.-registered light helicopters must be performed
by holders of an Inspection Authorization (IA) certificate 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 R66 Pilot’s Operating Handbook
and applicable aviation regulations.

1-30 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.

1-40 Maintenance Record

The Airframe Maintenance Record is available online at www.robinsonheli.com.
Airframe Maintenance Record blank PDF forms may be used for R22-series, R44-series,
and R66 Turbine helicopters. Component Record blank PDF forms may be used for life-
limited or TBO components. Blank paper copies are available for purchase (P/N R8478
Airframe Maintenance Record and P/N R8479 Component Record [pack of 20]).
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.
RHC’s 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 APR 2019

1-50 Notations
The following notations will be found throughout the manual:

NOTE
A NOTE provides emphasis or supplementary explanation.
CAUTION
Equipment damage can result if a CAUTION is not followed.
WARNING
Personal injury or death can result if a WARNING is not followed.

1-55 Maintenance Manual and Illustrated Parts Catalog References

Maintenance Manual and Illustrated Parts Catalog Section and Figure references are subject
to relocation and renumeration. 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.

APR 2019 Chapter 1 General Page 1.3

1-60 Definitions and Abbreviations
Refer to R66 Pilot's Operating Handbook (POH) Section 1 for additional definitions and
abbreviations.
A. Definitions
14 CFR § 27.602 A part identified as a 14 CFR § 27.602 critical part within this
Critical Part: manual is subject to special inspection requirements. 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 § 6-20 for R66 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 R66 Turbine Type Certificate Data Sheet
(TCDS) in § 4-30. Refer to Equipment List/Weight and Balance
Data Sheet (RF 134) and Weight and Balance Record in R66 POH
Section 6 for installed equipment.
Life-Limited Part: Refer to § 4-10. 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.

Page 1.4 Chapter 1 General APR 2019

1-60 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
CRA: Component Return/Authorization
ELT: Emergency Locator Transmitter
EMU: Engine Monitoring Unit
FCU: Fuel Control Unit
FS: Fuselage Station locations
GCU: Generator Control Unit
HID: High Intensity Discharge
HS: Horizontal Stabilizer Station locations
ICA: Instructions for Continued Airworthiness
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
PTG: Power Turbine Governor
R66 IPC: R66 Illustrated Parts Catalog
R66 MM: R66 Maintenance Manual
R66 POH: R66 Pilot’s Operating Handbook
RBL: Right Butt Line Station locations
RH: Right-hand
RHC: Robinson Helicopter Company
RR300 Series OMM: Rolls-Royce RR300 Series Operation and Maintenance Manual
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

JUL 2020 Chapter 1 General Page 1.4A

1-70 Service Information

1-71 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). Similarly, part numbers F049-6 and F049-06
are not interchangeable because the dash numbers are different.

1-72 Returning Parts

All parts shipped to RHC must include a signed Component Return/Authorization (CRA)
Form available online at www.robinsonheli.com.

1-73 Ordering and Shipping

Procure parts from any R66 Dealer or Service Center, or order directly from assigned RHC
Customer Service Representative via email, fax, or phone.

1-74 Warranty Claims

Complete CRA Form (refer to § 1-72) 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.

1-75 Customer Service Directory

Please visit www.robinsonheli.com for a complete service directory.

Page 1.4B Chapter 1 General JUL 2020

1-80 Assembly Instructions for R66 Helicopter Crated for Export

NOTE

Aircraft assembly to be performed by a certificated mechanic.

1. Remove top of cabin assembly crate. Remove wall marked “A” by removing lag bolts
painted black. Remove empennage assembly. Remove remaining walls. Remove all
parts, except cabin assembly, from crate base. Open crate containing blades, skid tubes,
and tailcone.
2. Refer to R66 Illustrated Parts Catalog (IPC) Figure 32-1. Install hardware securing forward
and aft strut assemblies (cross tubes installed) onto skid tubes. Standard torque bolts per
Section 20-32 and torque stripe per Figure 5-1.
3. Remove tailcone cowling per Section 53-23. Remove engine cowling per Section 53-21.
4. Remove shipping supports (ty-raps, foam, tape, etc.) from main rotor gearbox compartment,
but leave cannon plugs taped and fluid line dust caps installed. Remove engine air intake
cover by opening air filter bypass door and pulling string and cover through the door.
Remove main rotor gearbox mounting hardware, nylon spacers, and upper frame strut
assemblies.
5. Remove top of main rotor gearbox crate and position crate so gearbox is upright. Refer
to Section 7-20. Install hoisting equipment and lifting fixture or nylon rope on main
rotor hub. Remove hoist slack to support gearbox, remove lag bolts securing gearbox to
wooden divider, and carefully hoist gearbox from crate (do not damage pitot tube).
6. Install main rotor gearbox per Section 63-20 steps 1 thru 9, but do not remove hoisting
equipment and lifting fixture or nylon rope.
7. Perform (engine driveline) forward flex plate shimming per Section 63-11.
8. Refer to Section 7-20. Remove hoist slack to support cabin assembly, remove lag and
carriage bolts securing metal angles to crate, and hoist cabin & attached metal angles off
of crate base.

CAUTION

Do not lift helicopter and attached crate using main rotor hub;
damage to main rotor gearbox and frames could result.

9. Remove metal angles from cabin assembly landing gear attach points. Install landing gear
assembly per Section 32-10.

SEP 2012 R66 Maintenance Manual Chapter 1 General Page 1.5

FIGURE 1-1 ASSEMBLY INSTRUCTIONS FOR R66 HELICOPTER CRATED FOR EXPORT

FIGURE 1-2 ASSEMBLY INSTRUCTIONS FOR R66 HELICOPTER CRATED FOR EXPORT

Page 1.6 Chapter 1 General R66 Maintenance Manual SEP 2012

1-80 Assembly Instructions for R66 Helicopter Crated for Export (continued)

10. For air-conditioned ships:

a. Refer to Figure 1-1. Remove shipping supports (ty-raps, foam, tape, etc.) from G777-
1 compressor assembly. Install hardware securing G782-1 mount weldment to main
rotor gearbox. Standard torque hardware per § 20-32 and torque stripe per Figure
5-1. Hook B774-3 spring in drilled hole of NAS1352-4H14 screw. Verify security.
b. Refer to Figures 1-1 and 1-2. Verify B173-5 v-belt is in good condition. Fit belt around
G779-1 pulley and compressor pulley, and install hardware securing compressor to
G782-1 mount weldment. Standard torque bolts per § 20-32.
c. Refer to Figure 1-2. Install hardware securing compressor to G781-1 arm weldment.
Rotate compressor up and outboard to tension belt, then tighten hardware securing
compressor to weldment. Verify belt is properly aligned on both pulleys. Adjust belt
tension until 4.5-5.5 lb of force applied mid-span deflects belt 0.16-inch. Standard
torque bolts per § 20-32.
d. Connect compressor assembly wiring to airframe harness at connectors and install
ty-raps as required. Cinch ty-raps until snug without over-tightening, and trim tips
flush with heads.
11. Refer to IPC Figure 79-1. Remove F237-1 tailcone frame weldment and F305-5 (aft)
inlet. Install tail rotor drive fan shaft (fanwheel installed) through scroll assembly. Install
hardware securing aft inlet to scroll assembly. Verify security.
12. Refer to IPC Figure 65-1. Install hardware securing C947-3 plate assembly to F908-1
yoke and tail rotor drive fan shaft. Standard torque bolts and palnuts per § 20-32 and
torque stripe per Figure 5-1.
13. Remove shipping supports (ty-raps, foam, tape, etc.) from tailcone assembly, and install
tailcone per Section 53-40 steps 1 thru 7. Install strobe light. Install communication and
GPS antennas (if equipped).
14. Install empennage assembly per § 53-50. Install aux stabilizer assembly per § 53-52.
15. Service tail rotor gearbox per § 12-21. Service main rotor gearbox per § 12-11.
16. Remove hydraulic reservoir shipping plug. Install D487-3 vent assembly, special torque
vent to 100 in.-lb, and torque stripe per § Figure 5-1 (do not safety wire).
17. Install tail rotor assembly per § 64-10. Match color-coded markings on blades with pitch
links.
18. Install main rotor blades per § 62-10. Match color-coded markings on blades with
markings on hub and pitch links.
19. Inside engine compartment, remove anti-ice valve cap, starter-generator cap, inducer
bleed hose cover, exhaust pipe cover and desiccant, and combustion case drain valve
cap. Connect inducer bleed hose to box assembly and tighten clamp. Verify security.

MAY 2015 Chapter 1 General Page 1.7

1-80 Assembly Instructions for R66 Helicopter Crated for Export (continued)

20. If ship is equipped with attitude horizon, directional gyro, turn coordinator, and/or vertical
card magnetic compass:
A. Attitude Horizon, Directional Gyro, and Turn Coordinator Installation

CAUTION

Directional gyro mount screws must not exceed 1-inch in length.

1. Place a piece of foam under instrument face. Remove (6) screws securing face
to console and gently pull face forward. Remove hardware securing instrument
hole covers to face and remove covers. Install instruments and secure to face
with hardware provided.
2. Connect straight connector(s) to directional gyro and/or turn coordinator. Connect
angle connector to attitude horizon, ensuring strain relief points down. Ensure
connectors lock. Ty-rap excess wiring. Install screws securing instrument face
to console.
B. Vertical Card Magnetic Compass Installation
1. Locate airframe wiring (in windshield center bow), install 2-inch length of B158-3
heat shrink over wiring, and connect compass pins to airframe sockets (polarity
is not critical). Slide heat shrink over connection and apply heat. Install (4)
screws securing compass to mount, securing wiring atop compass.
21. Connect battery per § 96-10.

NOTE

Check battery open circuit voltage and perform boost charging

or capacity tests as required per Concorde Battery Instructions
for Continued Airworthiness.

22. Perform pitot-static leak check per § 95-10.

23. Install Emergency Locator Transmitter (ELT) per § 25-61, as required. Install tailcone
cowling assembly per § 53-23.
24. Install fire extinguisher per § 25-62, as required.
25. Fuel helicopter per § 12-41.
26. Verify all shipping supports (ty-raps, foam, tape etc.) have been removed from helicopter.
Refer to § 6-70. Secure access panels and inspection doors.

NOTE

Flight checks to be performed by a qualified pilot and certificated

mechanic.

27. Perform ground check per § 5-41 steps 2 thru 9.

Page 1.8 Chapter 1 General MAY 2015

1-80 Assembly Instructions for R66 Helicopter Crated for Export (continued)
28. Depreserve the engine after storage per RR300 Series Operation and Maintenance Manual
(OMM). Install starter-generator cooling hose. Install engine cowling per § 53-21.
29. Install tail rotor dynamic balance equipment per § 18-21.
30. Perform run-up per § 5-42 steps 2 thru 16.
31. Perform tail rotor dynamic balance per § 18-20.
32. Remove tail rotor dynamic balance equipment. Install main rotor balance equipment
per § 18-11.

CAUTION
Mast fairing, cowlings, and panels must be installed for flight.

33. Perform hover checks per § 5-43 step 1. DO NOT proceed into forward flight.
34. Track and balance main rotor per § 18-12.
35. While climbing at maximum continuous torque, 60 KIAS:
a. Evaluate vibration level and controllability.
b. Perform momentary 30° left yaw to check for adequate directional control.
36. Level flight at 2000 feet density altitude (deviate as required for weather and terrain),
maximum continuous torque:
a. Evaluate longitudinal and lateral cyclic control forces.
b. Evaluate collective control forces.
37. Evaluate vibration level at maximum continuous torque and straight-and-level flight.
38. During autorotation at 50 KIAS and 90% rotor RPM, perform momentary 30° right
yaw to check for adequate directional control.
39. Check all instruments, gages, and avionics for proper operation.

JUL 2020 Chapter 1 General Page 1.9

First 100 Hours*

3000 Cycles**
TABLE 1 SCHEDULED INSPECTIONS

1000 Hours**
2000 Hours**

12 Months**
24 Months**
100 Hours**
200 Hours**
300 Hours**
400 Hours**
600 Hours**

Annually***

12 Years**
15 Years**
3 Years**
5 Years**
6 Years**
Consult latest revision of listed
publications for specific applicability.

Replace main gearbox oil filter per § 12-12. • •

Perform 100-hour / annual inspection per § 5-45. • •

Perform main rotor blade tip maintenance per §

•
62-60.

As required by RR300 Series Operation and

Maintenance Manual (OMM), perform maintenance • • • • •
and inspection.

Service inlet barrier filter per § 71-21. • •

Replace main gearbox oil per § 12-11. •

Drain and flush tail rotor gearbox per § 12-23. •

Replace hydraulic filter per § 12-32. •

Clean gearbox chip detectors per § 12-13 & 12-22. • •

Lubricate swashplate bearings per § 12-90. • •

Perform 2000-hour inspection per § 5-50. •

Perform main gearbox internal visual inspection per

•
§ 5-74.

Inspect emergency locator transmitter (ELT) per 14

•
CFR § 91.207.

Perform pop-out float leak check per § 32-64 Part A. •

Test and inspect transponder per 14 CFR §

•
91.413.

Perform pop-out float inflation check per § 32-64

•
Part B.

Peform pop-out float pressure cylinder hydrostatic

•
test.

Perform 12-year inspection per § 5-55. •

Pop-out float pressure cylinder maximum life. •

* One-time maintenance after new or overhauled main rotor gearbox is installed.

** Recurring inspection not to exceed given interval.
*** See § 1-60 Definitions and Abbreviations.

Page 1.10 Chapter 1 General JUL 2020

1-90 Helicopter Servicing

1-91 Scheduled Maintenance and Inspections

Required maintenance and inspection intervals are given in Table 1. Publications listed
are subject to revision.
Also consult the following for specific applicability, as some aircraft may require
maintenance and inspections in addition to the requirements in Table 1:
• Aircraft maintenance records
• Manufacturers' 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.

JUL 2020 Chapter 1 General Page 1.11

1-92 Additional Component Maintenance

NOTE
RHC-manufactured parts not listed in § 1-92 as requiring
additional component maintenance, or replacement per § 4-30,
are "on condition".

A. 12 YEARS
Remove the following components when they have accumulated 12 years time in
service and less than 2000 hours time in service since new, since last overhaul, or
since last 12-year maintenance, and perform action indicated:

Part Number Description Action

A120-5 Bellcrank – Aft Replace with new.
A785-36 Hose (engine gearbox vent; earlier Install KI-258 Firewall Drain Tube Upgrade
ships) Kit.
A785-37 Hose (inducer bleed) Replace with new.
A785-38 Hose (starter-generator) Replace with new.
A918-1 thru Elastic Cord Assembly Replace with new. Dash number is selected
-8, -19, & -20 during flight test evaluation.
B173-5 V-Belt – Compressor Drive (cabin air Replace with new.
conditioning)
C005-4 Main Rotor Hub (C154-1) & Perform inspection and repair per § 62-22,
Bearing Assembly return to RHC for inspection and repair, or
replace with new.
C005-13 Main Rotor Blade and Spindle Submit to RHC-authorized component
Assembly maintenance facility for 12-year
maintenance, or replace with new or
overhaul exchange. 12-year maintenance
includes blade replacement, boot and o-ring
replacement, spindle bearing replacement
(as required), pitch horn screw replacement
(as required), boot and o-ring replacement,
and inspection.
C008-10 Tail Rotor Assembly Replace with new.
C017-6 Swashplate Assembly Perform 12-year inspection per § 5-52, or
replace with new or overhaul exchange.
C021-1 Tail Rotor Gearbox Assembly Replace input seal & o-ring, and output
seal & o-ring, per § 65-40. During seal
replacement, visually inspect exposed
portion of bearings for corrosion; replace
gearbox if corrosion is evident.
C031-1 Tail Rotor Pitch Control Replace with new.
C258-1 Main Rotor Pitch Link Assembly Replace with new C258-5 link assembly.
C258-5 Main Rotor Pitch Link Assembly Perform inspection per § 5-51, or replace
with new.

Page 1.12 Chapter 1 General JUL 2020

1-92 Additional Component Maintenance (continued)

1-92 Additional Component Maintenance (continued)
C. Engine Maintenance
Refer to RR300 Operation and Maintenance Manual (OMM) for engine maintenance.
Prepare engine for Rolls-Royce maintenance facility per § 71-11 as required.
D. Airframe and Engine Accessory Maintenance
Refer to accessory manufacturer’s instructions for continued airworthiness for
accessory maintenance. Remove accessories per R66 Maintenance Manual or
RR300 Operation and Maintenance Manual (OMM) as applicable.

JUL 2020 Chapter 1 General Page 1.17

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Page 1.18 Chapter 1 General JUL 2020

CHAPTER 4

AIRWORTHINESS LIMITATIONS

Section Title Page

4-10 Life-Limited Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1

4-11 Time-in-Service Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1
4-12 Fatigue Life-Limited Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
4-20 Type Certificate Data Sheet (TCDS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
4-30 Airworthiness Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9

JUL 2020 Chapter 4 Airworthiness Limitations Page 4.i

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Page 4.ii Chapter 4 Airworthiness Limitations JUL 2020

CHAPTER 4

AIRWORTHINESS LIMITATIONS

4-10 Life-Limited Components

4-11 Time-In-Service Records

It is the operator’s responsibility to maintain a record of time in service for the engine,
airframe, and all life-limited components, as well as the number of start cycles for the
engine. Two hourmeters are provided: the hourmeter on the console records all run
time including ground idle and is provided for reference. The hourmeter located outboard
of the pilot's seat is collective-activated and records run time only when the collective
is raised off the down stop. Both hourmeters are connected to main rotor gearbox oil-
pressure switch. The collective-activated hourmeter may be used to determine time in
service for maintenance purposes, including time in service for all life-limited components.
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 § 10-20, 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.
Engine life is limited by engine time in service and accumulated start cycles. The engine
is equipped with an electronic Engine Monitoring Unit (EMU), which may be used to verify
time in service and accumulated start cycles. An official, independent record of start
cycles must be maintained by the operator.
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.

JUL 2020 Chapter 4 Airworthiness Limitations Page 4.1

4-12 Fatigue Life-Limited Parts
The Airworthiness Limitations Section (ref. § 4-30) lists the mandatory replacement
schedule for fatigue life-limited parts.
If a part is fatigue life-limited or has a mandatory overhaul requirement and is interchanged
between an R44 and an R66 helicopter, and if the part life-limit or overhaul requirement
is different between an R44 and an R66 helicopter, the shorter life-limit or overhaul
requirement must be used. If a part is fatigue life-limited or has a mandatory overhaul
requirement, and the accumulated cycles and/or time in service are known but the
helicopter type is unknown, the shorter life-limit or overhaul requirement must be used.
Listed items (ref. § 4-30) must be removed from the helicopter at the specified intervals
and permanently retired from service, preferably by destroying or damaging each part so
it cannot inadvertently be returned to service.

4-20 Type Certificate Data Sheet (TCDS)

The Robinson R66 Type Certficate Data Sheet (TCDS) reprinted on the following pages is
subject to revision.
Visit the FAA Aircraft Certification Regulatory and Guidance Library to determine TCDS
revision status at: http://rgl.faa.gov.

Page 4.2 Chapter 4 Airworthiness Limitations JUL 2020

DEPARTMENT OF TRANSPORTATION
FEDERAL AVIATION ADMINISTRATION

R00015LA
Revision 3
Robinson
R66
August 17, 2018

TYPE CERTIFICATE DATA SHEET NO. R00015LA

This data sheet, which is a part of Type Certificate No. R00015LA, prescribes conditions and limitations under which
the product for which the type certificate was issued meets the airworthiness requirements of Title 14,
Code of Federal Regulations.

Type Certificate Holder: Robinson Helicopter Company

2901 Airport Drive
Torrance, California 90505

I. Model R66 (Normal Category Rotorcraft), Approved October 25, 2010

Engine One Rolls-Royce 250-C300/A1, Type Certificate number E4CE

Fuel Jet A or Jet A-1 conforming to ASTM D 1655

Jet B conforming to ASTM D 6615
JP-4 or JP-5 conforming to MIL-DTL-5624
JP-8 conforming to MIL-DTL-83133

Engine Limits Power Ratings at N2 speed of 6016 rpm (100% rpm):

Maximum continuous: 224 hp (83% Torque)
Takeoff (5 minute): 270 hp (100% Torque)
Maximum speeds:
Output shaft (N2): 101% (6076 rpm)
Gas producer shaft (N1): 105% (53519 rpm)
Maximum Measured gas temperature:
During start: 927° C (10 second limit above 782°C)
5 minute during operation: 782° C
Continuous during operation: 706° C

Rotor Speed Minimum Maximum Limits

Condition ( rpm* ) (%) ( rpm* ) (%)
Power On 404 99 412 101
Power Off 359 88 432 106
* Main Rotor

Transmission Torque Max Torque at 100% N2 Limits

Rating
( ft-lb ) (%)
Takeoff (5 min) 236 100
Max Continuous 196 83

Page No. 1 2 3 4 5
Rev. No. 3 3 3 3 3

JUL 2020 Chapter 4 Airworthiness Limitations Page 4.3

R00015LA Page 2 of 5

Airspeed Limits Takeoff Power On VNE Power Off VNE

Gross Weight or
( KIAS ) ( KIAS )
Configuration
Less than 2200 lb 140 100
2200 lb to 2700 lb
Or Police Version
(any Gross Weight)
Or with Pop-out 130 100
Floats (Floats
Stowed, any Gross
Weight)
Electronic News
Gathering Version 120 100
(any Gross Weight)

Sea level VNE values shown above. For reduction of VNE with altitude and
temperature, see R66 Pilot’s Operating Handbook and FAA Approved Rotorcraft
Flight Manual (RTR 661).
Airspeed limit is 65 KIAS for power settings above 83% torque.
Airspeed limit is 100 KIAS for any combination of doors off.
See R66 Pilot’s Operating Handbook and FAA Approved Rotorcraft Flight
Manual (RTR 661) for additional airspeed limitations associated with optional
equipment installations.

Center of Gravity (C.G.) Range Longitudinal C.G.

Gross
Forward
Weight Aft Limit
Limit
( lb ) ( in ) ( in )
1400 91.0 102.5
2300 102.5
2500 91.0
2700 92.0 98.0
Lateral C.G.
Longitudinal
Right
C.G. Left Limit
Limit
( in ) ( in ) ( in )
91.0 -3.5 +3.5
100.0 -3.5 +3.5
102.5 -2.5 +2.5
Notes:
1. Straight line variation between points shown
2. Lateral C.G. limits valid for all gross weights
3. See R66 Pilot’s Operating Handbook and FAA Approved Rotorcraft
Flight Manual (RTR 661) for expanded limits with external load.

Empty Weight C.G. Range None. The aircraft’s empty weight and empty weight C.G. must be determined
by the procedures in Chapter 8 of the R66 Maintenance Manual, RTR 660.

Datum 100 inches forward of main rotor centerline.

Leveling Means For weight and balance: Level placed laterally and longitudinally on aft tunnel
cover immediately forward of aft middle seat. If cover is not straight, use keel
panel upper flanges, accessed by removing aft tunnel cover.

Page 4.4 Chapter 4 Airworthiness Limitations JUL 2020

Page 3 of 5 R00015LA

For rigging: Level placed on top of main rotor hub parallel with teeter bolt. Main
rotor blades are aligned fore-aft for lateral levelling, and teeter bolt is aligned fore-
aft for longitudinal levelling.

Maximum Weight No External Load: 2700 lb

With External Load: 2900 lb (See Note 8 for external load limitations)

Minimum Crew 1 pilot in forward right seat. See R66 Pilot’s Operating Handbook and FAA
Approved Rotorcraft Flight Manual (RTR 661) for configurations that allow 1
pilot in forward left seat.

Number of Seats 5 (4 for Police and Electronic News Gathering versions)

Seat Locations Pilot and forward occupant at STA 49.0 in

Aft outboard occupants at STA 80.0 in
Aft center occupant at STA 78.0 in

Maximum Compartment Main baggage compartment

Weights Maximum weight is 300 lb at STA 107.0 in
Maximum weight is 250 lb at STA 103.0 in for Police and Electronic News
Gathering versions
Maximim weight is 100 lb at STA 117.0 in with auxiliary fuel tank installed
Maximum loading density is 50 lb/ft2
Underseat baggage compartments
Forward seats – Maximum weight is 50 lb at STA 42.0 in
Rear seats – Maximum weight is 50 lb at STA 82.0 in
Note: For any seat location, the maximum combined weight of the load on the
seat (e.g., occupant) plus the weight of stowed items and any installed
equipment in the underseat baggage compartment is 300 lb.
Fuel Capacity Fuel tank capacity is 74.6 U.S. gallons
Usable fuel quantity is 73.6 U.S. gallons at STA 102.5 in
Note: Aircraft empty weight includes 1.0 U.S. gallon of unusable fuel.

Oil Capacities Component Capacity (qt) STA ( in )

Engine 6 126.0
Main Rotor Transmission 2 100.0
Tail Rotor Transmission 0.11 327.0
Hydraulic Reservoir 0.65 110.8

Maximum Operating Altitude 14,000 feet Density Altitude.

Maximum altitude above ground level is 9,000 ft.

JUL 2020 Chapter 4 Airworthiness Limitations Page 4.5

R00015LA Page 4 of 5

Rotor Blade and Control For rigging information refer to the Robinson R66 Maintenance Manual and
Movements Instructions for Continued Airworthiness (RTR 660).

Manufacturer’s Serial Numbers 0002 and subsequent.

Certification Basis 14 CFR part 27, dated February 1, 1965, as amended by Amendment 27-1 through
Amendment 27-44.
Equivalent Safety Finding:
Number AT14992LA-R-S-1
14 CFR part 27.695(a)(1), Power boost and power-operated control system.
(see Note 7)
Special Condition:
No. 27-035-SC Robinson Model R66 Helicopter, Sec. 27.1309, Installation of
HeliSAS Autopilot and Stabilization Augmentation System (AP/SAS).
14 CFR Part 36, dated December 1, 1969, as amended by Amendment 36-1
through Amendment 36-28.
Compliance with the ditching requirements of § 27.801 was not demonstrated.
Compliance with the ice protection requirements of § 27.1419 was not
demonstrated.
The R66 is approved for day and night VFR operations only.
TC Application Date: September 06, 2006.
TC Issue Date: October 25, 2010.

Production Basis Production Certificate No. 424WE dated October 25, 2010.

Equipment The basic required equipment as prescribed in the applicable airworthiness

regulations (see Certification Basis) must be installed in the aircraft for
certification. In addition, the following FAA-approved Rotorcraft Flight Manual
is required:

R66 Pilot’s Operating Handbook and FAA Approved Rotorcraft Flight Manual
(RTR 661), dated October 25, 2010, or later approved revision.

GENERAL NOTES

NOTE 1. A current weight and balance report, including a list of equipment included in the certificated empty
weight, and loading instructions when necessary, must be provided for each aircraft at the time of
original airworthiness certification and at all times thereafter, except in the case of operators having
an approved weight control system.

NOTE 2. The following placard must be installed in clear view of the pilot:
“THIS ROTORCRAFT APPROVED FOR DAY AND NIGHT VFR OPERATIONS”
For additional placards, see the Rotorcraft Flight Manual. All placards required in the Rotorcraft
Flight Manual must be installed in the appropriate locations.

NOTE 3. Information essential to the proper maintenance of the helicopter, including retirement time of
critical components, is contained in the Robinson R66 Maintenance Manual and Instructions for
Continued Airworthiness (RTR 660). Retirement times are listed in the “AIRWORTHINESS
LIMITATIONS” section.

Page 4.6 Chapter 4 Airworthiness Limitations JUL 2020

Page 5 of 5 R00015LA

NOTE 4. Deleted as of March 10, 2015.

NOTE 5. Any cockpit instruments installed by a 3rd party must be marked with limit markings and range
markings in accordance with Robinson’s marking scheme.

NOTE 6. Deleted as of March 10, 2015.

NOTE 7. Exemption No. 9589, dated January 28, 2008, has been removed since Robinson Helicopter
Company was granted an Equivalent Level of Safety (ELOS) finding to CFR §27.695(a)(1), Number
AT14992LA-R-S-1, dated February 20, 2013. The exemption allowed a powered flight control
system without considering the jamming of a control valve as a possible single failure. There is no
impact to R66 helicopters that have been delivered or are in service.

NOTE 8. R66 helicopters equipped with the G132 Cargo Hook installation may be operated at up to 2900
pounds gross weight when the portion above 2700 pounds is jettisonable load on the cargo hook and
the helicopter is operating at or below 7000 feet density altitude. See Cargo Hook Supplement to
R66 Pilot’s Operating Handbook and FAA Approved Rotorcraft Flight Manual (RTR 661) for
additional operating limitations.

--- END ---

JUL 2020 Chapter 4 Airworthiness Limitations Page 4.7

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Page 4.8 Chapter 4 Airworthiness Limitations JUL 2020

4-30 Airworthiness Limitations
The Airworthiness Limitations Section is FAA approved and specifies inspections and other
maintenance required under 14 CFR §§ 43.16 and 91.403, unless an alternative program
has been FAA approved.

R66 Fatigue Life-Limited Parts

Part Number Description Maximum Service Life
C023-21, -24, -34, & -35 . . . . Tailcone Assembly . . . . . . . . . . . . . . . . . . . . . 2000 Hours
C044-1 & -2 . . . . . . . . . . . . . . Horizontal Stabilizer . . . . . . . . . . . . . . . . . . . . 2000 Hours
C154-1 . . . . . . . . . . . . . . . . . . Main Rotor Hub . . . . . . . . . . . . . . . . . . . . . . . 2000 Hours
C158-1 . . . . . . . . . . . . . . . . . . Main Rotor Spindle . . . . . . . . . . . . . . . . . . . . . 2000 Hours
C251-3 . . . . . . . . . . . . . . . . . . Main Rotor Shaft . . . . . . . . . . . . . . . . . . . . . . 2000 Hours
C545-1 . . . . . . . . . . . . . . . . . . Gear Set, Tail Gearbox . . . . . . . . . . . . . . . . . . 2000 Hours
C545-2 . . . . . . . . . . . . . . . . . . Pinion, Tail Gearbox . . . . . . . . . . . . . . . . . . . . 2000 Hours
C647-12 . . . . . . . . . . . . . . . . . Bearing Set, Swashplate . . . . . . . . . . . . . . . . 2000 Hours
D079-1 . . . . . . . . . . . . . . . . . . Tail Rotor Guard . . . . . . . . . . . . . . . . . . . . . . . 2000 Hours
D196-1 . . . . . . . . . . . . . . . . . . Tail Rotor Drive Shaft . . . . . . . . . . . . . . . . . . . 2000 Hours
F016-2 . . . . . . . . . . . . . . . . . . Main Rotor Blade . . . . . . . . . . . . . . . . . . . . . . 2000 Hours or 12 years1
F020-1 . . . . . . . . . . . . . . . . . . Upper Frame . . . . . . . . . . . . . . . . . . . . . . . . . 2000 Hours
F029-1 & -2 . . . . . . . . . . . . . . Tail Rotor Blade . . . . . . . . . . . . . . . . . . . . . . . 2000 Hours or 12 years1
F143-1 . . . . . . . . . . . . . . . . . . Pinion, Main Gearbox . . . . . . . . . . . . . . . . . . . 2000 Hours
F146-1 . . . . . . . . . . . . . . . . . . Pinion, Main Gearbox . . . . . . . . . . . . . . . . . . . 2000 Hours
F195-1 . . . . . . . . . . . . . . . . . . Yoke, Tail Rotor Drive Shaft . . . . . . . . . . . . . . 2000 Hours
F235-13 . . . . . . . . . . . . . . . . . Strut, Upper Frame . . . . . . . . . . . . . . . . . . . . . . . . . . 2000 Hours
F252-1 . . . . . . . . . . . . . . . . . . Strut, Upper Frame . . . . . . . . . . . . . . . . . . . . . . . . . . 2000 Hours
F263-1 . . . . . . . . . . . . . . . . . . Housing, Main Gearbox . . . . . . . . . . . . . . . . . 2000 Hours
F270-1 . . . . . . . . . . . . . . . . . . Cartridge, Main Gearbox . . . . . . . . . . . . . . . . . . . . . . 2000 Hours
G062-2 . . . . . . . . . . . . . . . . . . Tail Rotor Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2000 Hours
G201-1 . . . . . . . . . . . . . . . . . . Frame, Servo Support . . . . . . . . . . . . . . . . . . 2000 Hours
G950-2 . . . . . . . . . . . . . . . . . . Stabilizer, Pop-out Floats . . . . . . . . . . . . . . . . 800 Hours
1
Whichever limit occurs first. Calendar time starts on date of original RHC-issued Airworthiness Approval.

Approved By: Date:

Manager, Federal Aviation Administration
Los Angeles ACO Branch, AIR-790

FAA Approved: This page constitutes the Airworthiness Limitations Section in its entirety,
is considered segregated from the rest of the document, and sets forth the FAA-approved
mandatory replacement times for fatigue life-limited parts.

JUL 2020 Chapter 4 Airworthiness Limitations Page 4.9

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Page 4.10 Chapter 4 Airworthiness Limitations JUL 2020

CHAPTER 5

INSPECTIONS
Section Title Page

5-10 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1

5-20 [Reserved] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1
5-30 General Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1
5-31 Ball and Roller Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1
5-32 Push-Pull Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
5-33 Rod Ends and Spherical Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
5-34 Elastomeric Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5
5-35 Telatemp Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6
5-36 Torque Stripes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7
5-40 Operation Checks for 100-Hour/Annual Inspection . . . . . . . . . . . . . . . . . . . . . 5.8
5-41 Ground Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8
5-42 Run-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9B
5-43 Flight Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11
5-45 100-Hour/Annual Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.13
5-50 2000-Hour/12-Year Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.39
5-51 C258-5 Main Rotor Pitch Link Assembly Inspection . . . . . . . . . . . . . . . . . . 5.39A
5-52 Swashplate Assembly 12-Year Inspection . . . . . . . . . . . . . . . . . . . . . . . . 5.39B
5-53 Landing Gear Assembly 12-Year Inspection . . . . . . . . . . . . . . . . . . . . . . . 5.39C
5-54 Hydraulic Reservoir 12-Year Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 5.39D
5-60 Special Maintenance and Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.41
5-61 Tail Skid Strike . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.41
5-62 Tail Rotor Strike . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.42
5-63 Main Rotor Strike . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.43
5-64 Rotor/Engine Overspeed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.44
5-65 Hard Landing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.47
5-66 Dye Penetrant Inspection of F020-1 Upper Frame . . . . . . . . . . . . . . . . . . . 5.48
5-67 Corrosion on F020-1 Upper Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.48
5-68 Main Rotor Gearbox Overtemp Illumination . . . . . . . . . . . . . . . . . . . . . . . . 5.48
5-69 Main Rotor Gearbox (MR) Chip Light Illumination . . . . . . . . . . . . . . . . . . . . 5.49
5-70 Tail Rotor Gearbox (TR) Chip Light Illumination . . . . . . . . . . . . . . . . . . . . . 5.49
5-71 Main Rotor Gearbox Filter Bypass Indicator . . . . . . . . . . . . . . . . . . . . . . . . 5.49
5-72 Lightning Strike . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.50
5-73 Pop-Out Float-Equipped Helicopter Water Landing with Tail Rotor Contact . . 5.50
5-74 Main Rotor Gearbox Internal Visual Inspection . . . . . . . . . . . . . . . . . . . . . 5.51

JUL 2020 Chapter 5 Inspections Page 5.i

CHAPTER 5

INSPECTIONS (Continued)
Section Title Page

5-75 Inspection After Stabilizer Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.52

Page 5.ii Chapter 5 Inspections JUL 2020

CHAPTER 5

INSPECTIONS

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

5-20 [Reserved]

5-30 General Procedures

Unless otherwise specified, the following general procedures apply to R66 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.

5-31 Ball and Roller Bearings

The first indication of bearing failure is usually an increase in bearing noise. Noise will
almost always start several hours prior to bearing failure. Listen to drive system during
start-up and shutdown. 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.
Monitor bearings for increase in temperature, but do not rely on Telatemps to detect failing
bearings as temperature increase may occur only seconds before bearing disintegrates.

JUL 2020 Chapter 5 Inspections Page 5.1

FIGURE 5-1 ROD END AND SPHERICAL BEARING PLAY LIMITS AND TORQUE STRIPE APPLICATION

Position rod ends for maximum rotation

FIGURE 5-2 ROD END CENTERING

Page 5.2 Chapter 5 Inspections JUL 2020

5-32 Push-Pull Tubes
1. Nicks, cuts, or scratches in tube not more than 0.010 inch deep and not more than
1/4 of tube circumference may be polished out in lengthwise direction using 320-grit
or finer wet-or-dry abrasive paper to 1 inch minimum blend radius. Replace push-pull
tube if depth exceeds these limits.
2. Replace push-pull tube if tube is dented or flattened more than 5% of its diameter in
unswaged area; dents or flattening is not permitted in swaged (tapered and threaded)
ends of tubes.

5-33 Rod Ends and Spherical Bearings

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. Refer to Figure 5-1 for maximum rod end extension when no witness
hole is provided.
4. Rod end jam nuts and palnuts must be torqued per § 20-32 and torque striped per
Figure 5-1 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. Refer to Figure 5-2. Rod ends must be centered, or positioned, to allow as much push-
pull tube or link rotational movement as possible without binding.

CAUTION
Teflon-lined bearings must not be lubricated or solvent cleaned.
WARNING
Assembly of flight controls is critical and requires inspection
by a qualified person. If a second person is not available,
RHC recommends the installer take a 5-minute break prior to
inspecting flight control connections he has assembled.

JUL 2020 Chapter 5 Inspections Page 5.3

Elastomer Fatigue Elastomer Oil Contamination

Elastomer Overload

FIGURE 5-3 ELASTOMERIC BEARING DAMAGE

Page 5.4 Chapter 5 Inspections JUL 2020

5-34 Elastomeric Bearings
Refer to Figure 5-3. Elastomeric bearings are used in the G062-1 tail rotor hub assembly.
Fatigue, oil contamination, or overload can degrade the elastomer.
Small surface cracks (fatigue cracks) and elastomer dust or “eraser crumbs” are normal
and are not cause for replacement. As cracks grow, enough elastomer will be lost to
cause reduced stiffness and increased vibration. Replace bearing if crack is deeper than
0.10 inch or cracks are present over more than 25% of elastomer face.
Avoid elastomer exposure to oil, grease, hydraulic fluid, cleaning solvent, and rust-
preventative fluids. Immediately wash off contaminants with detergent and water.
Replace a contaminated bearing that exhibits swelling, wavy edges, or debonding.
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 clean cracks or extrusions
from elastomer.
Elastomer may also separate (debond) from metal bushings. Replace bearing if separation
exceeds 25% of bonded area.

JUL 2020 Chapter 5 Inspections Page 5.5

5-35 Telatemp Indicators
Refer to Figure 5-4. Self-adhesive Telatemp indicators record increases in operating
temperatures of the hydraulic pump and tail rotor gearbox. To use a Telatemp, draw a
reference line between the highest temperature square which has darkened during normal
operation and the next undarkened square. 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
F110-3 82°C / 180°F — 110°C / 230°F
F110-4 104°C / 220°F — 132°C / 270°F

FIGURE 5-4 TELETEMP INDICATOR WITH DRAWN REFERENCE LINE

Page 5.6 Chapter 5 Inspections JUL 2020

5-36 Torque Stripes
If, during inspection, the remaining torque stripe on a fastener is insufficient to determine
joint integrity, then remove accompanying palnut as required and apply specified torque
to fastener. If fastener moves, disassemble joint and inspect parts for damage such as
fretting, thread deformation, hole elongation, etc.; replace damaged parts. If fastener
does not move, install new palnut as required & standard torque per § 20-32. Torque
stripe fastener per § 20-31.

JUL 2020 Chapter 5 Inspections Page 5.7

5-40 Operation Checks for 100-Hour / Annual Inspection
Complete the following checklists in conjunction with 100-hour / annual inspection. Note
and correct any discrepancies.

5-41 Ground Check (aircraft not running)

1. Twist Grip:
Verify twist grip smooth rotation without binding in full up and full down
collective position. Verify over center spring holds twist grip full open or
closed.
2. Fuel Cutoff Valve:
Verify smooth actuation without binding. Verify proper function of lock button.
3. Collective Control:
Verify proper operation through full control travel with and without friction
applied. With friction off, verify approximately one-half inch total free
play before encountering hydraulic resistance. Verify normal hydraulic
resistance throughout remainder of control travel. With friction on, verify
increased resistance but no binding or locking of control. Verify power
turbine governor rigging as follows:
a. Turn battery switch on. With collective full down, hold beep
switch actuator all the way down. Have a second person
verify the PTG reads approximately 45°.
b. With collective full down, hold beep switch actuator all
the way up. Have a second person verify the PTG reads
approximately 65°. Return actuator to nominal position.
Turn battery switch off.
4. Cyclic Control:
With friction off, verify approximately one-half inch total longitudinal and one
inch total lateral free play before encountering hydraulic resistance. Verify
normal hydraulic resistance throughout remainder of control travel. With
friction on, verify increased resistance but no binding or locking of control.
5. Tail Rotor Pedals:
Verify smooth actuation without binding. Verify proper pedal position for
pilot and locking pin security.
6. Removable Controls (if installed):
Verify proper operation and locking pin security.

Page 5.8 Chapter 5 Inspections JUL 2020

5-41 Ground Check (continued)

7. Lighting, Instruments, and Audio Alerts: (Turn battery switch on.)

ANNUNCIATOR PANEL AND ROTOR BRAKE LIGHTS

a. MR TEMP PRESS segment illuminates.

b. ENGINE OIL segment illuminates.
c. GEN segment illuminates.
d. LOW RPM segment illuminates.
e. HYD segment illuminates (if hydraulic switch is OFF; later
helicopters).
f. COWL DOOR segment illuminates when fuel filler cowl door or
baggage door is not closed. On later helicopters, the COWL
DOOR segment also illuminates when an engine cowl door is
not closed.
g. ROTOR BRAKE segment illuminates (if rotor brake is applied).
h. All annunciator panel segments illuminate when test button is
depressed (segments below have additional behaviors):
i. LOW FUEL and <12 GAL FUEL segments take
approximately two seconds before they illuminate
due to a time delay in circuit. If LOW FUEL segment
illuminates immediately after test button depress,
a fault is indicated.
ii. EMU segment will illuminate only when test button
is depressed. EMU segment takes approximately
10 seconds to perform self-test after battery is
switched ON before it will illuminate.
INSPECTION LIGHTING

a. Left side cowl door – verify LEDs illuminate main rotor gearbox
and hydraulic reservoir sight gages when cowl door is open
(battery switch on or off).
EXTERIOR LIGHTING

a. Position lights – check function.

b. Anti-collision light – check function.
c. Landing lights – check function.

JUL 2020 Chapter 5 Inspections Page 5.9

5-41 Ground Check (continued)

7. Lighting, Instruments, and Audio Alerts (continued): (Turn battery switch on.)
INTERIOR LIGHTING
a. Panel lighting & dimmer control – check function (position lights
must be illuminated to enable panel lighting and dimmer control).
b. Map light – check function.
c. Digital voltmeter – indicates approximately 24 volts.
d. Oil temperature gage – slight needle deflection with engine cold.
e. Fuel quantity gage – indication of fuel level.
AUDIO ALERTS (Later helicopters; verify tone in headset)
a. High rotor RPM: a high/low "warble" tone will sound when test
button is depressed (five times per second).
b. High engine torque/MGT: a beeping tone will sound when test
button is depressed (four beeps per second for two seconds
followed by 12 beeps per second).
(Turn battery switch off.)
8. Aircraft Documents:
(Additional documents may be required in countries other than the US.)
a. Inspect condition and verify R66 MT699-1 laminated pilot's
checklist is current revision. Check revision status online at:
www.robinsonheli.com.
b. Inspect condition and verify R66 Pilot’s Operating Handbook
is current revision and contains correct Equipment List/Weight
& Balance Data. Check revision status online at: www.
robinsonheli.com.
c. Verify airworthiness certificate onboard & matches helicopter S/N.
d. Verify registration certificate onboard & matches helicopter S/N
and all registration markings.

Page 5.9A Chapter 5 Inspections JUL 2020

5-42 Run-Up

1. Clean engine gas path, if required, per RR300 Series Operation and
Maintenance Manual (OMM).
2. Perform Pilot's Operating Handbook (POH) Section 4 “Preflight” checklist.
3. Perform POH Section 4 “Before Starting Engine” checklist.
4. Prior to start, verify rotor brake locks out starter.
5. Prior to start, review the Cautions and Notes in POH Section 4 “Starting
Engine and Run-Up”.
6. Perform POH Section 4 “Starting Engine and Run-Up” checklist.
7. Once stabilized idle is reached, disconnect ground power and switch
generator ON. Verify ammeter shows non-zero generator load and GEN
light out. Verify aircraft voltmeter reads 28.0 to 29.0 volts and calibrated
voltmeter indicates 28.2 to 28.8 volts. When complete, disconnect
calibrated voltmeter.
8. Switch generator OFF. Verify GEN annunciator illuminates, voltmeter
reading decreases but remains at or above 24 volts, and ammeter decreases
to zero.
9. Switch battery and generator OFF. Verify dual tachometer continues to
function, then switch battery and generator back ON. Ensure avionics
master switch is OFF, and depress annunciator panel Test button. Both
sides of dual tachometer should drop to off-scale low indication while
button is depressed.
10. With avionics master switch OFF, verify generator continues to supply
power with battery OFF (instruments continue to function, voltmeter
reading remains steady), then switch battery back ON.
11. Switch avionics master ON, and turn on avionics. Once avionics are on,
verify avionics master controls power to all avionics by switching OFF
then back ON.
12. Perform annunciator panel test with avionics master ON. Verify all
segments illuminate. Verify dual tachometer continues to function during
test.
13. Open collective twist grip (throttle) to flight position and allow RPM to
stabilize. Set N2 RPM to 100%. N2 and rotor tach needles must be
within 1% of point-to-point.
14. Beep RPM full down and verify N2 RPM is 98% or lower. Attempt to
beep RPM full up, but DO NOT exceed 105%. Verify N2 at full beep up
is 102% to 104%. Beep N2 back to 100%.

JUL 2020 Chapter 5 Inspections Page 5.9B

5-42 Run-Up (continued)

15. Transmit on 118.0, 125.0, and 135.0 MHz. Verify no variation in dual
tachometer readings during transmission.
16. Briefly operate the heater at 100% N2 to ensure system functions and is
clear of debris.
17. Check engine anti-ice system. Green anti-ice indicator should illuminate
accompanied by small MGT increase when anti-ice is switched ON.
18. Raise collective slightly, reduce N2 RPM slowly via twist grip. Verify low
RPM horns and light activate at 95% to 94% and continue at all lower
RPMs.
19. Perform engine N1 DECELERATION CHECK per Section 4 of the Pilot’s
Operating Handbook. (With N2/R at 100% and N1 at 80%, N1 decel to
70% following rapid throttle closure should take at least 2 seconds.)
20. Check hydraulic system operation. Using cyclic-mounted hydraulics switch,
turn hydraulics OFF and verify HYD light on (if equipped). Using small
longitudinal cyclic inputs, there should be approximately one-half inch of
freeplay before encountering stiffness and feedback. Turn hydraulics ON.
Controls should be free with no feedback or uncommanded motion. Pull
hydraulic circuit breaker, and verify that hydraulics remain on regardless
of cyclic hydraulic switch position. Reset system to breaker in, hydraulics
switch ON.
21. Air conditioning (if installed): Verify system blows cold air on both low
and high settings. Verify no EMI/RFI with other instruments and systems.
After a flight with air conditioning on, verify water drains from drain tube
in ship’s belly (may be little or no water in very dry conditions).

Page 5.10 Chapter 5 Inspections JUL 2020

5-43 Flight Check

1. Hover:
a. Verify normal gage indications.
b. Verify controllability in left and right pedal turns.
c. Verify hydraulic system zeros cyclic stick forces.
d. Evaluate vibration levels; if unacceptable, measure imbalance
and correct.
2. Level Flight:
Conduct at typical cruise altitude (weather permitting) and maximum
continuous torque. Loading to typical operating conditions or nominal
weight and CG in middle of envelope will provide the most useful evaluation.
a. Verify tail rotor pedal position when yaw string is centered.
Right pedal 0.25 to 0.75 inch forward of left pedal.
b. Verify tail rotor elastic trim cord zeros pedal forces (cord
applies left pedal force).
c. Verify hydraulic system zeros cyclic stick forces and collective
is balanced with no feedback.

d. Verify acceptable control forces (feedback) with hydraulics

off.
e. Evaluate vibration levels; if unacceptable, measure imbalance
and correct.

JUL 2020 Chapter 5 Inspections Page 5.11

5-43 Flight Check (continued)

3. Power Assurance Check:

Refer to R66 Pilot's Operating Handbook (POH) Chapter 5 power assurance
chart. Conduct at typical cruise altitude (weather permitting) and maximum
continuous torque (83%). Turn heater, generator, and anti-ice switches
OFF. Stabilize N2/R at 100% (beep as required) and record the following
values:
a. N1
b. % Torque (83% nominal)
c. OAT
d. MGT
e. Pressure altitude
f. Oil pressure
g. Oil temperature
h. Determine max allowable MGT from power assurance chart.
i. Calculate margin. Margin = Max allowable MGT - Indicated
MGT.
4. Autorotation:
a. Autorotate at 100 KIAS. Verify normal control forces and
flying characteristics.
5. Shutdown:
a. Perform POH “Shutdown Procedure” checklist.
b. Verify rotor brake function and ROTOR BRAKE annunciator
segment illuminates.

Page 5.12 Chapter 5 Inspections JUL 2020

5-45 100-Hour / Annual Maintenance and Inspection

RHC recommends retaining a copy of the most recently performed 100-hour / annual checklist
with the aircraft’s maintenance records to meet the requirement of 14 CFR § 91.417 (b)(1).

R66 Serial No.: Technician Name:

Registration No.:
Collective-Activated
(Time In Service) Technician
Hourmeter Indication: Certificate Number:
Helicopter Total
Time In Service:
A. Preparation
Operation Checks:
Perform ground and flight checks per § 5-40.
Cleaning (required by 14 CFR Part 43, Appendix D, paragraph (a)):
Note any fluid leakage before cleaning. Clean main and tail rotor blades, hubs,
and airframe exterior with a mild soap and water solution per Chapter 20.

CAUTION
Do not spray main rotor hub, tail rotor gearbox vent, hydraulic
reservoir vent, swashplate area, or bearing seals with high-
pressure water or solvent as water or solvent may cause
corrosion or breakdown of lubricants. See RR300 Series
Operation and Maintenance Manual (OMM) for engine cleaning
instructions and precautions.

Access and Inspection Panels:

Refer to R66 Illustrated Parts Catalog Chapter 6 for access and inspection panel
locations. Remove or open necessary panels, doors, covers, fairings, and cowlings
in accordance with 14 CFR Part 43, Appendix D, paragraph (a).

NOTE
If radio antennas are installed on removed panels, disconnect
antenna lead and corresponding ground wire. Pull respective
radio circuit breaker and tag circuit breaker with “Antenna
Removed.”
CAUTION
Instrument console removal (§ 95-50) is not required for
scheduled inspections. Sufficient access for inspection is gained
by removing the chin inspection panel, as well as removal of
installed avionics, as required (refer to Chapter 97).

JUL 2020 Chapter 5 Inspections Page 5.13

5-45 100-Hour / Annual Inspection (continued)

B. Inspection

CABIN FORWARD FOOTWELLS

Tail Rotor Pedal Bearing Blocks:

Remove pedal bearing block covers as required. Examine accessible portion with
inspection light and mirror. Inspect condition. Check for looseness or play in
pedal bearings. Maximum allowable play is 0.080 inch axially and 0.030 inch
radially. Verify bearing block security.
Adjustable Tail Rotor Pedals:
Inspect condition. Verify no cracks in welds. Verify locking pins engage holes to
secure adjustable pedals. Verify proper operating clearance and smooth actuation.
Co-Pilot Removable Tail Rotor Pedals:
Inspect condition. Verify no cracks in welds. Verify locking pins engage holes to
secure removable pedals. Verify proper operating clearance and smooth actuation.
Cabin Heater Diffusers:
Inspect condition. Verify marking legibility. Verify no significant nicks, scratches
or dents, or cracks in welds. Verify security.
Fire Extinguisher and Mount:
Inspect condition. Inspect fire extinguisher per manufacturer’s instructions.
Verify no loss of charge or obstructions in extinguisher nozzle. Verify security.
Map Holders:
Inspect condition. Verify no defects, tears, or material deterioration. Remove
foreign objects and verify security.
License Holder:
Inspect condition. Verify no defects, cracks in plastic, or material deterioration.
Verify security.
Cabin Chin and Floor:
Inspect condition. Verify equipment security. Retrieve and discard trapped debris.
CONSOLE

Console Assembly:
Inspect condition. Verify no significant nicks, scratches or dents; verify no cracks,
corrosion, or loose rivets in lower console assembly. Verify hinge security.
HID Landing Lights:
Inspect condition. Verify proper installation and security of wiring and equipment.
Flight & Engine Instruments:
Inspect condition. Verify proper instrument markings per R66 POH Section 2.
Verify proper installation and security of wiring and equipment.

Page 5.14 Chapter 5 Inspections JUL 2020

5-45 100-Hour / Annual Inspection (continued)

CONSOLE (continued)

Post Lights:
Inspect condition. Verify proper function and equipment security.
Fuel Cutoff Control and Guard:
Inspect condition. Verify cable and mounting bezel security. Verify proper adjustment
and smooth operation of knob. Verify guard is attached to console.
Radios and Radio Trays:
Inspect condition. Verify no cracks or corrosion. Verify proper installation and
security of wiring and equipment.
Pitot & Static Lines:
Inspect pitot and static lines for obstructions, cracking, chafing, pinching or kinking.
Verify integrity of pitot and static line connections. Verify line security.
Tail Rotor Pedal Bearing Block Supports:
Examine accessible portion with inspection light and mirror. Inspect both vertical sheet
metal supports inside lower console and verify no cracks. Pay particular attention to
area near NAS6603-13 bolts. Replace any cracked support prior to flight.
Tail Rotor Controls:
Examine accessible portion with inspection light and mirror. Inspect tail rotor control
components for obvious defects. Verify operating clearance.
Cabin Heater Hose:
Inspect condition. Verify no collapsed areas or chafing. Verify hose clamp and hose
security.
Copper Bus Bars:
Inspect condition. Verify no corrosion or bends in bus bar. Verify bus bar security and
isolation from surrounding structure.
Wiring:
Inspect condition. Verify no loose, chafed, or broken wires or terminals. Verify
neatness, proper routing and installation, and security.
Fasteners & Torque Stripes:
Inspect condition. Verify proper installation and security of fasteners. Renew
deteriorated torque stripes per Figure 5-1.
Close & Secure:
Verify foreign objects are removed. Verify equipment security and cleanliness of
interior. Close console and verify security.

APR 2017 Chapter 5 Inspections Page 5.15

5-45 100-Hour / Annual Inspection (continued)

PILOT-SIDE CONSOLE (Optional equipment)

Pilot Avionics Support Weldment:

Inspect condition. Verify no significant nicks, scratches, or dents on console shell.
Verify no cracks in welds. Verify weldment mounting security.
CIRCUIT BREAKER PANEL

CAUTION
Ensure BATTERY switch is turned off while circuit breaker panel
is open.
Panel Cover:
Inspect condition. Verify no damage to nutplates and rails in panel interior. Verify
marking legibility.
Fuses and Fuse Holders:
Inspect condition. Verify security and no corrosion. Verify correct fuse installation.

Circuit Breakers:
Inspect condition. Check airworthiness directive applicability. Verify proper
installation and security.
Copper Bus Bars:
Inspect condition. Verify no corrosion or bends in bus bars. Verify bus bar security
and isolation from surrounding structure.
Wiring:
Inspect condition. Verify no loose, chafed, or broken wires or terminals. Verify
neatness, proper routing and installation, and security.
Fasteners & Torque Stripes:
Inspect condition. Verify proper installation and security of fasteners. Renew
deteriorated torque stripes per Figure 5-1.
Close & Secure:
Verify foreign objects are removed. Verify equipment security. Verify cleanliness of
interior and of access cover. Close cover and verify security.
UNDER LEFT FRONT SEAT

Lithium-Ion Battery Circuit Back-Up Batteries (required with optional Lithium-ion main
battery):
Inspect condition. Verify presence and proper orientation of (2) 9V back-up batteries.
Verify security of battery trays and G468-1 mount assembly. Verify legibility of
silkscreen lettering on mount. Inspect wiring for obvious damage.

Page 5.16 Chapter 5 Inspections APR 2017

5-45 100-Hour / Annual Inspection (continued)

HORIZONTAL CONTROL TUNNEL (Front seats; continued)

Covers:
Inspect condition. Verify marking legibility.
Antenna Wiring & Connectors:
Inspect condition. Verify no loose, chafed, frayed, or broken wires. Verify no
damaged connectors. Verify neatness, proper routing and installation, and security.
Cyclic Box Assembly:
Inspect condition. Verify no nicks, scratches, dents, cracks, corrosion, or loose
rivets. Verify no distortion or damage on cyclic stop sheet metal assembly. Verify
security.
Cyclic Stick Assembly:
Inspect condition. Verify no nicks, scratches, dents, cracks, or corrosion. Verify no
cracks in welds. Verify security, proper operating clearance, and smooth actuation.
Verify security of co-pilot control and locking pin.
Cyclic Boot:
Inspect condition. Verify proper locking function of boot snaps. Verify no defects,
tears, or material deterioration. Verify security.
Cyclic Friction Assembly:
Inspect condition. Inspect link rod end bearings per § 5-33. Verify no excessive flaring
at either end of friction spacer. Verify proper installation, security, and operation.
Cyclic Pivot:
Inspect condition. Verify no nicks, scratches, dents, cracks, or corrosion. Inspect
spherical bearings per § 5-33. Verify proper installation, security, and operating
clearance.

APR 2017 Chapter 5 Inspections Page 5.16A

Intentionally Blank

Page 5.16B Chapter 5 Inspections APR 2017

5-45 100-Hour / Annual Maintenance and Inspection [5 of 26 Pages]

HORIZONTAL CONTROL TUNNEL (Front seats; continued)

Cyclic Horizontal Torque Tube:

Examine accessible portion with inspection light and mirror. Verify no nicks, scratches,
dents, cracks, or corrosion. Verify no cracks around reinforcement blocks on both
ends of torque tube. Verify proper installation, security, and operating clearance.
Horizontal Push-Pull Tubes:
Examine accessible portion with inspection light and mirror. Inspect condition per §
5-32. Verify no nicks, scratches, chafing, dents, cracks, or corrosion. Inspect rod
end bearings per § 5-33; verify rod ends are centered and palnut and jam nut are
tight. Check witness holes for proper thread engagement. Verify proper installation,
security, and operating clearance.
Collective Stick Assembly:
Inspect condition. Verify no nicks, scratches, dents, cracks, or corrosion. Verify
no cracks in welds. Verify proper installation, security, and operation of collective
micro switches. Verify security, proper operating clearance, and smooth actuation
of both flight and throttle controls. Verify over center spring holds twist grip full
open or full closed. Verify placard legibility.
Collective Stick Torque Tube:
Inspect condition. Verify no nicks, scratches, dents, cracks, or corrosion.
Collective Boot:
Inspect condition. Verify proper locking function of boot snaps. Verify ty-rap is
properly installed (loosely securing boot around collective stick). Verify no defects,
tears, or material deterioration. Verify security.
Fuel Valve Knob and Guard:
Inspect condition. Verify cable and mounting bezel security. Verify proper adjustment
and smooth operation of valve. Verify guard is present.
Collective Friction & Stop Assembly:
Inspect condition. Verify no nicks, scratches, dents, cracks, or corrosion in stop
assembly. Verify no bending or binding of stop through full control travel, with
and without friction applied. Measure collective friction per § 67-22. Verify proper
installation and security of collective friction lever and stop assembly.
Co-Pilot Removable Collective Stick Assembly:
Remove co-pilot collective stick assembly. Inspect condition. Verify no nicks,
scratches, dents, cracks, or corrosion. Verify no damage to spring pin and safety
wire at coupling. Firmly grasp coupling and rotate twist grip in each direction with
opposite hand. Verify no free play of coupling or spacer relative to torque tube. Install
removable collective stick in helicopter and verify both locking pins engage holes to
secure stick. Verify security, proper operating clearance, and smooth actuation of
both flight and throttle controls. Verify placard legibility.
Co-Pilot Removable Collective Boot:
Inspect condition. Verify proper locking function of boot snaps. Verify ty-rap is
properly installed (loosely securing boot around collective stick). Verify no defects,
tears, or material deterioration. Verify security.

MAY 2015 Chapter 5 Inspections Page 5.17

5-45 100-Hour / Annual Maintenance and Inspection [6 of 26 Pages]

HORIZONTAL CONTROL TUNNEL (Front seats; continued)

Pitot & Static Lines & Drains:

Inspect pitot and static lines for obstructions, cracking, chafing, pinching, or kinking.
Remove drain plugs from tee fittings in each line and clear any moisture from system.
Install drain plugs. Verify integrity of pitot and static line connections. Verify line security.
Wiring:
Inspect condition. Verify no loose, chafed, or broken wires or terminals. Verify
neatness, proper routing and installation, and security.
Fasteners & Torque Stripes:
Inspect condition. Verify proper installation and security of fasteners. Renew
deteriorated torque stripes per Figure 5-1.
Antennas:
Inspect condition. Verify no cracks where antennas mount to cowling. Verify security.
Close & Secure:
Verify foreign objects are removed. Verify equipment security. Verify cleanliness of
interior and of inspection and access covers and cowlings. Connect ELT (if installed)
wiring at connectors and anti-ice switch wiring terminals under cyclic box cover.
Connect antenna leads and ground wires (if installed). Install covers and cowlings
removed in preceding steps. Verify security. Verify security of removable and
adjustable controls. Fasten cyclic, collective, and removable collective boot snaps.
HORIZONTAL CONTROL TUNNEL (Aft seats)

Covers:
Inspect condition. Verify marking legibility.
Antenna Wiring & Connectors:
Inspect condition. Verify no loose, chafed, frayed, or broken wires. Verify no
damaged connectors. Verify neatness, proper routing and installation, and security.
Cyclic Yoke:
Inspect condition. Verify no cracks, corrosion, or fretting. Inspect spherical bearings
per § 5-33. Verify proper installation, security, and operating clearance.
Cyclic Fork:
Inspect condition. Verify no nicks, scratches, dents, cracks, or corrosion. Inspect rod
end bearings per § 5-33. Verify proper installation, security, and operating clearance.
Cyclic Horizontal Torque Tube:
Examine accessible portion with inspection light and mirror. Verify no nicks, scratches,
dents, cracks, or corrosion. Verify no cracks around reinforcement blocks on both
ends of torque tube. Verify proper installation, security, and operating clearance.
Horizontal Push-Pull Tubes:
Examine accessible portion with inspection light and mirror. Inspect condition per §
5-32. Verify no nicks, scratches, chafing, dents, cracks, or corrosion. Inspect rod
end bearings per § 5-33; verify rod ends are centered and palnut and jam nut are
tight. Check witness holes for proper thread engagement. Verify proper installation,
security, and operating clearance.

Page 5.18 Chapter 5 Inspections MAY 2015

5-45 100-Hour / Annual Inspection (continued)

HORIZONTAL CONTROL TUNNEL (Aft seats; continued)

Fuel Cutoff and Throttle Control:
Inspect condition. Verify proper fuel cutoff and throttle control clearance to installed
equipment and surrounding structure. Verify proper installation and security.
Cabin Heater Valve and Control:
Inspect condition. Verify control clearance to installed equipment and surrounding
structure. Verify heater valve security. Verify proper installation and smooth
operation of valve.
Flight Control Bellcranks:
Inspect condition. Verify no nicks, scratches, dents, cracks, or corrosion. Inspect
spherical bearings per § 5-33. Verify proper installation, security, and operating clearance.
Bellcrank Support:
Inspect condition. Verify no cracks or corrosion in welds. Verify no cracks where
support mounts to keel panels. Verify proper installation and security.
Evaporator and Blower Assembly (Air Conditioning; if installed):
Remove middle seat assembly and cover, and inspect condition. Verify refrigerant
line security, no damage, and clearance to adjacent structure. Verify no loose,
chafed, frayed, or broken wires. Verify proper installation and security of blower
and evaporator components.
Evaporator Drain Tubes and Valve (Air Conditioning; if installed):
Remove middle seat assembly and cover, and covers inside left and right seat
compartments to access drain system. Verify tubes are unobstructed. Function-
check drain system by simultaneously squeezing drain tube and sediment tube near
tee-fitting and verify check-valve ball moves up momentarily.
VERTICAL CONTROL TUNNEL
Vertical Push-Pull Tubes:
Examine accessible portion with inspection light and mirror. Inspect condition per §
5-32. Verify no nicks, scratches, chafing, dents, cracks, or corrosion. Inspect rod
end bearings per § 5-33; verify rod ends are centered and palnut and jam nut are
tight. Check witness holes for proper thread engagement. Verify proper installation,
security, and operating clearance.
Beep Switch Actuator:
Inspect condition. Verify proper control clearance to installed equipment and
surrounding structure. Verify proper actuator installation, security, and operation.
Tunnel Interior:
Verify general cleanliness of tunnel interior. Inspect for fluid leaks or seepage;
investigate cause and correct.
Seat Backs:
Inspect condition. Verify upholstery cleanliness and security.

JUL 2020 Chapter 5 Inspections Page 5.19

5-45 100-Hour / Annual Inspection (continued)

CABIN BULKHEAD
Blind Encoder & Engine Monitoring Unit (EMU):
Inspect condition. Inspect wiring for obvious damage. Verify no cracks where units
mount to bulkhead. Verify proper installation and security. Download EMU data as
required per RR300 Series OMM.
Fuse Block and Fuses (Air Conditioning; if installed):
Inspect condition. Verify no corrosion. Verify correct fuse amperage and security.
Antenna Wiring:
Inspect condition. Verify no loose, chafed, frayed, or broken wires. Verify neatness,
proper routing and installation, and security. Check grommets for proper installation.
Pitot & Static Lines:
Inspect pitot and static lines for obstructions, cracking, chafing, pinching, or kinking.
Verify integrity of pitot and static line connections. Verify line security.
Seat Back Interior:
Verify general cleanliness of seat back interior. Inspect for fluid leaks or seepage;
investigate cause and correct.
Fuel Flow Meter Adapter (if installed):
Refer to § 28-23. Visually inspect adapter for any obvious damage; verify proper
installation and security. Inspect wiring for loose, chafed, frayed, or broken wires.
Verify no damaged connectors. Verify wiring neatness, proper routing and installation,
and security.
Cabin Bulkhead:
Examine accessible portion with inspection light and mirror. Verify no nicks,
scratches, dents, cracks, corrosion, or loose rivets. Verify stiffener security. Verify
upholstery cleanliness and security.
Wiring:
Inspect condition. Verify no loose, chafed, or broken, wires or terminals. Verify
neatness, proper routing and installation, and security.
Fasteners & Torque Stripes:
Inspect condition. Verify proper installation and security of fasteners. Renew
deteriorated torque stripes per Figure 5-1.
Antennas:
Inspect condition. Verify no cracks where antennas mount to cowlings. Verify
security.
Close & Secure:
Verify foreign objects are removed. Verify equipment security. Verify cleanliness of
interior and of inspection and access covers and cowlings. Connect antenna leads
and ground wires (if installed). Install covers and cowlings removed in preceding
steps. Verify security.

Page 5.20 Chapter 5 Inspections JUL 2020

5-45 100-Hour / Annual Inspection (continued)

BAGGAGE COMPARTMENT

Door:
Inspect condition. Verify proper operation of micro switch and COWL DOOR warning
segment. Inspect hinges and latches for obvious defects. Verify security and proper
latching/locking function.
Carpet:
Inspect condition. Verify no defects, tears, or material deterioration. Verify proper
installation and security.
Interior:
Inspect condition. Verify no structural damage. Verify general cleanliness of baggage
compartment. Verify any installed equipment or passenger cargo are secure.
Generator Control Unit (GCU) & Wiring:
Inspect condition. Verify no exposed, loose, chafed, or broken, wires & terminals.
Verify proper installation and security of wiring covers and Generator Control Unit
(GCU).
BATTERY

Lead-Acid Battery Installations:

Inspect condition. Verify no cracks or corrosion on or near battery cable terminals.
As required, perform capacity test or replace battery per manufacturer’s instructions.
Verify battery cable security. Verify no corrosion in surrounding structure.
Lithium-Ion Battery Installation (if equipped):
Refer to § 96-12. Inspect condition. Verify no cracks or corrosion on or near battery
terminals. Verify vent hose, comm connector wiring, and battery cable security. Perform
scheduled maintenance as required. Verify no corrosion in surrounding structure.
AUX FUEL SYSTEM (If equipped)

Placards:
Verify placard legibility, proper installation, and security.
Aux Fuel Tank:
Examine accessible portion with inspection light and mirror. Inspect condition of
exterior and verify no leakage. Check bladder interior for foreign objects or debris.
Verify security.
Aux Fuel Tank Support:
Examine accessible portion with inspection light and mirror. Inspect condition of
exterior; verify no cracks or obvious damage. Verify security.
Aux Fuel Hoses:
Inspect condition. Verify no leakage, chafing, or obvious damage to fuel lines. Verify
line clearance to installed equipment and surrounding structure. Verify security.

JUL 2020 Chapter 5 Inspections Page 5.21

5-45 100-Hour / Annual Inspection (continued)

AUX FUEL SYSTEM (If equipped; continued)

Aux Fuel Gage Sender & Wiring:
Inspect condition. Verify no loose, chafed, or broken wires or terminals. Verify
proper installation and security of sender and wiring.
Aux Fuel Pump Wiring:
Inspect condition. Verify no loose, chafed, or broken wires. Verify proper installation
and security of wiring.
Aux Fuel Cap:
Inspect condition. Verify no damage or deterioration of gasket. Install cap and
verify proper locking function. Verify security.
Aux Fuel Tank Sump Drain:
Inspect condition. Verify drain valve opens easily, drains fuel freely, springs closed,
and seals completely. Inspect drain hose assembly for defects, tears, or material
deterioration. Secure hose at tab near drain valve.
MT183-1 Tool Kit:
Inspect condition. Remove kit and verify kit contains loose parts listed in R66
Illustrated Parts Catalog. Clip kit to aux tank and verify security.
MAIN ROTOR GEARBOX COMPARTMENT
Cowling Doors:
Inspect condition. Verify proper operation of fasteners.
Antenna Wiring & Connectors:
Inspect condition. Verify no loose, chafed, frayed, or broken wires. Verify no
damaged connectors. Verify neatness, proper routing and installation, and security.
Check grommets for proper installation.
Placards:
Verify placard legibility, proper installation, and security. Refer to Chapter 11.
Fuel Tank:
Examine accessible portion with inspection light and mirror. Inspect condition of
exterior and verify no leakage. Check bladder interior for foreign objects or debris.
Verify security.
Fuel Gage Sender & Wiring:
Inspect condition. Verify no loose, chafed, or broken, wires or terminals. Verify
proper installation and security of sender and wiring.
Low-Fuel Switch Assembly Warning:
Turn battery switch on. With a clean wooden dowel, gently depress low-fuel
sender float in fuel bladder and verify LOW FUEL warning segment illuminates after
approximate 1-second delay. Turn battery switch off.
Fuel Cap:
Inspect condition. Verify no damage or deterioration of gasket. Install cap and
verify proper locking function. Verify security.

Page 5.21A Chapter 5 Inspections JUL 2020

5-45 100-Hour / Annual Inspection (continued)
MAIN ROTOR GEARBOX COMPARTMENT (continued)

Fuel Tank Rollover Vents:

Inspect condition. Inspect Tygon® tube for defects, tears, or material deterioration.
Verify proper safety wire installation and security. Verify 0.25 inch minimum
clearance between cable assembly and vent assembly Tygon® tube; adjust cable as
required. Verify no obstructions in vents.
Fuel Tank Sump Drain:
Inspect condition. Verify drain valve opens easily, drains fuel freely, springs closed,
and seals completely. Inspect drain tube and clamp for defects, tears, or material
deterioration. Clear fuel from drain tube and install clamp.
Fuel Valve:
Inspect condition. Verify cable and component security. Verify proper installation
and (smooth) operation of valve.
Cabin Bulkhead:
Inspect condition. Verify no deformation, buckling, wrinkling, nicks, scratches,
dents, cracks, corrosion, fretting, or loose rivets. Verify no leakage from fuel tanks.
Verify security.
Main Rotor Gearbox:
Inspect condition. Verify no damage, material deterioration, or deformation of gearbox
mounts. Verify no leakage at mast tube-to-gearbox attachment. Inspect mast tube
for cracks. With ship on level ground, verify correct oil level and cleanliness through
sight gage and adjust or flush as required. Verify security of Hall Effect senders and
yoke magnets. Inspect oil lines for leakage, chafing, or obvious damage. Inspect
oil pump mounting and fittings for leaking or obvious damage. Inspect gearbox oil
filter for leakage or for tripped bypass indicator. Verify oil system proper installation
and security.
NOTE
At 600 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 § 12-13 Part B. Service
gearbox, change oil and filter, and clean chip detector at intervals
recommended in § 5-20.

Rotor Brake:
Inspect condition. Verify integrity of brake pads and 0.030 inch minimum pad
thickness. Verify brake pads are clear of engine shaft with brake released. Inspect
micro switches for cracks. Verify no loose, chafed, or broken wires or terminals. Verify
security. Inspect both pulleys (one at end of lever, one next to fuel tank) for cracks.
Verify no frayed strands or binding of rotor brake activating cable. Verify proper
routing and installation, security, and operation of brake and brake micro switch.

APR 2019 Chapter 5 Inspections Page 5.21B

5-45 100-Hour / Annual Inspection (continued)

MAIN ROTOR GEARBOX COMPARTMENT (continued)

Hydraulic Servo Support Frame:

Inspect condition. Inspect rod ends per § 5-33. Use an inspection light and mirror to
inspect all parts of each weld. Verify no cracks or corrosion in servo support. Verify
proper installation and security.
Jackshaft:
Inspect condition. Verify no cracks or corrosion in welded assembly. Inspect
jackshaft to vertical push-pull tube attachment. Inspect jackshaft aft support frame
attachment and forward attachment rod end per § 5-33. Inspect C343-8 tube and rod
ends linking jackshaft to aft servo. Verify security and proper operating clearance.
Main Rotor Push-Pull Tubes:
Examine accessible portion with inspection light and mirror. Inspect condition per
§ 5-32. Verify no nicks, scratches, chafing, dents, cracks or corrosion. Inspect
rod end bearings per Section 5-33; verify rod ends are centered and palnut and jam
nut are tight. Check witness holes for proper thread engagement. Verify proper
installation, security, and operating clearance.
Tail Rotor Push-Pull Tube & Forward Bellcrank:
Examine accessible portion with inspection light and mirror. Inspect condition per §
5-32. Verify no nicks, scratches, chafing, dents, cracks, or corrosion. Inspect rod
end bearings per § 5-33; verify rod ends are centered and palnut and jam nut are
tight. Check witness holes for proper thread engagement. Inspect bellcrank and
bellcrank sheet metal mounting for nicks, scratches, dents, cracks, or corrosion.
Inspect spherical bearings per § 5-33. Verify proper installation, security, and
operating clearance.
Hydraulic Reservoir:
Inspect condition. Verify no significant leakage. Replace filter and packing at
intervals specified in § 5-20. Drain and flush hydraulic system per § 12-33 if oil has
turned dark or emits bad odor. Add fluid as required. Verify security.

CAUTION
Cleanliness of hydraulic fluid is vital to proper system operation.
Service hydraulic system with clean fluid from sealed containers.
Verify funnels, tubing, and other service tooling is free of
contaminants.

Page 5.21C Chapter 5 Inspections APR 2019

5-45 100-Hour / Annual Inspection (continued)

MAIN ROTOR GEARBOX COMPARTMENT (continued)

Hydraulic Servos:
Inspect condition. Inspect rod ends per § 5-33. Verify approximately 0.040 inch
total free play at servo valve input. Verify no significant servo leakage. Clean servo
input rod end/clevis area with no-residue, non-alcoholic solvent as required. Verify
no obvious defects and security of scissors at upper clevis of servos. Verify proper
installation and clearance from surrounding structure through full control travel.
CAUTION
Use LPS PreSolve to clean hydraulic parts. Do not use alcohol.

Hydraulic Hoses, Lines, & Fittings:

Inspect condition. Verify no leakage, chafing, or obvious damage to hydraulic lines.
Verify integrity of connections. Verify fluid line clearance to installed equipment and
surrounding structure and sufficient fluid hose slack available through full control
travel. Verify proper installation and security.
Hydraulic Pump:
Inspect condition. Inspect Telatemp per § 5-35. Verify no significant leakage.
Verify proper installation and security.
Upper Steel Tube Frame:
Inspect condition. Verify no nicks, scratches, dents, cracks, or corrosion. Verify
no chafing where wires, hoses, or clamps attach to frame. Examine each weld for
cracks with an inspection light and mirror.

CAUTION
Upper steel tube frame is fatigue loaded and therefore susceptible
to fatigue cracks. Inspect all joints thoroughly.

F908-1 (Tail Rotor Drive) Yoke Assembly:

Inspect condition. Verify no cracks, corrosion, or fretting. Verify proper installation,
security, and operating clearance. Verify security of magnets.
G779-1 Pulley (Air Conditioning; if installed):
Inspect condition. Verify no cracks, corrosion, or fretting. Verify no nicks or sharp
edges in fins that could damage v-belt. Verify proper installation, security, and
operating clearance.
V-Belt (Air Conditioning; if installed):
Inspect condition. Replace belt if exhibiting frayed edges, excessive cracking, heat
damage, or rubber deterioration. Verify 4.5-5.5 lb of force applied mid-span deflects
belt 0.16-inch; adjust as required per § 21-21.

APR 2019 Chapter 5 Inspections Page 5.21D

FIGURE 5-4A FLEX PLATE INSPECTION

5-45 100-Hour / Annual Inspection (continued)

MAIN ROTOR GEARBOX COMPARTMENT (continued)

Compressor Assembly (Air Conditioning; if installed):

Inspect condition, including integrity of belt-tension slotted plate. Verify security of
mounting. Verify no loose, chafed, frayed, or broken wires. Verify proper installation
and security of pressure switches, snubber, and refrigerant lines.
Refrigerant Hose Assemblies (Air Conditioning; if installed):
Verify security, no damage, and clearance to adjacent structure. Verify dust caps
installed on service fittings where lines mount to compressor.
F196-1 (Tail Rotor Drive) Fan Shaft:
Inspect condition. Verify no shaft corrosion. Remove any light surface corrosion and
apply wax or suitable corrosion inhibitor. Verify no cracks, corrosion, or fretting in
fore and aft weldment. Verify proper installation, security, and operating clearance.

Page 5.22 Chapter 5 Inspections APR 2019

5-45 100-Hour / Annual Inspection (continued)

MAIN ROTOR GEARBOX COMPARTMENT (continued)

C947-3 (Tail Rotor Drive) Plate Assemblies, Forward and Intermediate:

Refer to Figure 5-4A. Inspect condition. Verify no distortion, nicks, scratches,
cracks, corrosion, or fretting. If fretting is detected, contact RHC Technical Support.
Verify bonded washers are installed on both sides of each flex plate ear. Verify
proper installation, security, and operating clearance.
Fanwheel Assembly and Scroll Assembly:
Clean fanwheel blades and inspect condition. Verify no cracks, corrosion, or obvious
damage on blade leading edges or fan assembly. Verify 0.10 inch minimum gap
between G174-1 fanwheel assembly and forward and aft F305-5 inlets. Check gap
all the way around; rotate fanwheel and check gap again (several positions). If gap
does not meet minimum limit, trim inlets per § 79-11. Verify proper installation,
security, and operating clearance. Verify no cracks or damage to scroll assembly.
Emergency Locator Transmitter (ELT; if installed):
Inspect condition. Comply with 14 CFR § 91.207 (d), if required. Verify proper
installation, security, and clearance from drive train components. Verify D693-4
strap assembly is installed and buckled securely.
Pitot Line & Static Vent:
Inspect pitot and static lines for obstructions, cracking, chafing, pinching or kinking.
Verify integrity of pitot and static line connections. Verify line security.
Horizontal Firewall:
Inspect condition. Verify no deformation, buckling, wrinkling, nicks, scratches,
dents, cracks, corrosion, fretting, or loose rivets. Verify no leakage from fuel tanks.
Wiring:
Inspect condition. Verify no loose, chafed, or broken wires or terminals. Verify
neatness, proper routing and installation, and security.
Fasteners & Torque Stripes:
Inspect condition. Verify proper installation and security of fasteners. Renew
deteriorated torque stripes per Figure 5-1.
Antennas:
Inspect condition. Verify no cracks where antennas mount to cowling. Verify security.
Cowling Doors:
Inspect condition. Verify proper operation of fasteners.
F910-1 (Main Rotor Drive) Yoke:
Inspect condition. Verify no cracks, corrosion, or fretting. Verify proper installation,
security, and operating clearance.

JUL 2020 Chapter 5 Inspections Page 5.23

5-45 100-Hour / Annual Inspection (continued)

MAIN ROTOR GEARBOX COMPARTMENT (continued)

A947-2 (Main Rotor Drive) Plate Assemblies:

CAUTION
Upper steel tube frame is fatigue loaded and therefore suscep-
tible to fatigue cracks. Inspect all joints thoroughly.

Antenna Wiring & Connectors:

Inspect condition. Verify no loose, chafed, frayed, or broken wires. Verify no
damaged connectors. Verify neatness, proper routing and installation, and security.
Check grommets for proper installation.
Fasteners & Torque Stripes:
Inspect condition. Verify proper installation and security of fasteners. Renew
deteriorated torque stripes per Figure 5-1.

Page 5.24 Chapter 5 Inspections JUL 2020

5-45 100-Hour / Annual Inspection (continued)

MAIN ROTOR GEARBOX COMPARTMENT (continued)

Antennas:
Inspect condition. Verify no cracks where antennas mount to cowling. Verify security.
Close & Secure:
Verify foreign objects are removed. Verify equipment security. Verify cleanliness
of interior and of inspection and access doors and cowlings. Connect antenna leads
and ground wires, if installed. Install/close doors and cowlings removed in preceding
steps. Verify security.

APR 2019 Chapter 5 Inspections Page 5.25

Intentionally Blank

Page 5.26 Chapter 5 Inspections APR 2019

5-45 100-Hour / Annual Inspection (continued)

ENGINE

Refer to RR300 Series OMM, and applicable engine component manufacturer’s maintenance
publications for service and inspection procedures.
Additional service and inspection intervals are specified in § 5-20.

NOTE
For engine-related matters, if there is a conflict between this
manual and Rolls-Royce instructions, Rolls-Royce instructions
take precedence. Notify RHC of discrepancy.

Inlet Plenum and Filter Bypass Indication:

Inspect plenum condition. Verify no foreign object debris or loose items. Turn
battery switch on. Verify annunciator panel warning segment illuminates when
bypass doors are opened individually, then simultaneously. Turn battery switch off.
Standard (Foam) Air Filter Assembly:
Inspect condition. Verify no tears, punctures, or damage to filter media or cage
assembly; verify no corrosion, cracks, or distortion to filter assembly components.
Service filter as required per § 71-21, Part D. Verify proper installation and security.
Inlet Barrier Filter (if installed):
Inspect condition. Verify no tears, punctures, or damage to filter media or cage
assembly; verify no corrosion, cracks, or distortion to filter assembly components.
Service or replace filter assemblies as required per § 71-21, Part E. Note indication
on filter maintenance aid. Verify proper installation and security.
Engine Hoses:
Inspect condition. Verify no rips, holes, or collapsed areas. Verify proper installation
and security.
Exhaust Pipe:
Inspect condition. Verify no cracks (illuminating exterior with bright light while
viewing interior facilitates crack detection). Inspect condition and security of F173‑1
struts. Inspect condition and security of gearbox vent and clamps.
Starter-Generator & Wiring:
Inspect condition. Verify no loose, chafed, frayed, or broken wires. Verify no
damaged connectors. Verify neatness, proper routing and installation, and security.
Engine Oil and Oil Filter:
Add oil as required per R66 POH Section 8. Change oil and oil filter as required per
RR300 OMM. Verify filter security.

JUL 2020 Chapter 5 Inspections Page 5.27

5-45 100-Hour / Annual Inspection (continued)

ENGINE (continued)

Oil Lines:
Inspect condition. Verify no leakage where lines connect to tank. Verify no leakage,
chafing, or obvious damage to oil lines. Verify line clearance to installed equipment
and surrounding structure. Verify security.
Cooling Duct and Oil Coolers:
Verify installation security with no cracks in duct or mounting. Verify cooler line
connections are tight and coolers have no nicks, dents, cracks, or corrosion. Verify
duct and cooler cores are free of debris to allow full airflow.
Power Turbine Governor (PTG) Control:
Refer to Figure 76-2. Verify D333-13 fitting in PTG input lever moves in and out
slightly with light finger pressure. If D333-13 fitting does not move in response to
light finger pressure then follow compliance procedure in R66 Service Bulletin SB-01.
Fuel Control Unit (FCU) and Control Rigging:
Verify proper routing and security of throttle and fuel cutoff controls; verify smooth
actuation of both controls without binding. Verify FCU throttle arm contacts idle
stop with twist grip closed and contacts maximum throttle stop with twist grip open.
Verify FCU cutoff lever rests in detent when control is OFF and has 0.030–0.090
inch clearance from maximum fuel stop when control is ON.
Fuel Filter:
Inspect condition; service fuel filter per RR300 OMM, as required. Verify proper
installation and security of wiring and housing.
Fuel Hose:
Inspect condition. Verify no leakage, chafing, or obvious damage to fuel lines. Verify
line clearance to installed equipment and surrounding structure. Verify security.
Fuel Flow Meter Transducer (if installed):
Refer to § 28-23. Visually inspect fuel control unit-to-transducer fuel tube connections,
transducer, and reducer connections to transducer and check valve for evidence
of leakage. Visually inspect components for any obvious damage; verify proper
installation and security. Verify no damaged connectors. Verify wiring neatness,
proper routing and installation, and security.
Firewalls:
Inspect condition. Verify no deformation, buckling, wrinkling, nicks, scratches,
dents, cracks, corrosion, fretting, or loose rivets. Pay particular attention to structural
attachment points. Inspect condition of engine-to-firewall seal. Verify no open holes.

WARNING
Open holes in engine-to-firewall seals are potential fire leak paths.

Page 5.28 Chapter 5 Inspections JUL 2020

5-45 100-Hour / Annual Inspection (continued)

ENGINE (continued)

Engine Mounts:
Inspect condition. Verify no cracks or corrosion in engine mount weldment. Verify
safety wire and security of mounting bolts.
Lower Steel Tube Frame:
Inspect condition. Verify no nicks, scratches, dents, cracks, or corrosion. Verify
no chafing where wires, hoses, or clamps attach to frame. Examine each weld for
cracks with an inspection light and mirror.
Condenser and Fan Assemblies (Air Conditioning; if installed):
Inspect condition. Verify security of fans, box assembly, condenser, and firewall
supports. Verify security of desiccant cap.
Refrigerant Line Assemblies (Air Conditioning; if installed):
Inspect condition. Verify security, no damage, and clearance to adjacent structure.
Wiring:
Inspect condition. Verify no loose, chafed, or broken wires or terminals. Check for
heat or fluid damage. Verify neatness, proper routing and installation, and security.
Fasteners & Torque Stripes:
Inspect condition. Verify proper installation and security of fasteners. Renew
deteriorated torque stripes per Figure 5-1.
Close & Secure:
Verify foreign objects are removed. Verify equipment security. Verify cleanliness of
interior and of cover or cowling. Install/close inspection covers or cowlings removed
in preceding steps. Verify security.

JUL 2020 Chapter 5 Inspections Page 5.28A

5-45 100-Hour / Annual Inspection (continued)

TAILCONE

Inspection Plugs:
Inspect condition. Verify proper operation of fasteners.
Tail Rotor Drive Shaft Assembly:
Examine accessible portion through inspection holes with inspection light and mirror.
Verify no cracks, corrosion, or fretting in fore and aft weldment. Verify no evidence
of drive shaft contact with tailcone bays. Verify no bowing, bends, dents, cracks, or
corrosion. Perform tail rotor drive shaft runout per § 65-21. Verify proper installation,
security, and operating clearance.
CAUTION
Bowing, bends, dents, cracks, or corrosion are cause for immediate
replacement of tail rotor drive shaft.
Tail Rotor Push-Pull Tube & Forward Bellcrank:
Examine accessible portion through inspection holes with inspection light and mirror.
Inspect condition per § 5-32. Verify no nicks, scratches, chafing, dents, cracks,
or corrosion. Inspect rod end bearings per § 5-33; verify rod ends are centered and
palnut and jam nut are tight. Check witness holes for proper thread engagement.
Inspect bellcrank and bellcrank mount for nicks, scratches, dents, cracks, or corrosion.
Inspect spherical bearings per § 5-33. Verify proper installation, security, and operating
clearance. Verify tail rotor guard mounting screw shanks clear push-pull tube.
Tail Rotor Drive Shaft Hanger Bearing & Hanger:
Inspect condition. Inspect bearing for obvious damage. Verify integrity of bearing
seals. Verify bearing’s inner race-to-drive shaft torque stripe is intact and no evidence
of bearing slippage on shaft. Verify no bends, cracks, corrosion, or obvious damage
to hanger and hanger mount to tailcone bulkhead. Verify proper installation, security,
and smooth operation.
Tail Rotor Drive Shaft Damper Assembly:
Inspect condition. Inspect bearing for obvious damage. Verify integrity of bearing
seals. Inspect bearing housing for cracks or corrosion. Verify bearing’s inner race-
to-drive shaft torque stripe is intact and no evidence of bearing slippage. Verify no
bends, cracks, corrosion or obvious damage to friction arms and (Teflon) bearings.
Verify proper installation, security, and smooth operation.
Tailcone Interior:
Inspect condition. Verify no nicks, scratches, dents, cracks, corrosion, fretting or
loose rivets. Verify no cracks where damper assembly mounts to tailcone. Verify
no excessive wear in bulkhead bushings from push-pull tubes. Retrieve and discard
trapped debris.

Page 5.28B Chapter 5 Inspections JUL 2020

5-45 100-Hour / Annual Inspection (continued)

TAILCONE (continued)

Tailcone Exterior:
Inspect condition. Refer to § 53-41. Inspect tailcone exterior for nicks, scratches,
dents, cracks, corrosion, fretting or loose rivets. Verify no obstructions in drain hole
at forward edge of each bay (except forward bay).
Antennas:
Inspect condition. Verify no cracks where antennas mount to tailcone. Verify
security.
Anti-Collision Light:
Inspect condition. Verify no cracks where anti-collision light mounts to tailcone.
Verify lens cleanliness, clarity, and security. Verify proper operation.
Tail Rotor Visual Warning Guard:
Inspect condition. Verify no cracks where guard mounts to tailcone. Inspect guard
welds for cracks or corrosion. Verify security.
Wiring:
Inspect condition. Verify no loose, chafed, or broken wires or terminals. Verify
neatness, proper routing and installation, and security.
Fasteners & Torque Stripes:
Inspect condition. Verify proper installation and security of fasteners. Renew
deteriorated torque stripes per Figure 5-1.
Close & Secure:
Verify foreign objects are removed. Verify equipment security. Verify cleanliness
of interior and of inspection plugs. Install plugs removed in preceding steps. Verify
security.

APR 2019 Chapter 5 Inspections Page 5.29

5-45 100-Hour / Annual Inspection (continued)

TAIL ROTOR & TAIL ROTOR GEARBOX

NOTE
Verify proper hardware installation securing plastic inspection
cover. Longer screws could contact aft flex coupling and yoke.

Plastic Inspection Cover:

Clean cover and inspect condition. Replace as required.
C947-3 (Tail Rotor Drive) Plate Assembly, Aft:
Refer to Figure 5-4A. Inspect condition. Verify no distortion, nicks, scratches,
cracks, corrosion, and 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.
Tail Rotor Gearbox Input Yoke:
Inspect condition. Verify no cracks, corrosion, or fretting. Inspect weld for cracks
or corrosion. Verify proper installation, security, and operating clearance.
Tail Rotor Gearbox:
Inspect condition. Verify gearbox-to-tailcone mounting security. Verify no leakage
at input or output seals, chip detector, vent plug-filler assembly, or sight gage. With
ship on level ground, verify correct oil level and oil cleanliness through sight gage
and adjust or flush as required. Inspect Telatemp per § 5-35. Inspect output shaft
for nicks, scratches, dents, cracks, or corrosion. Verify proper installation of safety
wire (if installed).
Empennage:
Inspect condition. Verify no nicks, scratches, dents, cracks, corrosion, fretting, or
loose rivets on skins or near attachment points. Check tail rotor skid for evidence of
tail rotor or tail rotor skid strike. Refer to § 5-61 for tail rotor skid strike inspection
criteria. Verify no obstructions in lower vertical stabilizer and skid drain holes. Verify
proper installation and security.
Aft Navigation Light:
Inspect condition. Verify no cracks where aft navigation light mounts to empennage.
Verify lens cleanliness, clarity, and security. Verify proper operation.

Page 5.30 Chapter 5 Inspections APR 2019

5-45 100-Hour / Annual Inspection (continued)
TAIL ROTOR & TAIL ROTOR GEARBOX (continued)

Pitch Control Bearing Assembly & Aft Bellcrank:

Inspect condition. Verify pitch control assembly has less than 0.25 inch rotational
play measured at pitch link attach bolt. Verify no leakage at bearing seals. Verify
no nicks, scratches, dents, cracks, or corrosion on pitch control housing or bellcrank.
Inspect bellcrank spherical bearings per § 5-33. Inspect spherical bearing atop stud
protruding from underside of pitch control for cracks. Verify proper installation,
security, and smooth actuation without binding.

NOTE
B345-4 tail rotor pitch links can have different shaft diameters
(0.250 inch or 0.300 inch). Balance tail rotor per § 18-20 if a
different shaft diameter pitch link is installed.

Pitch Links:
Inspect condition. Inspect rod ends per § 5-33. Remove and reinstall pitch links
with outboard end inboard and inboard end outboard as required to obtain maximum
service life; additionally, an optional A215-012 o-ring may be installed between
A214-3 washer and A115-1 spacer at pitch control. Reinstall chordwise weights at
respective attachment points for balance purposes. Verify proper installation of hat
washers. Verify proper installation, security and operating clearance.
Tail Rotor Blades:
Inspect condition. Inspect blade surfaces for excessive erosion, nicks, scratches,
buckling, voids or debonding, dents, cracks, or corrosion. Refer to § 64-30 for tap
testing instructions and damage limitations. Verify no fretting of tail rotor blade root
fitting bearings. Inspect bearings per § 5-33. Verify no obstructions in blade tip drain
holes. Verify proper installation, security, and pitch change operation.

WARNING
Structural damage may occur if compressed air is applied to
blade tip drain holes.

Tail Rotor Hub:

Inspect condition. Verify no nicks, scratches, gouges, dents, cracks, or corrosion.
Inspect elastomeric teeter bearings per § 5-34. Teeter rotor hub and verify teeter
bearing bolt, spacers, and nuts do not rotate. Verify hub teeters smoothly. Verify
proper installation and security of blade bolts.
Wiring:
Inspect condition. Verify no loose, chafed, or broken wires or terminals. Verify
neatness, proper routing and installation, and security.
Fasteners & Torque Stripes:
Inspect condition. Verify proper installation and security of fasteners. Renew
deteriorated torque stripes per Figure 5-1.

JUL 2020 Chapter 5 Inspections Page 5.31

5-45 100-Hour / Annual Inspection (continued)

MAST FAIRING

Mast Fairing:
Inspect condition. Verify no nicks, scratches, dents, cracks, corrosion, fretting,
or loose rivets. Verify no yielding or cracking of pitot line and fuel vent restraint
assembly.
NOTE
Yielding can be caused by over tightening screws in restraint
nutplates.
Upper & Lower Ribs:
Inspect condition. Inspect for cracks especially around mast tube attachments.
Verify proper installation and security of ribs and lower rib clamp.
Vertical Push-Pull Tubes:
Examine accessible portion with inspection light and mirror. Inspect condition per §
5-32. Verify no nicks, scratches, chafing, dents, cracks or corrosion. Inspect rod
end bearings per § 5-33; verify rod ends are centered and palnut and jam nut are
tight. Check witness holes for proper thread engagement. Verify proper installation,
security, and operating clearance.
Pitot Tube & Line:
Inspect pitot lines for obstructions, cracking, chafing, pinching or kinking. Verify
integrity of pitot and static line connections. Verify proper routing and security of
pitot tube and line. Verify no cracks where pitot tube mounts to mast fairing. Verify
no obstructions in pitot tube.
Fuel Vent Weldment and Tygon® Tubes:
Inspect condition. Verify no obstructions, cracking, chafing, pinching or kinking in
plastic tubes. Inspect vents for cracks or obvious damage. Verify proper installation
and security of safety wire.
Swashplate Upper Scissors:
Inspect condition. Verify bearing play within limits referenced in § 67-40, steps 9
and 10. Closely examine scissor linkage while a second person raises and lowers
collective stick. Verify bolts and washers rotate together through full control travel
without binding. Inspect fork assembly rod end bearing per § 5-33; verify rod end is
centered and palnut and jam nut are tight. Verify proper installation of all parts, part
security, and operating clearance.

Page 5.32 Chapter 5 Inspections JUL 2020

5-45 100-Hour / Annual Inspection (continued)

MAST FAIRING (continued)

Swashplate Lower Scissors:

Inspect condition. Verify bearing play within limits referenced in § 67-40, steps 9
and 10. Closely examine scissor linkage while a second person raises and lowers
collective stick. Verify bolts and washers rotate together through full control travel
without binding. Inspect fork assembly rod end bearing per § 5-33; verify rod end is
centered and palnut and jam nut are tight. Verify proper installation of all parts, part
security, and operating clearance.
Swashplate Slider Tube:
Inspect condition. Verify no cracks, corrosion, or loose rivets near tube base flange.
Verify no damage or wearing through of anodized coating on tube surface. When viewed
under 10X magnification, minute "checkerboarding" of anodized surface is normal.
Swashplate Interior:
Remove swashplate boot lower ty-rap. Lift boot from swashplate, and verify no
boot defects, tears, or material deterioration. Examine swashplate interior with
inspection light and mirror. Verify no corrosion or debris between main rotor drive
shaft and inside of slider tube. Install swashplate boot lower ty-rap. Verify proper
boot position, security, and operating clearance.
Swashplate:
Inspect condition. Verify no nicks, scratches, gouges, dents, cracks, or corrosion.
Verify 0.020 inch maximum radial play between swashplate ball and slider tube.
Rotate rotor by hand and verify no rough or dry bearings. Verify proper operation.
Swashplate Shimming:
Closely examine area between lower swashplate and swashplate ball while a second
person slowly raises and lowers collective stick. Verify synchronized movement of
swashplate ball with swashplate when swashplate reverses direction.

NOTE
Swashplate shimming is required when swashplate ball lags
collective inputs, indicating axial play. Shim swashplate per
Chapter 67.

Fasteners & Torque Stripes:

Inspect condition. Verify proper installation and security of fasteners. Renew
deteriorated torque stripes per Figure 5-1.
Close & Secure:
Verify foreign objects are removed. Verify equipment security. Verify cleanliness of
interior and of access fairing. Close mast fairing and verify security.

JUL 2020 Chapter 5 Inspections Page 5.33

5-45 100-Hour / Annual Inspection (continued)

ROTOR HUB & MAIN ROTOR BLADES

Hub:
Inspect condition. Verify no nicks, scratches, gouges, dents, cracks, or corrosion.
Verify no brown or black residue indicating bearing wear. Verify proper installation
and security.
Hinge Bolts:
Inspect condition. Check blade hinge friction by lifting blades until spindle tusks clear
droop stops. Hold one blade level and cone opposite blade; rotor hub should not teeter
as blade is coned. Repeat check on opposite blade. Verify cotter pins are properly
installed and secure. Verify bolt heads and nuts are torque striped to thrust washers.
Pitch Links & Rod Ends:
Inspect condition. Inspect rod end bearings per § 5-33; verify rod ends are centered
and palnut and jam nut are tight. Check witness holes for proper thread engagement.
Verify security of rivet in pitch link barrel. Verify no corrosion of pitch link assembly.
Verify proper installation of safety wire and hat washers. Inspect condition of
mandatory spacers contacting lower rod end bearings. Verify proper installation,
security, and operating clearance.
Blade Spindles & Root Fittings:
Inspect condition. Verify no cracks, corrosion, or obvious damage to blade spindles
and horns. Verify no cracks, corrosion or missing paint in blade root fittings, especially
in area adjacent to inboard edges of skin and doublers.
Blade Boots:
Inspect condition. Verify no boot defects, tears, material deterioration, or pinholes
resulting in oil leakage. Verify proper boot position and security. Verify sufficient
clearance from hub assembly through full control travel.
Fasteners & Torque Stripes:
Inspect condition. Verify proper installation and security of fasteners. Renew
deteriorated torque stripes per Figure 5-1.
Main Rotor Blade Tip Maintenance:
Perform main rotor blade tip maintenance per § 62-60.
Blade Inspection and Care:
Refer to § 62-40. Inspect skins and doublers for scratches and corrosion. Inspect
blades for dents, local deformations, and voids. 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. Verify placard legibility and
remove old tracking tape and/or residue.

WARNING
Structural damage may occur if compressed air is applied to
blade tip drain holes.

Page 5.34 Chapter 5 Inspections JUL 2020

5-45 100-Hour / Annual Inspection
LANDING GEAR

Landing Gear Fairings (if installed):

Open as required to access landing gear structure for inspection. Inspect condition.
Verify no nicks, scratches, dents, cracks, corrosion, fretting, or loose rivets. Verify
hose clamp security and acceptable general cleanliness of fairing interior. Close and
secure fairings.
Skid Tubes & Shoes:
Inspect condition. Verify skid tube and skid shoe wear is within limits specified in §
32-30 & 32-31. Verify drain holes are not obstructed. Verify security of rain caps;
if rain cap is loose or damaged, verify no internal corrosion. Verify security of ground
handling wheel brackets and step(s) if installed.
Struts Assemblies:
Inspect condition. Verify no cracks or corrosion, especially at collar and gusset
joints and in weld areas at bottom of struts. Torque-check strut-to-skid-tube bolts.
Verify security.
Cross Tubes:
Inspect condition. With helicopter on level ground, verify minimum tail skid height
per § 32-20. Verify no cracks, corrosion, or fretting at elbows. Verify security of
(clear plastic) rain caps; if rain cap is loose or damaged, verify no internal corrosion.
(Note that one vent hole per cross tube is located near left or right end of tube to
prevent pressurization.)
Landing Gear Attach Points:
Inspect condition. Verify no buckling, cracks, fretting, or loose fasteners. Inspect
mounts and verify no loose swages or worn bearings.
Fasteners & Torque Stripes:
Inspect condition. Verify proper installation and security of fasteners. Renew
deteriorated torque stripes per Figure 5-1.
D679 Cylinder assembly (Pop-out floats; if installed):
Inspect condition. Verify security. Verify pressure gage indicates correct pressure
for ambient temperature; refer to placard on cylinder for limits.
Inflation manifold (Pop-out floats; if installed):
Inspect condition. Verify no chafing or pinching of hoses, especially where hoses
pass though structure.
Float assemblies (Pop-out floats; if installed):
Inspect condition of stowed floats. Verify no holes, cuts, tears, abrasion through
or unraveling of, float covers. If cover damage is found, inflate and inspect floats
per § 32-64. Annually apply A257-7 dry-film lubricant to float cover snap mating
surfaces. Verify snaps and hook-and-loop fasteners are properly secured. Verify
float-to-skid attachment security.

JUL 2020 Chapter 5 Inspections Page 5.35

5-45 100-Hour / Annual Inspection

CABIN

General Interior:
Inspect condition. Verify general cleanliness of cabin and seat compartment interior.
Verify no loose objects or equipment, which could foul controls or injure occupants
in a hard landing. Verify legibility of placards and markings. Verify serviceable
condition of switches, knobs, handles, and other controls.
Seat Belts & Shoulder Harnesses:
Inspect condition. Verify no fraying or broken stitching of seat belts or shoulder
harnesses. Verify no significant UV damage. Check inertia reels for proper operation
by pulling harness quickly to verify locking function. Check buckles for proper
operation. Check belt and reel attachment points for security. Verify no cracks in
seat belt anchor welds. Verify security.

NOTE
TSO tag not required on factory-installed harnesses.

Windshields & Windows:

Inspect condition. Verify no significant UV damage (yellowing). Minor defects
or imperfections that do not impair pilot visibility or indicate impending structural
failure are acceptable. Refer to § 52-30 for damage and repair limits. Verify proper
installation and security.
Static Ports:
Inspect condition. Verify no obstructions.

Page 5.36 Chapter 5 Inspections JUL 2020

5-45 100-Hour / Annual Maintenance and Inspection [25 of 26 Pages]

CABIN (continued)

Yaw String:
Inspect condition. Verify minimum string length is 3 inches on each side of clip.
Verify security.
Landing & Taxi Lights:
Inspect condition. Verify lens cleanliness, clarity, and security. Verify proper operation.
Landing Light Retainer & Support:
Inspect condition. Verify no cracks where retainer mounts to support. Verify security.
Left & Right Navigation Lights:
Inspect condition. Verify no cracks where right and left navigation lights mount to
fuselage. Verify red left, green right, lens cleanliness, clarity, and security. Verify
proper operation.
Exterior:
Inspect condition. Inspect cabin exterior for nicks, scratches, dents, cracks,
corrosion, fretting, or loose rivets. Loose rivets may be indicated by cracked paint
and/or black residue around heads. Verify general cleanliness.
Doors:
Inspect condition. Verify no cracks and proper fit of door-to-door frame. Verify
no structural cracks near door hinges or latches. Verify proper operation of door
latching and locking mechanisms. Ensure door hinge pins are secured with cotter
rings. Verify security of hinge mounting screws. Verify proper installation and
operation of gas struts and door vent assembly.
SPECIAL EQUIPMENT

Transmit and Intercom Switches:

Verify proper operation of special transmit and intercom switches.
PA/Siren Speaker:
Inspect condition. Verify no cracks in speaker. Verify security of mounting.
Wiring:
Inspect condition. Verify no loose, chafed, or broken wires or terminals. Verify
neatness, proper routing and installation, and security.
LIFE-LIMITED PARTS, PARTS WITH A RECOMMENDED TBO OR REPLACEMENT TIME, ADs, & SBs
Life-Limited Parts:
Refer to § 4-10. Verify life-limited parts correspond with aircraft maintenance records.
Verify life-limited parts have sufficient time remaining for projected operations.
Parts with a Recommended Time Between Overhauls (TBO) or Replacement Time:
Refer to § 4-20. Verify parts with a recommended TBO or replacement time
correspond with aircraft maintenance records. Verify parts with a recommended
TBO or replacement time have sufficient time remaining for projected operations.

MAY 2015 Chapter 5 Inspections Page 5.37

5-45 100-Hour / Annual Maintenance and Inspection [26 of 26 Pages]

LIFE-LIMITED PARTS, PARTS WITH A RECOMMENDED TBO OR REPLACEMENT TIME, ADs, & SBs

Airframe and Engine Accessories:

Refer to § 4-20 and accessory manufacturer’s maintenance publications. Verify
accessories correspond with aircraft maintenance records. Verify accessories
scheduled for maintenance have sufficient time remaining for projected operations.
Airworthiness Directives:
Verify applicable airframe, engine, and accessory Airworthiness Directives (ADs)
have been performed according to AD compliance procedures. Some helicopters
may be affected by ADs that require recurring inspections at less than 100-hour or
annual intervals. Recent U.S. Airworthiness Directives are online at www.faa.gov.
Service Bulletins and Letters:
Verify applicable airframe, engine, and accessory Service Bulletins (SBs) and Service
Letters (SLs) have been complied with according to manufacturers’ instructions.
Some helicopters may be affected by SBs or SLs that require recurring inspections
at less than 100-hour or annual intervals. RHC Service Bulletins and Service Letters
are online at www.robinsonheli.com under the Publications tab.
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 onboard, legible, and current.
Placards:
Verify required placards are properly installed, legible, and current. Refer to Pilot’s
Operating Handbook Section 2 for placard requirements.
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:
Refer to Section 6-70. Install/close inspection and access covers and cowlings
removed in preceding steps. Verify proper installation and security.
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
helicopter for return to service.

Inspection Procedures and Checklist completed:

Mechanic’s signature: Date:

Page 5.38 Chapter 5 Inspections MAY 2015

5-50 2000-Hour/12-Year Inspection

NOTE
Fuel bladder(s) are on condition.
NOTE
KI-6602 2000-Hour Inspection Kit contents are available online
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 2000 hours time
in service since new, since last 2000-hour inspection, or since
last 12-year inspection.

1. Refer to helicopter maintenance records and § 4-30; replace life-limited parts, or next
higher assemblies, as required.
2. Refer to helicopter maintenance records and § 1-92; perform additional component
maintenance, as required.
3. Visually inspect stabilizers. Verify no cracks, corrosion, loose rivets, dents, or
deformation.
4. Remove fuel bladder(s) per Chapter 28. Visually inspect interior and exterior. 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 § 28-11. Remove any foreign object debris. Install bladder(s) per Chapter 28.
5. Perform (engine driveline) forward flex plate shimming per § 63-11 and (tail rotor
driveline) intermediate flex plate shimming per § 65-30.
6. Fill and bleed hydraulic system per § 12-34 as required.
7. Drain engine oil per § 12-60; utilize a suitable clean container if reuse of oil is intended.
Using a borescope or remote camera, inspect oil tank internal baffle and welds for signs
of cracking. If cracks are detected, or if a broken baffle is found, replace oil tank per §
79-20. Add engine oil per § 12-60.
8. Perform main rotor flight control and blade angle rigging per §§ 18-30 and 18-40.
9. Perform tail rotor flight control and blade rigging per §§ 18-50 and 18-60.
10. If installed, perform leak check of air conditioning system per § 12-83.
11. Perform 100-Hour / Annual Maintenance and Inspection per § 5-45.
12. Weigh helicopter per § 8-20.

JUL 2020 Chapter 5 Inspections Page 5.39

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

5-51 C258-5 Main Rotor Pitch Link Assembly Inspection

1. Temporarily mark each pitch link and associated swashplate ear with unique color.
Record overall lengths of both links.
2. Remove pitch links.
3. Disassemble pitch links, keeping parts from each link separate from the other.
4. Evaluate rod ends per § 5-33 and replace as required.
5. Visually inspect parts with 10X magnification for obvious damage. Replace damaged
parts.
6. Visually inspect interior of barrels with borescope for obvious damage. Replace
damaged barrels.
7. Assemble pitch links and adjust to recorded lengths. Torque jam nut & adjacent palnut
per § 20-32. Special torque self-locking jam nut per § 20-33.
8. Install pitch links to associated swashplate ear and, if installed, main rotor blade.
Torque fasteners per § 20-32 and torque stripe per Figure 5-1.

Page 5.39A Chapter 5 Inspections JUL 2020

5-52 Swashplate Assembly 12-Year Inspection
1. Remove swashplate assembly per § 67-40.
2. Remove both pitch links and upper A205-7 fork assembly from swashplate.
3. Determine revision (“REV”) letters on C017-6 swashplate data plate. If revision
letters are “AD” or subsequent, proceed to step 2. If revision letters are “AA”, “AB”,
or “AC”, perform R66 Service Bulletin SB-30.
4. Refer to Figure 12-7. Remove (10) NAS1352 screws (with washers) securing C206-2
& C200‑3 retainers to upper swashplate. Remove both retainers and C219-3 spacer
and set aside.
5. Remove inner screws securing sleeve to lower swashplate. Remove sleeve, shims,
and ball and set aside.
6. Using a 0.006 inch feeler gage, gently pry up outer edge of upper C217-1 seal and
expose top ball bearing. Discard upper seal.
7. Clean all parts, including C203-5 yokes.
8. Visually inspect cleaned parts with 10X magnification, to include blind screw-holes
in upper & lower swashplates, for obvious damage. Replace swashplate assembly if
damage is detected on either upper or lower swashplate. Replace damaged parts.
9. Perform swashplate tilting friction adjustment per § 67-41 step 4.
10. Lubricate swashplate bearings per § 12-90 steps 7 thru 11. Install new upper seal
during procedure.
11. Remove rod end form upper fork. Using non-metallic tools, remove majority of sealant
in threaded hole of fork. Visually inspect parts with 10X magnification for obvious
damage. Replace damaged parts. Assemble upper fork assembly and adjust pivots’
center-to-center dimension to 3.85±0.03 inches. Standard torque jam nut & palnut
per § 20-32 and torque stripe per Figure 5-1. Fill exposed cavity with B270-13 sealant.
12. Remove lower A205-7 fork assembly from non-rotating scissors and clean. Remove
rod end from lower fork. Visually inspect parts with 10X magnification for obvious
damage. Replace damaged parts. Assemble lower fork assembly and adjust pivots’
center-to-center dimension to 3.70±0.03 inches. Standard torque jam nut & palnut
per § 20-32 and torque stripe per Figure 5-1. Install lower fork on C204-2 arm and
standard torque bolt per § 20-32. Install palnut, standard torque per § 20-32, and
torque stripe per Figure 5-1.
13. Install swashplate assembly per § 67-40 Part B.

JUL 2020 Chapter 5 Inspections Page 5.39B

5-53 Landing Gear Assembly 12-Year Inspection
1. Inspect cross tubes per § 32-20.
2. Remove landing gear per § 32-10.
3. Remove left skid tube, and remove rain cap and skid extension from tube.
4. Remove fasteners securing struts to cross tubes. Using a twisting motion, remove left
struts from cross tubes.
5. Remove right skid tube, and remove rain cap and skid extension from tube.
6. Using a twisting motion, remove right struts from cross tubes.
7. Clean cross tubes, struts, and skid tubes.
8. Visually inspect interior of struts with borescope (or similar) for obvious damage.
Visually inspect exterior of struts using minimum 3X magnification for obvious damage.
Any corrosion on, or adjacent to, a weld requires corrosion & paint removal followed
by MPI. Upon favorable MPI results, apply § 20-76 powder coat.
9. Refer to § 32-30. Visually inspect interior of skid tube with borescope (or similar).
Visually inspect exterior of parts using minimum 3X magnification. As required, touch-
up coatings with § 20-75 primers and § 20-77 paints.
10. Visually inspect interior of cross tubes with borescope (or similar) for obvious damage.
Visually inspect exterior of cross tubes using minimum 3X magnification for obvious
damage. As required, touch-up coatings with § 20-75 primers and § 20-77 paints.
11. Assemble landing gear.
12. Install landing gear per § 32-10.

Page 5.39C Chapter 5 Inspections JUL 2020

5-54 Hydraulic Reservoir 12-Year Inspection
1. Perform hydraulic system drain and flush per § 12-33 step 1. Remove D516-1 cap.
2. Refer to Figure 5-5. Suction remaining fluid using suitable, clean, plastic tube (do not
use metal tool). Wipe out any residue from both traps with clean, foam-tip swab.
3. Inspect interior of reservoir for corrosion with borescope (or similar). Replace reservoir
if corrosion is detected.
4. Perform hydraulic system drain and flush per § 12-33, steps 2 thru 12.

FIGURE 5-5 HYDRAULIC RESERVOIR INSPECTION

JUL 2020 Chapter 5 Inspections Page 5.39D

Intentionally Blank

Page 5.40 Chapter 5 Inspections JUL 2020

5-60 Special Maintenance and Instructions

WARNING
Do not install or return to service any part removed from a
damaged aircraft unless the part can be verified as undamaged.
Return suspect parts to RHC, with details of damage history,
for airworthiness evaluation.

5-61 Tail Skid Strike

A. If evidence of scuffing is found on the tail skid, inspect the rotorcraft as follows:
1. Visually inspect tail rotor blades for evidence of solid object or ground
contact. If tail rotor damage is found, inspect tail rotor for strike per §
5-62.
2. Visually inspect vertical stabilizer for evidence of buckling, cracks,
or loose rivets at tail skid and at lower vertical stabilizer-to-horizontal
stabilizer attach points.
3. Visually inspect tail rotor guard for bending or cracking at attach mounts.
4. Visually inspect the horizontal stabilizer-to-tailcone attach points for
evidence of buckling, loose rivets, or cracking.
5. Visually inspect tailcone for damage and tailcone-to-upper steel tube
structure attach points for buckling and loose attach bolts.
B. For skid bending or breakage, or buckling of lower vertical stabilizer, perform the
following inspections in addition to those listed in Step A.
1. Perform tail rotor drive shaft runout per § 65-21.
2. Remove tailcone assembly per § 53-40. Perform dye penetrant inspection
of F020 upper frame at tailcone attach points per § 5-66.
3. Visually inspect tailcone attachment points for elongated holes (0.454-
inch diameter maximum).
4. Remove empennage assembly per § 53-50. Remove tail rotor gearbox
per § 65-40. Remove paint from tailcone casting using a suitable paint
remover per § 20-70. Dye penetrant inspect casting according to
manufacturer's instructions.
5. Visually inspect horizontal stabilizer attach points for elongated holes
(0.386-inch diameter maximum) loose rivets or buckling.
6. Remove lower vertical stabilizer per § 53-51. Visually inspect attach
points on vertical and horizontal stabilizers for elongated holes (0.266-
inch diameter maximum); verify no buckling, cracks or loose rivets. Loose
rivets may be drilled out and replaced.
7. Remove tail rotor guard per § 53-53. Remove paint from forward and aft
attachment points and dye penetrant inspect according to manufacturer's
instructions. Remove guard mount from tailcone by removing four 10-32
screws and dye penetrant inspect same as above step.

MAY 2015 Chapter 5 Inspections Page 5.41

5-62 Tail Rotor Strike

The tail rotor strike inspection is listed in two parts. Part 1 concerns damage received
by a tail rotor blade due to contact with a small stone, tall grass, or some small object
contacting rotor blade in free air. Part 2 is concerned with sudden stoppage of tail rotor
due to ground or solid object contact causing bending or shearing of a tail rotor blade or
blades.

1. Inspect tail rotor blades per § 64-30 and perform Part 2, step (a).

2. If one or both tail rotor blades contact ground or a solid object causing bending or
shearing of blades a tail rotor sudden stoppage inspection must be performed. Inspect
per following procedure:

a. Perform tail rotor drive shaft runout per § 65-21. If runout exceeds 0.025 inch at
any location the shaft must be replaced or repaired.

b. Remove tail rotor assembly per § 64-10 and tail rotor gearbox per § 65-40 and
return to RHC.

c. Visually inspect D224 tail rotor drive shaft for evidence of twisting, nicks, dents or
scratches. Nicks and scratches may be polished out to a maximum of 0.003 inch
deep. Evidence of twisting or dents is cause for replacement of the drive shaft.

d. Remove yokes from each end of tail rotor drive shaft. Inspect arms for deformation
and holes for any elongation. Strip paint and dye penetrant inspect yokes according
to manufacturer's instructions (forward yoke may be magnetic particle inspected).

e. Remove F196-1 (tail rotor drive) shaft weldment per § 65-10. Strip paint back at
least 2 inches from welds at both ends of shaft and dye penetrant or magnetic
particle inspect. Verify no cracks.

f. Replace C947-3 plate assemblies (forward, intermediate, and aft).

g. Visually inspect F193-2 hanger and F172-3 (bearing) housing for cracks or
deformation.

h. Visually inspect tailcone and empennage for evidence of a tail rotor blade strike.

i. Visually inspect main rotor system.

Page 5.42 Chapter 5 Inspections MAY 2015

5-63 Main Rotor Strike

The main rotor strike inspection is listed in two parts. Part 1 concerns contact of main
rotor blades with object in free air such as small stones, brush, small birds, etc. Part 2
is concerned with sudden stoppage of main rotor due to ground or solid object contact.

1. If main rotor blade has contacted a small object in free air such as small stones, brush,
small birds, etc., inspect main rotor blades as follows:

a. Verify any nicks, scratches, and dents are within § 62-10 limits; repair as required.

b. Visually inspect trailing edge of blade for evidence of buckling or bending. This will
be most evident near root of blade.

CAUTION

Any blade buckling or permanent bending is considered sudden

stoppage and requires a sudden stoppage inspection of the entire
rotorcraft.

2. If main rotor blade or blades have contacted ground or a solid object, they must be
inspected for sudden stoppage. Sudden stoppage is evident when buckling or bending
of the main rotor blades has occurred. Use the following procedure for inspecting
rotorcraft after main rotor sudden stoppage has occurred:

a. Perform tail rotor drive shaft runout per § 65-21.

b. Visually inspect G027 scroll assembly and F193 bearing hanger for cracks and/or
deformation.

c. Remove the following components and return to RHC for inspection.

C005-10 Main Rotor System

F006 Main Rotor Gearbox
F018 Clutch Assembly
A947-2 Flex Plates
C947-3 Flex Plates
C017 Swashplate
F906 Yoke
F908 Yoke
F910 Yoke
F196 Shaft Weldment
F642 Shaft Weldment
G174 Fanwheel

d. Inspect engine for sudden stoppage per engine manufacturer’s instructions.

MAY 2015 Chapter 5 Inspections Page 5.43

5-64 Rotor/Engine Overspeed

1. For rotor overspeeds between 106 and 112%:

NOTE

Refer to Part 3 if a power-on overspeed occurs.

a. Check main rotor and tail rotor dynamic balance. Compare pre-overspeed and
post-overspeed balance.

CAUTION

Any change in rotor dynamic balance greater than 0.3 ips

requires inspection per Part 2.

b. 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 drag is normal. If roughness

is evident, return blade and spindle assembly to RHC for repair.

c. Visually inspect main and tail rotor blades.

d. Check tail rotor drive shaft runout per § 65-21.

2. If an overspeed at or above 112% is reported or suspected or if balance changes or

pitch bearing roughness is evident, perform following inspections in addition to Part 1.

NOTE

Refer to Part 3 if a power-on overspeed occurs.

a. Perform Part 1 inspection.

b. Check coning hinge bolts for evidence of bending. Replace any bent bolts.

c. Coning hinge bolts, washers, and journals must be magnetic particle inspected.
Replace any cracked bolts, journals or washers.

d. Visually inspect hub and dye penetrant inspect any areas suspected of having
cracks. Dye penetrant inspect according to manufacturer's instructions.

e. Reinstall blades and check balance. If a change in balance is evident, rotor system
should be returned to RHC for inspection and/or repair.

3. Refer to RR300 Series Operation and Maintenance Manual (OMM) for overspeed
inspection requirements.

Page 5.44 Chapter 5 Inspections MAY 2015

Intentionally Blank

APR 2019 Chapter 5 Inspections Page 5.45

FIGURE 5-6 SYMMETRY CHECK

Page 5.46 Chapter 5 Inspections APR 2019

5-65 Hard Landing

NOTE
RR300 Operation and Maintenance Manual requires special
engine inspection (subtask 05-50-00-210-002) when a hard
landing exceeds 10g. While there is no single indicator for
a 10g impact, an impact was less than 10g if there was no
contact between the fuselage belly or landing gear cross tubes
and the ground. Yielding or buckling of any engine mount tubes
or crushing of the energy absorbers within any occupied seat
indicates the impact was likely greater than 10g.

The hard landing inspection is listed in two parts. Part 1 concerns yielding (bending) of
the cross tubes due to hard landing such as hovering autorotations or run-on landings that
do not apply side loads to the landing gear. Part 2 concerns hard landings that, in addition
to yielding of cross tubes, have yielding of steel tube frames or fuselage primary structure.

NOTE
Buckling and bent steel tube structure are evidence of side loads
on the airframe.

1. Yielding of cross tube due to hard landing with no side loads:

a. Perform tail rotor drive shaft runout per § 65-21.
b. Visually inspect main rotor blades for oil canning of skins and buckling. Inspect
and repair main rotor blades per §§ 62-40 and 62-50.
c. Check landing gear cross tubes for yielding beyond serviceable limit. Place
rotorcraft on level ground, push up on tail rotor gearbox and release, allowing
rotorcraft to settle, then measure from tip of tail skid to ground. If less than 38
inches, one or both cross tubes must be replaced.
d. Inspect front seat structure for yielding. Visually inspect, thru vent holes in
seat bottoms, the internal box structure for any deformation. Inspect aft seat
structure for yielding.
2. If yielding of steel tube frame(s) OR fuselage has occurred, inspect rotorcraft as
follows:
a. Perform Part 1 inspection.
b. Verify no yielding or cracks in steel tube frames.
c. Visually inspect fuselage, landing gear attach points, and firewalls for buckling
or cracks.
d. Dye penetrant inspect upper steel tube structure and all welded joints.

APR 2019 Chapter 5 Inspections Page 5.47

5-65 Hard Landing (continued)
2. e. Visually inspect tailcone for buckling or loose rivets.
f. Visually inspect landing gear skid tube-to-strut attach points for bending and
cracks.
g. Hard landings can be accompanied by tail skid strikes, tail rotor strikes, main
rotor blade strikes, etc. To inspect for these conditions, refer to the appropriate
instructions in § 5-60. Refer to § 53-11 for cabin repairs. Any cracks, yielding
or buckling in steel tube structure or tailcone are cause for replacement or factory
repair.
h. Replace parts as required.
i. Check for symmetry if there is evidence of buckling of the cabin assembly per
Figure 5-6. Position helicopter on a hard, level surface with the weight of the
helicopter settled on the skids. Measure and record distances of lines A, B, C,
and D. Verify the difference between lines A & B is not more than 0.30 inch and
the difference between lines C & D is not more than 0.40 inch. If the difference
between lines A & B or C & D is greater than the limits given, the cabin assembly
must be returned to RHC for repair.

Page 5.47A Chapter 5 Inspections APR 2019

Intentionally Blank

APR 2017 Chapter 5 Inspections Page 5.47B

5-66 Dye Penetrant Inspection of F020-1 Upper Frame
1. Carefully clean all paint, primer, oil, grease, etc from steel tube structure around and
adjacent to four tailcone mounts.
2. Apply epoxy paint remover and allow the softening action to complete (temperature
affects time required).
3. Remove softened paint by hand using a wire brush. Be sure steel structure is perfectly
clean before application of dye penetrant.
4. Carefully check for cracks in and around each weld bead and along each steel supporting
tube for at least two inches away from weld beads. Replace any frame exhibiting
crack indications.
5. If no cracks are found, clean all inspection materials from steel tubing.
6. Prime with good quality zinc chromate or epoxy primer and allow adequate drying
time.
7. Refinish area with gray epoxy top coat or equivalent.

5-67 Corrosion on F020-1 Upper Frame

1. Polish out corrosion on steel frame tube members.
a. Polish out light surface corrosion on frame members using Scotchbrite or 400 grit
wet-or-dry sandpaper. Verify 0.002 inch maximum depth after rework.
b. Polish out corrosion pitting using 320-grit wet-or-dry sandpaper. Verify 0.004
inch maximum depth and 0.10 inch maximum diameter, after rework.

NOTE
For large areas of corrosion, it may be necessary to remove
entire upper frame from aircraft and strip off paint to adequately
determine extent of damage.

2. Prime bare metal with a good quality zinc chromate or epoxy primer.
3. Refinish area with gray epoxy top coat or equivalent.

5-68 Main Rotor Gearbox Overtemp Illumination

If the gearbox overtemp annunciator segment illuminates, remove main rotor gearbox per
§ 63-20 and return to RHC.

NOTE
Light illuminates at 240±5ºF.

Page 5.48 Chapter 5 Inspections APR 2017

5-69 Main Rotor Gearbox (MR) Chip Light Illumination
If the MR CHIP annunciator segment illuminates:
1. Remove main rotor gearbox chip detector per § 12-13. Inspect any particles found
on the chip detector. Examine the particles and perform following appropriate
corrective action:
a. For fuzz particles: Clean chip detector with compressed air or toothbrush (do not
use magnet) and reinstall per § 12-13. Normal wear, especially new gearboxes,
will produce fine fuzz.
b. For flake particles or slivers longer than 0.12 inch or wider than 0.02 inch:
Clean chip detector. Replace gearbox filter per § 12-12. Visually examine
old filter with 10X magnification; return gearbox to RHC if metallic debris is
detected.
c. For large ferrous chips or chunky particles: Remove gearbox per § 63-20 and
return to RHC. Return chips and/or particles if possible.

5-70 Tail Rotor Gearbox (TR) Chip Light Illumination

If the TR CHIP annunciator segment illuminates:
1. Drain the gearbox per § 12-21, straining the oil through a 190-micron (or finer) paint
filter into a clean container.
2. Inspect any particles found in the paint filter or on the chip detector. Examine the
particles for size; any particles larger (0.09 inch long or 0.02 inch wide) than fine
fuzz (normal wear) should be identified as ferrous or non-ferrous by using a magnet.
If particles are ferrous, remove tail rotor gearbox per § 65-40 and return it to RHC.

5-71 Main Rotor Gearbox Filter Bypass Indicator

NOTE
Extremely cold temperatures may cause the bypass to activate.

If the main rotor gearbox filter bypass indicator button continues to activate after two
consecutive resets (at operating temperature), perform the following:
1. Service filter per § 12-12. Examine filter for particles.
a. If filter is clean, replace (Purolator-Facet P/N) 1740839 bowl assembly or F651-
1 filter assembly.
b. If filter is contaminated, return main rotor gearbox to RHC for overhaul, replace
main rotor gearbox oil cooler and flush oil lines.

APR 2017 Chapter 5 Inspections Page 5.49

5-72 Lightning Strike
Lightning strikes are extremely rare for helicopters operating in VFR conditions.
If a lightning strike does occur, RHC recommends performing a 100-hour inspection per
§ 5-45 and performing the inspection for lightning strike damage per Rolls-Royce RR300
Operation and Maintenance Manual (OMM).
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.

5-73 Pop-Out Float-Equipped Helicopter Water Landing with Tail Rotor Contact
1. Clean tail rotor blades, hub, and airframe exterior with a mild soap and water solution
per Chapter 20.

2. Inspect tail rotor blades per § 64-30; inspect trailing edges for buckling, and leading
edges for bending. If either blade is damaged, remove tail rotor assembly per § 64-10
and tail rotor gearbox per § 65-40 and return components to RHC.
3. Perform tail rotor drive shaft runout per § 65-21. If runout exceeds 0.025 inch at any
location:
a. Remove tail rotor drive shaft assembly per § 65-20 and return drive shaft to RHC.
b. Visually inspect F193-2 hanger and F172-3 (bearing) housing for cracks or
deformation.
c. Replace C947-3 plate assemblies (forward, intermediate, and aft).

Page 5.50 Chapter 5 Inspections APR 2017

FIGURE 5-7 MAIN GEARBOX INTERNAL
VISUAL INSPECTION

5-74 Main Rotor Gearbox Internal Visual Inspection

1. Refer to Figure 5-7. Gain access to and remove main gearbox filler plug.
2. Via filler plug hole and using borescope, miniature camera, or smartphone camera with
flash, visually inspect specified area of gear carrier. Rotate gearbox by hand-turning
main or tail rotor as required to view entire circumference.
3. If no corrosion is evident, install filler plug and special torque per § 20-33.
4. If corrosion is detected, contact RHC Technical Support.

JUL 2020 Chapter 5 Inspections Page 5.51

5-75 Inspection After Stabilizer Damage
For damage to an installed C042-1 upper vertical stabilizer, C043-1 lower vertical
stabilizer, and/or C044 horizontal stabilizer that results in denting, tearing, or cracking of
stabilizer metal:
1. On associated tailcone’s aft casting, strip paint from cross-hatched surfaces shown
in Figure 5-8.
2. Perform fluorescent penetrant inspection (FPI) per ASTM E 1417 of stripped surfaces.
Replace tailcone if crack is indicated.
3. Prime & paint stripped surfaces per §§ 20-60.

FIGURE 5-8 CROSS-HATCHED SURFACES OF TAILCONE'S AFT CASTING

Page 5.52 Chapter 5 Inspections JUL 2020

CHAPTER 6

DIMENSIONS AND DESCRIPTIONS

Section Title Page

6-10 Version Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1

6-20 Datum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1
6-30 Method of Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1
6-40 External Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
6-50 Baggage Compartment Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4
6-60 Station Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6
6-61 Fuselage Station (FS) Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6
6-62 Tailcone Station (TS) Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7
6-63 Water Line (WL) Station Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.8
6-64 Butt Line (BL) Station Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.9
6-70 Access and Inspection Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.10
6-71 B526 Screws and B527-08 Washers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.10
6-80 Antenna Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.11

APR 2017 Chapter 6 Dimensions and Descriptions Page 6.i

Intentionally Blank

Page 6.ii Chapter 6 Dimensions and Descriptions APR 2017

CHAPTER 6

DIMENSIONS AND DESCRIPTIONS

6-10 Version Description

Refer to Section 4-20 for Type Certificate Data Sheet.

R66, Turbine: Five place, single-engine, single main rotor, light turbine helicopter. Two-
bladed teetering main rotor system with conventional two-bladed tail rotor.
Rolls-Royce model 250-C300/A1 turboshaft engine normally rated at 300
shaft horsepower (SHP); 270 SHP 5-minute take-off rating. Maximum
gross weight 2700 pounds. Primary fuel is Jet-A (see R66 Pilot's Operating
Handbook); 74.6 US gallon fuel tank capacity.

6-20 Datum

The datum is located 100 inches forward of main rotor centerline.

6-30 Method of Measurement

Fuselage station, tailcone station, water line station, and butt line station values are measured
in inches, rounded to the nearest hundredth.

25 OCT 2010 R66 Maintenance Manual Chapter 6 Dimensions and Descriptions Page 6.1
Intentionally Blank

Page 6.2 Chapter 6 Dimensions and Descriptions R66 Maintenance Manual 25 OCT 2010
6-40 External Dimensions

FIGURE 6-1 EXTERNAL DIMENSIONS

25 OCT 2010 R66 Maintenance Manual Chapter 6 Dimensions and Descriptions Page 6.3
6-50 Baggage Compartment Dimensions

FIGURE 6-2 BAGGAGE COMPARTMENT INTERIOR DIMENSIONS

(Dimensions given are approximate)

Page 6.4 Chapter 6 Dimensions and Descriptions R66 Maintenance Manual 25 OCT 2010
6-50 Baggage Compartment Dimensions (continued)

FIGURE 6-3 BAGGAGE COMPARTMENT ACCESS DIMENSIONS

(Dimensions given are approximate)

25 OCT 2010 R66 Maintenance Manual Chapter 6 Dimensions and Descriptions Page 6.5
6-60 Station Diagrams

6-61 Fuselage Station (FS) Locations

1 Datum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FS 0.00
2 Nose Bracket (tie-down) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FS 2.36
3 Ground Handling Ball (center point, bottom). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FS 32.67
4 Seat Box Assembly - Forward (front wall) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FS 39.50
5 Seat Box Assembly - Aft (front wall) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FS 69.30
6 Cross Tube - Forward (centerline, at strut) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FS 71.56
7 Baggage Compartment (forward wall) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FS 92.00
8 Main Rotor Drive Shaft (centerline) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FS 100.00
9 Fuel Cell - Structure (aft wall) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FS 115.00
10 Engine Firewall - Vertical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FS 125.00
11 Cross Tube - Aft (centerline, at strut) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FS 127.35
12 Skid Extension (aft edge) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FS 134.78
13 Engine Cowling (aft point) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FS 171.45

FIGURE 6-4 FUSELAGE STATION LOCATIONS

Page 6.6 Chapter 6 Dimensions and Descriptions R66 Maintenance Manual 25 OCT 2010
Page 6.7
NOTE
Typical angle between tailcone station lines & skin aft edges is
4°30’ from longitudinal centerline. Forward edge of C023-6 skin
& aft edge of C023-12 skin are (true) tailcone station lines.
1 Forward Edge C023-6 Skin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TS 0.00
2 Aft Edge C023-6 Skin & Tailcone Centerline Intersection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TS 25.00
3 Aft Edge C023-7 Skin & Tailcone Centerline Intersection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TS 51.00

Chapter 6 Dimensions and Descriptions

4 Aft Edge C023-8 Skin & Tailcone Centerline Intersection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TS 74.00
5 Aft Edge C023-9 Skin & Tailcone Centerline Intersection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TS 98.00
6 Aft Edge C023-10 Skin & Tailcone Centerline Intersection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TS 122.00
7 Aft Edge C023-11 Skin & Tailcone Centerline Intersection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TS 146.00
8 Aft Edge C023-12 Skin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TS 177.30
9* Tail Rotor Gearbox (centerline) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FS 327.00
6-62 Tailcone Station (TS) Locations

R66 Maintenance Manual

25 OCT 2010
FIGURE 6-5 TAILCONE STATION LOCATIONS
6-63 Water Line (WL) Station Locations
1 Teeter Hinge Bolt (main rotor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WL 138.00
2 Upper Rib (top) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WL 125.17
3 Middle Rib (top) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WL 104.88
4 Lower Rib (top) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WL 84.59
5* Tail Rotor Gearbox (centerline) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WL 75.50
6 Main Rotor Gearbox (tail rotor and main rotor drive shaft intersection point) . . . . . . . . . . WL 66.00
7 Baggage Compartment (ceiling, lowest point) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WL 45.60
8 Baggage Compartment (floor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WL 22.59
9 Belly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WL 20.78
10 Landing Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WL 0.79
11 Origin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WL 0.00

FIGURE 6-6 WATER LINE STATION LOCATIONS

Page 6.8 Chapter 6 Dimensions and Descriptions R66 Maintenance Manual 25 OCT 2010
6-64 Butt Line (BL) Station Locations
1 Horizontal Stabilizer (outboard point) . . . . . . . . . BL 46.75
2 Skid Tube (centerline) . . . . . . . . . . . . . . . . . . . . BL 42.00
3 Door Post (between forward & aft doors) . . . . . . BL 28.25
4 Jack Lug/Tab (aft strut assembly) . . . . . . . . . . . BL 16.73
5 Ground Handling Ball (jack point) . . . . . . . . . . . . BL 4.13
6 Origin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BL 0.00
7 Teeter Hinge Bolt (tail rotor) . . . . . . . . . . . . . . . LBL 11.01
8 Jack Tab (aft strut assembly) . . . . . . . . . . . . . . LBL 16.73

FIGURE 6-7 BUTT LINE STATION LOCATIONS

JUL 2020 Chapter 6 Dimensions and Descriptions Page 6.9

6-70 Access and Inspection Panels
Refer to R66 Illustrated Parts Catalog Chapter 6 for access and inspection panel locations.

6-71 B526 Screws and B527-08 Washers

B526 (TORX Plus®) truss head screws may be used to secure cowlings and access
panels. A B527-08 nylon washer may be used under a B526 screw head to further
protect thin or painted surfaces.
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:
PART: INTERCHANGEABLE WITH:
AN525-832R6 or AN526C832R6 screw . . . . B526-6 screw
AN525-832R7 or AN526C832R7 screw . . . . B526-8 screw
AN525-832R8 or AN526C832R8 screw . . . . B526-8 screw

NOTE
B526 screws are compatible with T20 or 20IP drivers.

Page 6.10 Chapter 6 Dimensions and Descriptions JUL 2020

6-80 Antenna Locations
ITEM ANTENNA MHz PART NO. ITEM ANTENNA MHz PART NO.
1 Glidescope . . . . . . . — CI 193 12 Cowling GPS . . . . . . . — GA 35
2 ADF . . . . . . . . . . . . — KA44B Cowling XM . . . . . . . . — GA 55
3 Marker Beacon . . . . — CI 102 13 Upper Fwd COM . . . . . — CI 121, CI 248-5
4 RH Belly UHF . . . . . 400-960 CI 285 Upper Fwd FM . . . . . . — CI 177
5 DME . . . . . . . . . . . . — CI 105-16, KA60 Upper Fwd FM . . . . . . 403-512 CI 273, CI 272-1, CI 271
Transponder . . . . . . — CI 105-16, KA60 800-870 CI 306
ADS-B . . . . . . . . . . — CI 105-16, KA60 Upper Fwd COM/GPS — CI 2580-200
6 LH/RH Belly (Ref) . . — See items 8 and 9 14 Upper Mid RSM/GPS . — 921-00003-001
7 Transponder . . . . . . — CI 105-16, KA60 15 Upper Aft COM . . . . . — CI 121, CI 248-5
8 RH Belly FM . . . . . . 138-174 CI 292-3 Upper Aft FM . . . . . . . — CI 177
450-470 CI 177-20 Upper Aft FM . . . . . . . 403-512 CI 273, CI 272-1, CI 271
RH Belly AM/FM . . . — CI 222 Upper Aft COM/GPS . . — CI 2580-200
RH Belly FM . . . . . . 403-512 CI 273, CI 272-1, CI 271 16 Lower Fwd FM . . . . . . — CI 177
9 LH Belly FM . . . . . . 138-174 CI 292-3 Lower Fwd FM . . . . . . 403-512 CI 273, CI 272-1, CI 271
450-470 CI 177-20 17 Lower Aft FM . . . . . . . — CI 177
220-225 D721-1 Lower Aft VHF . . . . . . 118-136 CI 122
LH Belly FM . . . . . . 403-512 CI 273, CI 272-1, CI 271 Lower Aft FM . . . . . . . 403-512 CI 273, CI 272-1, CI 271
LH Belly COM . . . . . 118-136 CI 122 800-870 CI 306
10 NAV . . . . . . . . . . . . 108-118 & D20543 (VOR & 18 NAV . . . . . . . . . . . . . . 108-118 & D20543 (VOR &
329-335 LOCALIZER) 329-335 LOCALIZER)
108-118 & D20543 (VOR & 108-118 & D20543 (VOR &
329-335 LOCALIZER W/DIPLEXER) 329-335 LOCALIZER W/DIPLEXER)
11 ELT . . . . . . . . . . . . . — AV-300 19 Cowling GPS* . . . . . . . — GA 35
*Earlier aircraft.

FIGURE 6-10 ANTENNA LOCATIONS

APR 2017 Chapter 6 Dimensions and Descriptions Page 6.11

Intentionally Blank

Page 6.12 Chapter 6 Dimensions and Descriptions APR 2017

CHAPTER 7

JACKING AND HOISTING

Section Title Page

7-10 Jacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1
7-20 Hoisting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5

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

Page 7.ii Chapter 7 Jacking and Hoisting R66 Maintenance Manual 25 OCT 2010
CHAPTER 7

JACKING AND HOISTING

7-10 Jacking

CAUTION

When jacking helicopter, use mechanical or locking hydraulic

jacks, when available. Unlocked hydraulic jacks are subject
to pressure-loss which can affect critical measurements during
leveling or cause a raised helicopter to become unstable.
CAUTION

Never jack helicopter in windy conditions.

2. Clear jacks from lugs/tabs and ball, and clear equipment from area.

SEP 2012 R66 Maintenance Manual Chapter 7 Jacking and Hoisting Page 7.3
FIGURE 7-2 HOISTING

Page 7.4 Chapter 7 Jacking and Hoisting R66 Maintenance Manual SEP 2012
7-20 Hoisting

CAUTION

Avoid hoisting helicopter in windy conditions.

CAUTION

Verify ground is free of water, oil, solvent, grease, or residue

that could cause equipment or personnel to slip during hoisting
procedure.
CAUTION

Remain clear of area beneath helicopter when helicopter is raised.

Minimize personnel movement around raised helicopter.

A. Hoisting with Lifting Fixture

1. Refer to Figure 7-2. Verify hoisting equipment has minimum load capacity of 3000 lbs.

2. Position main rotor hub directly under hoist to minimize helicopter swing once aloft.

3. Remove two spring pins and four nylon bushings from MT527-1 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 7-2. Verify hoisting equipment has minimum load capacity of 3000 lbs.
Verify minimum work load limit for 1-inch diameter twisted or double braided (preferred)
soft nylon rope is 3000 lbs.

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.

25 OCT 2010 R66 Maintenance Manual Chapter 7 Jacking and Hoisting Page 7.5
7-20 Hoisting (continued)

C. Lowering

CAUTION

Skids spread as aircraft weight settles on landing gear.

1. Refer to Figure 7-2. Stabilize helicopter as required by guiding tail skid, but do not exert
force (tail skid is secondary structure). Slowly lower aircraft to ground.

2. Disconnect hoisting equipment, remove lifting fixture or nylon rope from main rotor hub,
and clear equipment from area.

Page 7.6 Chapter 7 Jacking and Hoisting R66 Maintenance Manual 25 OCT 2010
CHAPTER 8

WEIGHT AND BALANCE

Section Title Page

8-10 Leveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1
8-11 Leveling for Weight and Balance . . . . . . . . . . . . . . . . . 8.1
8-12 Leveling for Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
8-20 Weighing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5
8-21 Preparing Helicopter for Weighing . . . . . . . . . . . . . . . . 8.5
8-22 Weighing Procedure and Calculations . . . . . . . . . . . . . . 8.7
8-30 Fixed Ballast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.11
8-31 Nose Ballast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.11
8-32 Empennage Ballast . . . . . . . . . . . . . . . . . . . . . . . . . . 8.13

25 OCT 2010 R66 Maintenance Manual Chapter 8 Weight and Balance Page 8.i
Intentionally Blank

Page 8.ii Chapter 8 Weight and Balance R66 Maintenance Manual 25 OCT 2010
CHAPTER 8

WEIGHT AND BALANCE

8-10 Leveling

NOTE

Perform leveling and weighing in a zero-wind environment.

NOTE

Verify spirit level is calibrated by placing level on a designated

surface and noting bubble position. Rotate spirit level 180°;
verify bubble is in the same position.

8-11 Leveling for Weight and Balance

NOTE

Main rotor blade position does not affect weight and balance
calculations.

1. Jack helicopter per Section 7-10.

2. Refer to Figure 8-1. Place a spirit level laterally on F463-1 aft tunnel cover. Verify
cover is flat; if cover is not flat, remove cover and place spirit level across keel panel
flanges.

3. Adjust jacks at (landing gear) aft strut assembly jack lugs/tabs until helicopter is level
laterally.

4. Position spirit level longitudinally on aft tunnel cover, or atop left or right keel panel
if cover is removed. Adjust jack under ground handling ball until helicopter is level
longitudinally.

SEP 2012 R66 Maintenance Manual Chapter 8 Weight and Balance Page 8.1
FIGURE 8-1 LEVELING FOR WEIGHT AND BALANCE
(Lateral shown; view looking down between aft seat footwells)

FIGURE 8-2 LEVELING FOR RIGGING

(Lateral shown)

Page 8.2 Chapter 8 Weight and Balance R66 Maintenance Manual SEP 2012
8-12 Leveling for Rigging

1. Refer to Figure 8-2. Place cyclic stick in vertical position and apply cyclic friction.
Position main rotor blades approximately fore and aft and apply rotor brake. (Teeter
hinge bolt is aligned with lateral axis of helicopter.)

2. Jack helicopter per Section 7-10.

3. Place a spirit level parallel with teeter hinge bolt at location marked "LEVEL HERE" on
top of main rotor hub.

4. Adjust jack at (landing gear) aft strut assembly jack lugs/tabs until helicopter is level
laterally.

5. Release rotor brake and rotate main rotor until teeter hinge bolt is aligned with longitudinal
axis of the helicopter. Apply rotor brake. Verify cyclic stick is in vertical position with
friction applied.

6. Adjust jack under ground handling ball until helicopter is level longitudinally. Remove
spirit level.

SEP 2012 R66 Maintenance Manual Chapter 8 Weight and Balance Page 8.3
Intentionally Blank

Page 8.4 Chapter 8 Weight and Balance R66 Maintenance Manual SEP 2012
8-20 Weighing

Reweigh helicopter when helicopter empty weight and empty weight center of gravity have
been modified and if the accuracy of additional calculations is suspect.

Maintain a continuous record of the helicopter’s weight and balance using the Weight and
Balance Record in R66 Pilot’s Operating Handbook (POH) Section 6.

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

flat, hard surface in a zero-wind environment for accurate scale
readings.

8-21 Preparing Helicopter for Weighing

1. Defuel helicopter per Section 12-42.

2. Service engine oil, hydraulic fluid, and main & tail rotor gearboxes per Chapter 12.

3. Clean aircraft per Section 20-10. Ensure helicopter is completely dry prior to weighing.

4. Remove foreign objects from baggage compartments and stowage areas.

5. Verify cowlings, removable panels, cabin doors, removable controls, and R66 Pilot’s
Operating Handbook (POH) are installed.

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.

25 OCT 2010 R66 Maintenance Manual Chapter 8 Weight and Balance Page 8.5
FIGURE 8-3 WEIGHING
(Scale indications for demonstration only)

Page 8.6 Chapter 8 Weight and Balance R66 Maintenance Manual 25 OCT 2010
8-22 Weighing Procedure and Calculations

NOTE

• Arm is the distance in inches from datum.

• Datum is located 100 inches forward of main rotor centerline.
• CG (arm) is determined by dividing total moment by total weight.

1. Refer to Section 8-20. Prepare helicopter for weighing per Section 8-21.

2. Refer to Figure 8-3. Place a jack and one 1000-lb capacity (minimum) scale under each
(landing gear) aft strut assembly jack lug/tab and under the ground handling ball.

3. Zero scales, or record tare weight (items between scale and weighing point such as
adapter, jack, stand, sandbags, etc.) at each scale.

4. Level helicopter for weight and balance per Sections 8-10 and 8-11. Remove spirit
level. If removed, carefully replace F463-1 aft tunnel cover, unsecured, on top of keel
panels.

5. Calculate net weights:

Weighing Point Scale Indication Tare Weight Net Weight

Forward: – = lb
Left: – = lb
Right: – = lb

SEP 2012 R66 Maintenance Manual Chapter 8 Weight and Balance Page 8.7
8-22 Weighing Procedure and Calculations (continued)

6. Calculate weight and CG per the following table. Adjust ballast per steps 6b thru 6e as
required until calculated CG is between 101.50 and 102.50 per step 6a.

Longitudinal CG
Item Weight (lb) (arm, inches) Moment (in.-lb)
Forward Net: x 32.67 =
Left Net: x 127.35 =
Right Net: x 127.35 =
Pilot (right forward seat; add): 160.00 x 49.00 = 7840.00
Unusable fuel (add): 6.70 x 110.40 = 739.68

Calculated weight and CG:

a. If Calculated CG is between 101.50 and 102.50, (additional) ballast is not required.

Proceed to step 7.

b. If Calculated CG is less than 101.50 and nose ballast is not installed, install empennage
ballast per Section 8-32. Reweigh helicopter and calculate new weight and CG per
the previous steps.

c. If Calculated CG is less than 101.50 and nose ballast is installed, determine (minimum)
nose ballast to remove:

(102.50 - Calculated CG) X Calculated weight

=
97.35 lb
Round down to nearest 0.25 lb. Remove nose ballast per Section 8-31. Reweigh
helicopter and calculate new weight and CG per the previous steps.

d. If Calculated CG is greater than 102.50 and empennage ballast is installed, remove

empennage ballast per Section 8-32. Reweigh helicopter and calculate new weight
and CG per the previous steps.

e. If Calculated CG is greater than 102.50 and empennage ballast is not installed,

determine (minimum) additional nose ballast required:

(Calculated CG - 102.50) X Calculated weight

=
97.35 lb
Round up to nearest 0.25 lb. Install nose ballast per Section 8-31. Reweigh helicopter
and calculate new weight and CG per the previous steps.

7. Lower helicopter per Section 7-10. Secure aft tunnel cover.

Page 8.8 Chapter 8 Weight and Balance R66 Maintenance Manual SEP 2012
8-22 Weighing Procedure and Calculations (continued)

8. Calculate basic empty weight and longitudinal CG:

Longitudinal CG
Item Weight (lb) (arm, inches) Moment (in.-lb)
Forward Net: x 32.67 =
Left Net: x 127.35 =
Right Net: x 127.35 =
Unusable fuel (add): 6.70 x 110.40 = 739.68
Basic empty weight and
longitudinal CG:

9. Calculate basic empty weight and lateral CG:

Lateral CG
Item Weight (lb) (arm, inches) Moment (in.-lb)
Forward Net: x 4.13 =
Left Net: x – 16.73 =
Right Net: x 16.73 =
Unusable fuel (add): 6.70 x – 20.70 = – 138.69
Basic empty weight
and lateral CG:

25 OCT 2010 R66 Maintenance Manual Chapter 8 Weight and Balance Page 8.9
FIGURE 8-4 NOSE BALLAST
(View inside lower console assembly with upper console hinged aft)

Page 8.10 Chapter 8 Weight and Balance R66 Maintenance Manual 25 OCT 2010
8-30 Fixed Ballast

8-31 Nose Ballast

Refer to R66 Illustrated Parts Catalog (IPC) Figure 8-1.

NOTE

Maximum allowable nose ballast is 15.00 lb.

CAUTION

Altering fixed ballast can appreciably affect helicopter center of

gravity (CG). If fixed ballast information is unknown, reweigh
helicopter per Section 8-22.

1. Refer to Figure 8-4. Remove screws securing B050-22 or -23 upper console assembly to
F033-1 lower console assembly and hinge upper console assembly aft. Protect instrument
face with foam support or equivalent.

2. Remove hardware securing A941-5 or -6 ballast plate(s), if installed, to F361-1 panel.

3. Remove or install ballast plates per calculations performed in Section 8-22. Select NAS6603
bolt length to meet torque requirements per Section 20-30. Install hardware, torque bolts
per Section 20-32, and torque stripe per Figure 5-1.

4. Hinge upper console assembly forward and install screws securing upper and lower
console assemblies. Verify security.

5. Reweigh and/or calculate basic empty weight and CG per Section 8-22.

6. Revise Weight and Balance Record in R66 Pilot's Operating Handbook (POH) Section 6
to reflect ballast removal or installation using the following data:

Weight Longitudinal Longitudinal Lateral Arm Lateral

Arm Moment Moment
Nose ballast 0-15.00 lb 5.15 in. Variable 0.00 in. 0.00 in.-lb

25 OCT 2010 R66 Maintenance Manual Chapter 8 Weight and Balance Page 8.11
FIGURE 8-5 EMPENNAGE BALLAST

Page 8.12 Chapter 8 Weight and Balance R66 Maintenance Manual 25 OCT 2010
8-32 Empennage Ballast

NOTE
Use only approved materials listed in § 20-70.
CAUTION
Altering fixed ballast can appreciably affect helicopter center of
gravity (CG). If fixed ballast information is unknown, reweigh
helicopter per § 8-22.
CAUTION
Maximum allowable empennage ballast is 3.00 lb (except Police
and E.N.G. Versions).

A. Removal
1. Refer to Figure 8-5. Remove empennage assembly, including D301-2 ballast
weights, per § 53-50.
2. Solvent-clean bare metal around and between bolt holes on horizontal stabilizer
upper and lower surfaces.
3. Apply light coat zinc-chromate or epoxy primer to bare metal surfaces. While
primer is wet, install empennage assembly per § 53-50. Topcoat hardware with
colored paint as desired.
4. Reweigh and/or calculate basic empty weight and CG per § 8-22.
5. Revise Weight and Balance Record in R66 Pilot's Operating Handbook (POH)
Section 6 to reflect ballast removal using the following data:

Longitudinal Longitudinal Lateral Lateral

Item Weight
Arm Moment Arm Moment
Empennage
3.00 lb 325.44 in. 976.32 in.-lb 4.45 in. 13.35 in.-lb
Ballast

B. Installation
1. Refer to Figure 8-5. Remove empennage assembly per § 53-50.
2. Solvent-clean bare metal around and between bolt holes on horizontal stabilizer
upper and lower surfaces.
3. Temporarily install D301-2 weights per IPC Figure 8-1. Torque bolts per § 20-32.
4. Trace outline of weights onto horizontal stabilizer upper and lower surfaces using
felt-tip, non-permanent marker or tape. Remove weights.

JUL 2020 Chapter 8 Weight and Balance Page 8.13

8-32 Empennage Ballast (continued)
B. Installation (continued)
5. Remove paint within traced outlines on stabilizer by block sanding (to maintain
flatness). Finish sanding using 320-grit or finer wet-or-dry sandpaper, or using
approved stripper per § 20-71. Similarly, on each D301-2 weight, remove paint
from one flat surface which will clamp against stabilizer.
6. Remove tracing media. Solvent-clean bare metal on horizontal stabilizer and
weight clamping surfaces.
7. Reweigh and/or calculate basic empty weight and CG per § 8-22.
8. Revise Weight and Balance Record in R66 Pilot's Operating Handbook (POH)
Section 6 to reflect ballast installation using the following data:

Longitudinal Longitudinal Lateral Lateral

Item Weight
Arm Moment Arm Moment
Empennage
3.00 lb 325.44 in. 976.32 in.-lb 4.45 in. 13.35 in.-lb
Ballast

Page 8.14 Chapter 8 Weight and Balance JUL 2020

CHAPTER 9

GROUND HANDLING

Section Title Page

9-10 Ground Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1
9-11 Ground Handling Wheels . . . . . . . . . . . . . . . . . . . . . . 9.1
9-12 Moving Helicopter on Ground Handling Wheels . . . . . . . 9.3
9-13 Ground Handling Carts . . . . . . . . . . . . . . . . . . . . . . . . 9.3
9-14 Ground Power Start . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
9-20 Trailering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4

25 OCT 2010 R66 Maintenance Manual Chapter 9 Ground Handling Page 9.i
Intentionally Blank

Page 9.ii Chapter 9 Ground Handling R66 Maintenance Manual 25 OCT 2010
CHAPTER 9

GROUND HANDLING

9-10 Ground Handling

9-11 Ground Handling Wheels

Refer to R66 Illustrated Parts Catalog (IPC) Figure 9-1.

NOTE

R66 ground handling wheels are installed inboard of landing

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

A. Installation

NOTE

Verify proper inflation of ground handling wheel tires. Maximum

tire inflation pressure is 70 psi.

1. Extend ground handling wheel retractable handle by depressing locking pins and
sliding handle out until pins engage outer holes. Verify security.

2. Refer to Figure 9-1. Hold ground handling wheel assembly inboard of skid with
handle forward, wheel aft, and spindle pointed outboard. Insert spindle completely
into skid-mounted support, then pull handle in rearward arc (raises helicopter) until
handle is in locked position, parallel with the skid.

3. Repeat steps to install second wheel assembly. Helicopter will rest on skid toes.

25 OCT 2010 R66 Maintenance Manual Chapter 9 Ground Handling Page 9.1
1. Insert spindle into skid-mounted support. 2. Verify flange is outboard of cradle.

3. Pull handle in rearward arc to raise helicopter.

4. Handle is in locked position when parallel with the skid.

NOTE

R66 ground handling wheels are installed inboard of landing

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

FIGURE 9-1 GROUND HANDLING WHEELS

Page 9.2 Chapter 9 Ground Handling R66 Maintenance Manual 25 OCT 2010
9-11 Ground Handling Wheels (continued)
B. Removal
1. Refer to Figure 9-1. Pull ground handling wheel handle in forward arc (lowers
helicopter) until handle is in unlocked position, parallel with the skid. Remove spindle
from skid-mounted support and remove wheel assembly. Repeat step to remove
second wheel assembly.
2. Retract handle by depressing locking pins and sliding handle in until pins engage
inner holes. Verify security.
9-12 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 Section 9-11.
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. a. If moving helicopter forward, nose first: Open engine cowling door(s). Have one
person (or two people) push on the engine door frame(s) forward ledge.
b. If moving helicopter backward, tail first: Have one person (or two people) push on
either side of nose vent.
9-13 Ground Handling Carts
The R66 can be handled by one person using the MT950-1 Universal ground handling cart.
Product specifications, as well as MT950 Operating Instructions, Maintenance Manuals,
and Illustrated Parts Catalogs are available on our website, www.robinsonheli.com, under
the Customer Support tab.
9-14 Ground Power Start
See R66 Pilot's Operating Handbook (POH) Section 4.

SEP 2012 R66 Maintenance Manual Chapter 9 Ground Handling Page 9.3
9-20 Trailering

CAUTION

Trailering the R66 is not normally recommended. Most trailers

large enough to accommodate the helicopter are designed for
much heavier loads; the trailer’s springs and shock absorbers
will not function properly when lightly-loaded. Also, without
support, the tailcone can resonate with trailer vibrations,
subjecting the tailcone to greatly amplified loads.

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 Section 62-10. Pack blades in shipping crate. See R66
Illustrated Parts Catalog [IPC] Figure 99-11.

b. Install main rotor blade supports per Section 10-13.

c. Fabricate blade supports to unload droop stops. Position supports inboard of blade
extended tab. Cushion support points to prevent blade damage.

4. Restrain tail rotor to prevent teetering.

5. Fuel helicopter per Section 12-41.

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 Section 5-45.

Page 9.4 Chapter 9 Ground Handling R66 Maintenance Manual SEP 2012
CHAPTER 10

PARKING AND STORAGE

Section Title Page

10-10 Parking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1
10-11 Parking in High Wind or Turbulent Air . . . . . . . . . . . . . 10.1
10-12 Main Rotor Blade Tie-Downs . . . . . . . . . . . . . . . . . . . . 10.3
10-13 Main Rotor Blade Supports . . . . . . . . . . . . . . . . . . . . . 10.5
10-20 Storage (Greater than 30 days) . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6

25 OCT 2010 R66 Maintenance Manual Chapter 10 Parking and Storage Page 10.i
Intentionally Blank

Page 10.ii Chapter 10 Parking and Storage R66 Maintenance Manual 25 OCT 2010
CHAPTER 10

PARKING AND STORAGE

10-10 Parking

1. Place cyclic stick in vertical position and apply cyclic friction.

2. Place collective stick full down and apply collective friction.

CAUTION

Never pull down on main rotor blade. To teeter blades, push up

on the opposite blade.

3. Open three left-side fuselage access doors, observe placards, and climb steps to access
main rotor. Teeter blades by pushing up on one blade until opposite blade contacts teeter
stop. Rotate low blade forward. Position rotor blades approximately fore and aft and apply
rotor brake.

4. Install main rotor blade tie-down(s) per Section 10-12. Install engine exhaust cover.

5. Close and latch all access doors. Close and latch baggage compartment door.

6. Verify BATTERY switch is OFF, buckle seat harnesses, and close and latch cabin doors (if
installed).

10-11 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 Section 10-10. Position rotor blades slightly offset from fore and
aft to prevent aft blade from flapping into tailcone, and apply rotor brake.

B. Extreme Conditions

In extreme conditions, at the operator's discretion:

1. Remove main rotor blades per Section 62-10. Remove tail rotor assembly per Section
64-10. 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.

SEP 2012 R66 Maintenance Manual Chapter 10 Parking and Storage Page 10.1
FIGURE 10-1 MAIN ROTOR BLADE TIE-DOWNS

Page 10.2 Chapter 10 Parking and Storage R66 Maintenance Manual SEP 2012
10-11 Parking in High Wind or Turbulent Air (continued)

B. Extreme Conditions (continued)

2. b. Remove hardware securing pitch links to swashplate assembly.

3. Remove tail rotor pitch links per steps below:

a. Refer to Figure 64-1. Tag each pitch link with corresponding blade serial number.
Disconnect pitch links from tail rotor blades; keep associate balancing hardware
with each link.

b. Remove hardware securing pitch links to tail rotor pitch control assembly.

10-12 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 and position blades per Section 10-10 or 10-11.

2. Refer to Figure 10-1. Slide MT290-3 tie-down jacket over forward (lowered) main rotor
blade tip, with white lettering facing down. Thread strap through nose bracket and
secure tie-down hook and loop tape. Push up on secured blade to remove slack in tie-
down strap.

3. As required, install MT290-3 tie-down on aft main rotor blade. Slide jacket over blade
tip, with white lettering facing down. Wrap strap 1¾ times around tailcone forward of
strobe light, twist strap around strobe light base, and secure tie-down hook and loop
tape. Push up on secured blade to remove slack in tie-down strap.

25 OCT 2010 R66 Maintenance Manual Chapter 10 Parking and Storage Page 10.3
FIGURE 10-2 MAIN ROTOR BLADE SUPPORTS

Page 10.4 Chapter 10 Parking and Storage R66 Maintenance Manual 25 OCT 2010
10-13 Main Rotor Blade Supports

Refer to R66 Illustrated Parts Catalog (IPC) Figure 10-7.

CAUTION

Do not allow strut assemblies to hang from cradle assemblies

installed on main rotor blades. Support strut assemblies during
strut removal or installation.

A. Removal

1. Refer to Figure 10-2. Remove 92384A034 retaining pins securing MT347-7 strut
assembly to MT564-2 cradle assembly and MT348-7 clamp assembly; remove strut
assembly. Remove cradle and clamp assemblies.

2. Remove retaining pin securing one MT347-8 strut assembly to landing gear eyebolt,
then remove pin securing same strut to MT564-1 cradle assembly. Repeat step to
remove second strut assembly.

3. Detach MT568-3 strap assembly hook and loop tape near roof-mounted cleat and
unthread strap from cleat. Remove cradle assembly.

B. Installation

NOTE

B221-3 attachment installation (landing gear eyebolts and roof-

mounted cleat) is required for mounting blade supports.

1. Refer to Figure 10-2. Position main rotor blades approximately fore and aft.

2. Install MT564-1 cradle assembly inboard of forward blade extended tab, with MT568-
3 strap assembly attached. Thread opposite end of strap assembly through roof-
mounted cleat and secure strap hook and loop tape.

3. Secure one MT347-8 strut assembly to cradle assembly, then to landing gear eyebolt,
using 92384A034 retaining pins. Repeat step to secure second strut assembly.

4. Install MT564-2 cradle assembly inboard of aft blade extended tab. Install MT348-7
clamp assembly against forward edge of rivets between tailcone bays 3 and 4.

5. Secure MT347-7 strut assembly to cradle and clamp assemblies using retaining pins.
Verify strut is approximately vertical.

6. Engage rotor brake. If desired, mark cradle assembly location on blade using felt-tip
marker, to facilitate future installation.

25 OCT 2010 R66 Maintenance Manual Chapter 10 Parking and Storage Page 10.5
10-20 Storage (Greater than 30 days)

NOTE

Helicopter should be hangared or moved to a safe area during

storage.
NOTE

Periodically inspect aircraft for corrosion and correct as required.

Aircraft stored in humid environments are subject to aggressive
corrosive reaction and require more frequent inspection.

1. Record the date helicopter is prepared and placed in storage.

2. Preserve engine for aircraft storage per RR300 Series Operation and Maintenance Manual
(OMM).
3. Refinish main rotor blades per Section 62-52. Refinish tail rotor blades per Section 64-36.

4. Open applicable circuit breakers.

5. Remove battery per Chapter 96. Inspect & service battery according to battery manufacturer’s
instructions.

6. Service engine oil, hydraulic fluid, and main & tail rotor gearboxes per Chapter 12.

7. Fuel helicopter per Section 12-41.

NOTE

Fuel lubricates bladder inner liner and keeps it from drying out
or cracking. Refuel helicopter after run-ups during storage per
Section 12-41.

8. Clean aircraft per Section 20-10. Ensure helicopter is clean and dry prior to storing. Open
door vents and doors to ventilate cabin and baggage compartment as required.

9. Close and latch all access doors. Install engine exhaust cover.

Page 10.6 Chapter 10 Parking and Storage R66 Maintenance Manual 25 OCT 2010
CHAPTER 11

PLACARDS AND MARKINGS

Section Title Page

11-10 Placards and Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1

APR 2017 Chapter 11 Placards and Markings Page 11.i

Intentionally Blank

Page 11.ii Chapter 11 Placards and Markings APR 2017

CHAPTER 11

PLACARDS AND MARKINGS

11-10 Placards and Markings

Refer to R66 Illustrated Parts Catalog Chapter 11 for placard and marking locations.
A. Removal
To remove previously installed decals, start at corners and slowly peel off decal by
hand or using a plastic wedge. Avoid damaging or removing paint or primer from
surfaces. 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. Acetone can smudge or remove silk-screened
letters. Attach decal and rub decal surface with finger, applying slight pressure.

APR 2017 Chapter 11 Placards and Markings Page 11.1

Intentionally Blank

Page 11.2 Chapter 11 Placards and Markings APR 2017

CHAPTER 12

SERVICING
Section Title Page

12-10 Main Rotor Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.1

12-11 Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.1
12-12 Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.3
12-13 Chip Detector and Sight Gage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.3
12-20 Tail Rotor Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.7
12-21 Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.7
12-22 Chip Detector and Sight Gage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.8
12-23 Drain and Flush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.8
12-30 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.9
12-31 Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.9
12-32 Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.9
12-33 Drain and Flush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.11
12-34 Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.12
12-40 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.13
12-41 Fueling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.13
12-42 Defueling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.13A
12-50 Main Rotor Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.15
12-51 Pitch Bearing Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.15
12-60 Engine Oil Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.16
12-70 (Engine) Compressor Rinse and Wash . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.17
12-71 Drainage Spotface Inspection During Cleaning or Rinsing of RR300 Engine 12.17A
12-80 Air Conditioning System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.18
12-81 Refrigerant Recovery and System Charging . . . . . . . . . . . . . . . . . . . . . 12.18
12-82 Desiccant Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.19
12-83 Leak Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.19
12-90 Lubrication of Swashplate Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.21

JUL 2020 Chapter 12 Servicing Page 12.i

Intentionally Blank

Page 12.ii Chapter 12 Servicing JUL 2020

CHAPTER 12

SERVICING

12-10 Main Rotor Gearbox

WARNING

Refer to appropriate Material Safety Data Sheet (MSDS) and

take necessary safety precautions when working in proximity
to hazardous materials.

12-11 Servicing

NOTE

Inspect main rotor gearbox and gearbox lubrication system for

leaks when “top off” is required.
NOTE

Verify aircraft is on level ground when evaluating gearbox oil

level.

A. Draining Fluid

1. Refer to Figure 12-1. Disconnect chip detector wiring, as required. Remove chip
detector from housing.

2. Refer to Figure 12-2. Insert MT054-1 drain assembly into chip detector housing.
Position drain hose overboard into a suitable drain container. Jam wedge between
support panel stiffener and drain assembly fitting to open valve.

B. Adding Fluid

1. Install chip detector per Section 12-13, if removed.

2. Refer to Figure 12-1. Remove gearbox filler-plug. Fill gearbox with A257-22 lubricant
to center of sight glass.

3. Rotate rotor system by hand for several revolutions and pull down on tail rotor
gearbox several times. Check gearbox oil level and adjust level as required.

4. Install filler-plug and special torque plug per Section 20-33.

5. Run-up helicopter approximately five minutes at 60-70% RPM per R66 Pilot’s
Operating Handbook (POH) Section 4.

6. Check gearbox oil level, and adjust level per steps 2 thru 6 as required.

SEP 2012 R66 Maintenance Manual Chapter 12 Servicing Page 12.1

FIGURE 12-1 MAIN ROTOR GEARBOX SERVICING

Page 12.2 Chapter 12 Servicing R66 Maintenance Manual SEP 2012

12-12 Filter Replacement

NOTE
Replace main rotor gearbox oil every 600 hours. When
replacing a filter after new or overhauled main rotor gearbox
has accumulated 100 hours, replacing oil is not required.

1. Drain main rotor gearbox oil per § 12-11, if required.

2. Cut and discard safety wire securing bowl & indicator assembly to head assembly.
Unscrew bowl and remove and discard element. Remove o-ring and back-up ring from
head assembly.
3. Clean and dry bowl assembly; install new F651-3 seals kit and F651-2 element.
4. Hand-tighten bowl assembly until tight against head assembly. Install 0.032-inch
diameter lockwire and safety bowl to head.
5. Service main rotor gearbox per § 12-11.

12-13 Chip Detector and Sight Gage

A. Removal
1. Refer to Figure 12-1. Disconnect chip detector wiring, as required. Remove chip
detector from housing.

NOTE
Remove chip detector housing and inspect for obvious damage
if housing leaks.

2. Drain main rotor gearbox oil per § 12-11, if removing chip detector housing or
sight gage. Remove housing and/or gage as required.
B. Cleaning Chip Detector (and Housing)
1. Clean chip detector using a toothbrush and approved solvent (refer to § 20-70).
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.
2. Refer to Figure 12-1. Connect chip detector electrical wiring and special torque
terminal nut per § 20-33. Turn battery switch on and ground detector’s central
magnetic probe to airframe. Verify appropriate CHIP warning segment illuminates.
Turn battery switch off.

APR 2019 Chapter 12 Servicing Page 12.3

FIGURE 12-2 DRAINING MAIN ROTOR GEARBOX OIL

Page 12.4 Chapter 12 Servicing APR 2019

12-13 Chip Detector and Sight Gage (continued)

C. Installation

1. Refer to Figure 12-1. Verify cleanliness and clarity of sight gage. As required,
remove sight gage per Part A and clean with approved solvent per Section 20-70.
Install sight gage and special torque per Section 20-33.

2. Verify cleanliness of chip detector and housing. As required, remove and clean
chip detector and housing per Parts A and B. Install housing and special torque per
Section 20-33. Install chip detector.

3. Turn BATTERY switch ON. Verify MR CHIP warning segment illuminates when test
button is depressed. Turn BATTERY switch OFF.

SEP 2012 R66 Maintenance Manual Chapter 12 Servicing Page 12.5

FIGURE 12-3 TAIL ROTOR GEARBOX

Page 12.6 Chapter 12 Servicing R66 Maintenance Manual SEP 2012

12-20 Tail Rotor Gearbox

WARNING

Refer to appropriate Material Safety Data Sheet (MSDS) and

take necessary safety precautions when working in proximity
to hazardous materials.

12-21 Servicing

NOTE

Inspect tail rotor gearbox for leaks when “top off” is required.
NOTE

Verify aircraft is on level ground when evaluating gearbox oil

level.

A. Draining Fluid

1. Refer to Figure 12-3. Cut and discard ty-raps as required and disconnect chip detector
wiring from airframe harness at connectors.

2. Place a suitable drain container under gearbox to catch oil, then remove chip
detector.

B. Adding Fluid

1. Install chip detector per Section 12-22.

2. Refer to Figure 12-3. Remove filler-vent plug and fill gearbox with A257-22 lubricant
to center of sight glass.

3. Install plug and special torque per Section 20-33.

SEP 2012 R66 Maintenance Manual Chapter 12 Servicing Page 12.7

12-22 Chip Detector and Sight Gage

A. Removal

1. Drain tail rotor gearbox oil per Section 12-21.

2. Remove sight gage, as required.

B. Cleaning Chip Detector

1. Clean chip detector per Section 12-13 Part B (main rotor gearbox).

C. Installation
1. Refer to Figure 12-3. Verify cleanliness and clarity of sight gage. As required,
remove sight gage per Part A and clean with approved solvent per Section 20-70.
Install sight gage and special torque per Section 20-33.

2. Verify cleanliness of chip detector. As required, clean chip detector per Section 12-
13 Part B (main rotor gearbox). Install chip detector and special torque per Section
20-33.

3. Connect chip detector wiring and install ty-raps, as required. Cinch ty-raps until
snug without over-tightening, and trim tips flush with heads.

4. Turn BATTERY switch ON. Verify TR CHIP warning segment illuminates when test
button is depressed. Turn BATTERY switch OFF.

5. Service tail rotor gearbox per Section 12-21.

12-23 Drain and Flush

1. Drain tail rotor gearbox oil per Section 12-21.

2. Install chip detector and special torque per Section 20-33.

3. Remove filler-vent plug and add approximately five ounces of SAE30, SAE40, SAE50,
or SAE20W50 straight mineral engine oil to gearbox. Install plug and special torque per
Section 20-33.

4. Run-up helicopter approximately five minutes at 60-70% RPM per R66 Pilot's Operating
Handbook (POH) Section 4.

5. Drain tail rotor gearbox oil (mineral oil) per Section 12-21.

6. Clean and install chip detector per Section 12-22 Parts B and C.

Page 12.8 Chapter 12 Servicing R66 Maintenance Manual SEP 2012

12-30 Hydraulic System

CAUTION
Do not contaminate hydraulic fluid. Service hydraulic system
with clean fluid from sealed containers, using clean tools.
WARNING
Refer to appropriate Material Safety Data Sheet (MSDS) and
take necessary safety precautions when working in proximity to
hazardous materials.

12-31 Servicing

A. Draining Fluid

1. Perform drain and flush per Section 12-33.

B. Adding Fluid

NOTE
Inspect hydraulic system for leaks when “top off” is required.

1. Refer to Figure 12-4. Remove filler-vent plug. With system filled and bled, fill
hydraulic reservoir to center of sight glass with new A257-15 fluid.

2. Install filler-vent plug and special torque per Section 20-33.

12-32 Filter Replacement

1. Refer to Figure 12-4. Remove D516-1 cap and filter and visually inspect element for
contaminants. If element is clear, proceed to step 3. If metal contamination is found, use
a magnet to determine if metal is ferrous. If metal is ferrous, perform the following:

a. Install new filter per steps 3 thru 5.

b. After one flight-hour, remove filter and inspect for ferrous metal. If ferrous metal is
found upon second inspection, replace hydraulic pump per Section 67-50, then drain
and flush hydraulic system per Section 12-33.

2. Discard cap packing. Clean cap with approved solvent per Section 20-70, and dry cap
with compressed air or a lint-free cloth. Lubricate new packing with A257-15 fluid and
install on cap.

3. Lubricate packing inside new filter with A257-15 fluid and install filter in reservoir.
Install cap and special torque per Section 20-33.

4. Service hydraulic reservoir per Section 12-31.

SEP 2012 R66 Maintenance Manual Chapter 12 Servicing Page 12.9

FIGURE 12-4 HYDRAULIC SYSTEM

Page 12.10 Chapter 12 Servicing R66 Maintenance Manual SEP 2012

12-33 Drain and Flush

NOTE

Drain and flush hydraulic system if oil turns dark or emits bad
odor.
WARNING

Keep limbs clear of flight controls when operating test pump.

Hydraulic forces can cause injury.

1. Refer to Figure 12-4. Remove filler-vent plug. Place a suitable drain container under
F902-1 (pressure) and F902-2 (suction) line assembly T-fittings, and remove caps.
Pour small amount of new A257-15 fluid into hydraulic reservoir to purge suction line.
Pressure line will drain in following step, when D516-1 cap is removed.
2. Replace filter per Section 12-32.
3. Connect MT384 (or equivalent) 0.8-1.2 gpm hydraulic test pump assembly to T-fittings.
(Pressure and suction fittings are different sizes to ensure correct connection.)
4. Service hydraulic reservoir per Section 12-31.
5. Disconnect D205-18 hose assembly (return) from reservoir. Place line into drain
container; cap union with a T-fitting cap.
6. Activate test pump and inspect hydraulic system for leaks.
7. Simultaneously fully raise collective and move cyclic fully forward then simultaneously
fully lower collective and move cyclic fully aft. Monitor reservoir fluid level and fill as
required. Repeat procedure until return line fluid is clean.
8. Simultaneously fully raise collective and move cyclic fully aft then simultaneously fully
lower collective and move cyclic fully forward. Monitor reservoir fluid level and fill as
required. Repeat procedure until return line fluid is clean.
9. Turn off test pump and disconnect equipment. Remove cap and connect hose assembly
(return) to reservoir. Using back-up wrench, standard torque hose nut per Section 20-
32 and torque stripe per Figure 5-1. Install caps on T-fittings, special torque caps per
Section 20-33, and torque stripe per Figure 5-1.
10. Bleed hydraulic system per Section 12-34.
11. Remove cap and filter and visually inspect element for contaminants. If debris is found,
repeat drain and flush procedure. If filter is clean, install filter & cap and special torque
cap per Section 20-33.
12. Service hydraulic reservoir per Section 12-31.

SEP 2012 R66 Maintenance Manual Chapter 12 Servicing Page 12.11

12-34 Bleeding

WARNING

Keep limbs clear of flight controls when operating test pump.

Hydraulic forces can cause injury.

1. Remove F902-1 (pressure) line assembly T-fitting cap. Connect MT384 (or equivalent)
0.8-1.2 gpm hydraulic test pump pressure line to T-fitting. (Pressure and suction fittings
are different sizes to ensure correct connection.)

2. Remove filler-vent plug and cover hydraulic reservoir hole with finger to prevent fluid
loss (until suction line is connected). Remove F902-2 (suction) line assembly T-fitting
cap. Connect test pump suction line to T-fitting. Service reservoir with new A257-15
fluid, as required.

3. Activate test pump and inspect hydraulic system for leaks.

4. Simultaneously fully raise collective and move cyclic fully forward then simultaneously
fully lower collective and move cyclic fully aft. Repeat procedure ten times.

5. Simultaneously fully raise collective and move cyclic fully aft then simultaneously fully
lower collective and move cyclic fully forward. Repeat procedure ten times.

6. Turn off test pump and verify no leaks in hydraulic system.

7. Cover reservoir hole with finger (until suction line T-fitting is capped). Disconnect test
pump suction line from suction line T-fitting and install cap.

8. Disconnect test pump pressure line from pressure line T-fitting and install cap. Special
torque caps per Section 20-33 and torque stripe per Figure 5-1.

9. Service hydraulic reservoir per Section 12-31.

Page 12.12 Chapter 12 Servicing R66 Maintenance Manual SEP 2012

12-40 Fuel System

WARNING
Review appropriate Safety Data Sheet (SDS) when working in
proximity to hazardous materials. Specific recommendations
for use of personal protective equipment are located in the SDS.
WARNING
Always fuel helicopter in a well-ventilated area. No smoking
within 100 feet of aircraft during fueling.

12-41 Fueling
1. Turn battery switch off.
2. a. Main Fuel System: Ground helicopter and ground fuel vehicle. Open fueling cowl
door and connect fuel vehicle ground cable to helicopter at location identified by
decal.
b. Auxiliary Fuel System: Ground helicopter and ground fuel vehicle. Open baggage
compartment door and connect fuel vehicle ground cable to aux fuel tank at
location identified by decal.
3. Verify proper grade of aviation fuel. See R66 Pilot's Operating Handbook (POH)
Section 2 for approved fuel grades and instructions for use of anti-ice additive.
4. Remove fuel cap and fuel helicopter as required.

NOTE
If auxiliary fuel system is installed, press QUANTITY button on
aux fuel control panel for aux tank quantity, displayed on fuel
quantity gage.

5. a. Main Fuel System: Install fuel cap, remove grounding equipment, and close and
secure cowl door.
b. Auxiliary Fuel System: Install fuel cap, remove grounding equipment, and close
and secure baggage compartment door.

JUL 2020 Chapter 12 Servicing Page 12.13

12-42 Defueling
A. Main Fuel System
1. Remove engine cowling per § 53-21.
2. Turn battery switch off. Pull fuel valve control to Off position.
3. Disconnect B283-12 hose at engine and install cap on engine inlet fitting.
4. Position hose into a suitable, grounded drain container.

NOTE
If desired, perform low-fuel switch assembly check per § 28-
22.

5. Push fuel valve control into On position and drain fuel; drain residual fuel via
sump valve. Pull fuel valve control to Off position. Perform maintenance tasks
as required.
6. Add minimum 5 gallons fuel per § 12-41. Push fuel valve control into On position
until fuel flows thru hose without bubbles. Pull fuel valve control to Off position.
7. Remove cap from engine fuel inlet fitting. Connect B283-12 hose, special torque
hose nut per § 20-33, and torque stripe per Figure 5-1.
8. Defuel engine as required per RR300 Series Operation and Maintenance Manual
(OMM).

B. Auxiliary Fuel System

1. Turn battery switch off. Open baggage compartment door.
2. Release D205-35 (large tank; drain) or D205-37 (small tank; drain) hose assembly
from tab. Position hose overboard into a suitable, grounded drain container.
3. Open locking drain valve and drain fuel as required.
4. Close drain valve and secure hose near drain valve at tab. Secure baggage
compartment door.

NOTE
Alternately, and depending on projected operations and main fuel
system quantity, fuel may be transferred from the auxiliary fuel
tank to the main bladder using the auxiliary fuel pump (use of
external power is recommended). After fuel transfer using pump
method there will be some fuel remaining in auxiliary tank; to
completely drain tank, use drain hose method described above.

Page 12.13A Chapter 12 Servicing JUL 2020

Intentionally Blank

APR 2017 Chapter 12 Servicing Page 12.13B

FIGURE 12-5 MAIN ROTOR BLADE PITCH BEARING HOUSING

Page 12.14 Chapter 12 Servicing APR 2017

12-50 Main Rotor Blades

WARNING
Refer to appropriate Material Safety Data Sheet (MSDS) and
take necessary safety precautions when working in proximity
to hazardous materials.

12-51 Pitch Bearing Housing

NOTE
MT147-1 Main rotor blade spindle air bleed tool includes supply
container, hose assemblies, and bleed fittings.

A. Servicing
1. Remove main rotor blades per § 62-10.
2. Refer to Figure 12-5. Place a suitable drain container below main rotor blade
spindle assembly. Remove two B289-2 bolts and drain fluid.
3. Install MT147-1 bleed tool fittings into ports. Attach drain hose assembly to
(top) bleed fitting, secure with two wraps 0.032-inch diameter lockwire, and
safety tight. 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 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, “pitch” blade up & down, 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. Torque B289-2 bolts per § 20-33 and torque stripe per Figure 5-1.
9. Repeat steps for opposite blade.

APR 2017 Chapter 12 Servicing Page 12.15

12-60 Engine Oil Servicing
A. Draining Fluid
1. As required, run-up helicopter two to five minutes at 60-70% RPM per R66 Pilot's
Operating Handbook (POH) Section 4 to warm engine oil.
2. Remove engine cowling per § 53-21.
3. Place a suitable drain container below B289-2 bolt in bend of F723-1 line assembly,
and below AS5169D04 (drain) fitting in F649-1 oil cooler assembly.
4. Remove line assembly bolt and oil cooler assembly (drain) fitting and drain oil.
5. Service the engine oil system per RR300 Series Operation and Maintenance Manual
(OMM).
B. Adding Fluid

NOTE
Do not contaminate engine oil. Service engine oil system with
clean fluid from sealed containers, using clean tools.
NOTE
When servicing airframe oil tank, full oil quantity is six quarts;
minimum quantity for takeoff is four quarts.
Six quart indication is top of knurled section of dipstick. Four
quart indication is bottom of knurled section of dipstick or
center of oil tank sight gage.

1. Install B289-2 bolt in bend of F723-1 line assembly and special torque per § 20-33.
2. Install AS5169D04 (drain) fitting in F649-1 oil cooler assembly and special torque
per § 20-33.
3. Install engine cowling per § 53-21.
4. Open access door, remove dipstick, and service airframe oil tank using approved
turbine engine oil per R66 Pilot's Operating Handbook (POH) Section 8.
5. Install dipstick and close access door.
6. Perform engine test per RR300 Series Operation and Maintenance Manual (OMM)
as required.

Page 12.16 Chapter 12 Servicing APR 2017

12-70 (Engine) Compressor Rinse and Wash

CAUTION
See RR300 Series Operation and Maintenance Manual (OMM)
requirements for compressor rinse and wash intervals.
CAUTION
Always perform compressor rinse or wash with sufficient
clearance for possible rotor system rotation.

1. Remove engine cowling per § 53-21.

2. Open access door and remove (engine) compressor fluid-delivery tube cap.
3. Refer to RR300 Series Operation and Maintenance Manual (OMM) for equipment
and material requirements. Operate compressor cleaning system per manufacturer's
instructions.
4. Connect appropriate cleaning system hose to delivery tube.
5. Refer to RR300 Series OMM for compressor rinse and wash procedures.
To motor engine without ignition system:
a. Release rotor brake.
b. Turn battery switch on.
c. Verify fuel cutoff pulled OFF. Verify igniter (key) switched OFF.
d. Verify area is clear.
e. Close throttle.
f. Push and release start button as required to maintain N1 speed for required
interval.
6. Disconnect cleaning system hose from delivery tube. Install delivery tube cap and
standard torque per § 20-32. Close access door.
7. Refer to RR300 Series OMM for returning engine to service.
To perform ground run:
a. Refer to R66 Pilot's Operating Handbook (POH) Section 4 for run-up and shutdown
procedures.
8. Install engine cowling per § 53-21.

JUL 2020 Chapter 12 Servicing Page 12.17

12-71 Drainage Spotface Inspection During Cleaning or Rinsing of RR300 Engine
Follow published Rolls-Royce guidance (subject to revision) to maximize RR300 engine
corrosion prevention:
• RR300 Operation and Maintenance Manual (OMM) Task 05-50-00-100-801, Clean
the Engine after Operation in a Corrosive Environment, and
• NTO (Notice To Operators) No. RR300-020, RR300 Engine Wash Procedures.
Refer to Figure 12-6. During cleaning or rinsing of engine, RHC recommends verifying
the drainage spotface on the magnesium gearbox cover is unobstructed. Follow OMM
guidance; do NOT use metallic tools or wire to remove debris.

VIEW LOOKING UP & FORWARD

FIGURE 12-6 DRAINAGE SPOTFACE INSPECTION

Page 12.17A Chapter 12 Servicing JUL 2020

Intentionally Blank

JUL 2020 Chapter 12 Servicing Page 12.17B

12-80 Air Conditioning System

12-81 Refrigerant Recovery and System Charging

NOTE
In the United States, only personnel with EPA certification under
Section 609 of the Clean Air Act may charge the system with
refrigerant or work on the refrigerant system once it has been
charged. Different requirements may apply in countries other
than the United States.

Automotive-style air conditioning service equipment, compatible with R134a refrigerant,

is required to recover and charge the system with refrigerant. This equipment is available
from many manufacturers in varying levels of automation and complexity. Minimum
components include a vacuum pump, pressure pump, refrigerant supply, scale to measure
refrigerant charge, pressure/vacuum gage, and appropriate lines and fittings.
Ensure that the technician performing the task is appropriately qualified.
A. Refrigerant Recovery

NOTE
If a leak or other service problem is encountered after system is
charged with refrigerant, refrigerant must be recovered before
work on system can proceed.

1. Remove tailcone cowling per § 53-23.

CAUTION
Do not overcharge system. Perform leak detection per § 12-83
if a leak is suspected, then use correct charge.

1. Remove tailcone cowling per § 53-23.

2. Automotive-style high- and low-side system service ports are located on G794
hose assemblies where they mount to the compressor assembly. Connect
service equipment to system quick-disconnect ports.
3. Replace desiccant per § 12-82. Vacuum system, then charge with R134a
refrigerant per equipment manufacturer’s instructions. Correct charge is 2.25
lb (36 oz) refrigerant.
4. Install tailcone cowling per § 53-23.

Page 12.18 Chapter 12 Servicing JUL 2020

12-82 Desiccant Replacement

NOTE
Replace desiccant when condenser or refrigerant system is
exposed to air. To eliminate moisture, replace desiccant, then
immediately vacuum system for charging per § 12-81.

1. Remove engine cowling per § 53-21.

2. Recover refrigerant per § 12-81, if not previously accomplished. Remove condenser
cap and replace desiccant.
3. Install cap, special torque cap per § 20-33, and torque stripe.
4. Charge system with refrigerant per § 12-81.

12-83 Leak Detection

Leaks may be detected using several techniques, depending on equipment available. Leak
detection should not be attempted with the aircraft/system running. In addition to safety
hazards, leaks are more difficult to detect with the varying pressures and temperatures
of an operating system.
An empty system should hold full vacuum (27 to 29 inches mercury vacuum at sea level)
with no assistance from the vacuum pump for 20 minutes minimum. If a vacuumed
system creeps up in pressure, a leak may be present. The technician should be thoroughly
familiar with vacuum equipment to ensure leak is in aircraft system and not in vacuum
equipment or connections.
Leaks in a charged system may be detected using a mild soap and water solution applied
to lines and fittings in suspected leak areas (bubbles indicate leaks) or using commercially
available electronic refrigerant detectors. Follow detector manufacturer’s instructions.
Large leaks may be detected audibly if area is quiet or by formation of frost in area of leak.

NOTE
Frost does not necessarily indicate a leak. Normal system
operation and/or charging procedures can cause frost to
accumulate on some components.
NOTE
System pressure is not a reliable indicator of charge state or
the presence of leaks. Because R134a is a liquid/vapor mixture
with the system at rest, pressure will remain constant as more
liquid vaporizes until majority of charge is lost.

JUL 2020 Chapter 12 Servicing Page 12.19

12-83 Leak Detection (continued)
Very small leaks can be detected by charging the system with helium gas. Helium
molecules are smaller than R134a molecules and will leak more quickly. Charge system
to 200 psi maximum. Use commercially available electronic helium detector or soap and
water solution to locate leaks.
Leaks are most likely to occur at fittings and crimped transitions between hard line and
flexible hose. Concentrate initial leak detection efforts in these areas.

FIGURE 12-7 C017-6 REV AD OR LATER SWASHPLATE ASSEMBLY

Page 12.20 Chapter 12 Servicing JUL 2020

12-90 Lubrication of Swashplate Bearings
1. Determine revision (“REV”) letters on C017-6 swashplate data plate. If revision letters
are “AD” or subsequent, proceed to step 2. If revision letters are “AA”, “AB”, or “AC”,
perform R66 Service Bulletin SB-30.
2. Remove ty-rap securing C480 boot to upper (rotating) swashplate.
3. Remove hardware securing lower rod ends of both C258 pitch links to upper swashplate.
Temporarily secure boot, upper A205 fork, and both pitch links up & away from
swashplate.
4. Rotate upper swashplate by hand; if bearing roughness is detected, replace swashplate
or submit swashplate to RHC for repair.
5. Refer to Figure 12-7. Remove (10) NAS1352 screws (with washers) securing C206-2
& C200‑3 retainers to upper swashplate. Raise both retainers and C219-3 spacer and
either temporarily secure to chord arm (if on helicopter) or set aside (if on workbench).
6. Using a 0.006 inch feeler gage, gently pry up outer edge of upper C217-1 seal and
expose top ball bearing.
7. Using a syringe or grease gun, add A257-3 grease into cavity above bearing set until
grease is just below top of C205-1 sleeve (approx. 20 ml grease). Do not allow grease
into screw holes.
8. Position C217-1 seal atop grease followed by C219-3 spacer, C200-3 retainer, and
NAS1352N08-8 screws with NAS620-8L washers. Finger-tighten all screws, then snug
any (4) screws that are 90° apart, depressing seal and forcing grease into underlying
bearing set. Rotate upper swashplate several revolutions. Wipe off excess grease.
9. Repeat steps 5 thru 8 once, then proceed to step 10.
10. Remove screws & washers and solvent-clean. Raise and clean C200-3 retainer and
C219-3 spacer, then reinstall both.
11. Install C206-2 retainer, NAS620-8L washers, and NAS1352N08-8 screws with A257‑9
anti-seize. Special torque screws per § 20-33.
12. Refer to IPC Figure 62-5. Connect upper A205 fork rod end and lower rod end of
associated C258 pitch link, to interrupter-side swashplate ear; standard torque bolt per
§ 20-32. Install palnut, standard torque per § 20-32, and torque stripe per Figure 5-1.

13. Attach two A255-3 counterweights, and lower rod end of C258 pitch link, to swashplate
ear opposite interrupter; standard torque bolt per § 20-32. Install palnut, standard
torque per § 20-32, and torque stripe per Figure 5-1.
14. Verify safety washers (or counterweight) and C115 spacers installed at all rod ends per
Figure 5-1.

JUL 2020 Chapter 12 Servicing Page 12.21

12-90 Lubrication of Swashplate Bearings (continued)

15. While observing swashplate, have someone fully manipulate cyclic and collective controls.
Verify swashplate movement corresponds with cyclic and collective movement, and
without interference.
16. Position swashplate boot on upper swashplate and secure with MS3367-6-0 ty-rap.
17. With appropriately rated person at controls, start helicopter, run up to 100% NR, then
shutdown.
18. Remove ty-rap, and raise swashplate boot. Wipe off excess grease from swashplate.
Position swashplate boot on upper swashplate and secure with MS3367-6-0 ty-rap.

Page 12.22 Chapter 12 Servicing JUL 2020

CHAPTER 18

TRACK AND BALANCE

Section Title Page

18-10 Main Rotor Track and Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.1

18-11 Preparing Helicopter for Main Rotor Track and Balance . . . . . . . . . . . . . 18.3
18-12 Flight Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.5
18-13 Track Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.7
18-14 Balance Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.10A
18-15 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.11
18-16 Autorotational RPM Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.12
18-20 Tail Rotor Dynamic Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.17
18-21 Preparing Helicopter for Tail Rotor Dynamic Balance . . . . . . . . . . . . . . . 18.17
18-22 Ground Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.19
18-23 Balance Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.19
18-30 Main Rotor Flight Control Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.21
18-40 Main Rotor Blade Angle Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.23
18-41 Collective Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.24
18-42 Cyclic Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.26
18-50 Tail Rotor Flight Control Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.28
18-51 Pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.28
18-52 Forward Bellcrank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.28
18-53 Intermediate Bellcrank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.28
18-60 Tail Rotor Blade Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.29
18-70 Fan Shaft and Engine Shaft Balancing . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.33
18-71 Preparing Helicopter for Fan Shaft and Engine Shaft Balancing . . . . . . . . 18.33
18-72 Ground Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.35

APR 2019 Chapter 18 Track and Balance Page 18.i

Intentionally Blank

Page 18.ii Chapter 18 Track and Balance APR 2019

CHAPTER 18

TRACK AND BALANCE

18-10 Main Rotor Track and Balance

NOTE
Calibrate track and balance equipment per manufacturer's
recommendation, at least once a year, or if equipment is
dropped, misused, or calibration is suspect.
NOTE
The Chadwick-Helmuth Vibrex system, the TEC ACES system,
the Dynamic Solutions Systems’ MicroVib system, or equivalent
equipment is required to perform dynamic rotor balancing and
in-flight track checks.

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

Page 18.2 Chapter 18 Track and Balance R66 Maintenance Manual 25 OCT 2010
18-11 Preparing Helicopter for Main Rotor Track and Balance

NOTE
Use the following track & balance procedures in conjunction with
approved equipment manufacturer’s balancing instructions.
CAUTION
Cable security is critical; helicopter will be flown at VNE.

1. Perform swashplate and rotor hub inspection per Section 5-45. Inspect tail rotor rod
ends and elastomeric bearings per Sections 5-33 and 5-34.

2. Clean main and tail rotor blades per Section 20-10. Install main rotor blade target tape
per Figure 18-1.

3. Refer to Figure 18-1. Using appropriate hardware, attach brackets to vibration transducer
and attach assembly to F359-1 panel as shown. Remove removable controls.

4. Install magnetic pickup onto swashplate bracket. Set (swashplate-mounted) interrupter-

to-pickup gap to 0.030 inch ± 0.010 inch and tighten pickup nuts against bracket.
Safety nuts using 0.020-inch diameter lockwire. Recheck gap.

5. Pull collective stick full up, push cyclic stick full left, and apply frictions. Connect proper
cable to magnetic pickup. Route cable down seam and to base of mast fairing, across
the cabin roof left side, and through the aft left door vent door. Attach the cable to the
fuselage using MS21919WDG3 clamps and existing fasteners, or secure cable every
12 inches with duct tape. Release control frictions and verify sufficient cable slack and
freedom of controls through full range of travel.

6. Connect proper cable to vibration transducer. Connect transducer, magnetic pickup,

and tracker or strobe cables to analyzer. If strobe light is used, battery power may be
accessed thru auxiliary power socket located on circuit breaker panel. Neatly stow and
secure excess cables.

7. Verify security of installation.

25 OCT 2010 R66 Maintenance Manual Chapter 18 Track and Balance Page 18.3
DATE SERIAL NO. TIP WEIGHTS TEETER HINGE SHIMS
PAGE
(1) AN960-10 Washer = (2) AN960-10L Washers C117-8 0.012 inch
CHORD ARM WEIGHTS (1) C298-2 Weight = (5) AN960-10 Washers C117-9 0.015 inch
(1) A255-1 Weight = (8) AN970-4 Washers (1) C298-3 Weight = (11) AN960-10 Washers C117-10 0.020 inch
(1) A255-2 Weight = (3) A255-1 Weights (1) C298-4 Weight = (4) C298-3 Weights C117-11 0.025 inch

BALANCE TRACK (KNOTS)

CLOCK IPS HOVER 50 60 70 80 90 100 110 120 130 140
I I I I I I I I I I I
I I I I I I I I I I I

Adjustment:
CLOCK IPS HOVER 50 60 70 80 90 100 110 120 130 140
I I I I I I I I I I I
I I I I I I I I I I I

FIGURE 18-2 MAIN ROTOR TRACK AND BALANCE CHART

Page 18.4 Chapter 18 Track and Balance R66 Maintenance Manual 25 OCT 2010
18-12 Flight Checks

NOTE
Run-up and shutdown helicopter throughout procedure as
required per R66 Pilot's Operating Handbook (POH) Section 4.
NOTE
Refer to § 18-15 for track & balance troubleshooting procedures.
WARNING
Tail rotor balancing equipment must be removed for flight.
WARNING
Do not exceed VNE of helicopter during flight checks.

1. Prepare helicopter for main rotor track and balance per § 18-11.
2. As required, make a photocopy of Figure 18-2; use copy to record flight data. Check
main rotor blade track in a hover and record data. Maximum blade spread in a hover
is 0.25 inch. Adjust track per § 18-13 as required, record change, and recheck blade
track in a hover. Repeat step as required until blade track is within limits.
3. Check main rotor balance in a hover and record data. Maximum vibration allowance is
0.2 ips (inches per second). Adjust balance per § 18-14 as required, record data, and
recheck balance in a hover. Repeat step as required until main rotor balance is within
limits.
4. Fly helicopter at 50, 60, 70, 80, 90, 100, 110, 120, 130, and 140 knots. Check main
rotor blade track at each airspeed and record data. Maximum blade spread between
airspeeds is 3/8 inch. Adjust trim tab(s) per § 18-13 as required and record data.
Repeat step as required until blade track is within limits.
5. Recheck main rotor balance in a hover per step 3.
6. Perform autorotation RPM check per § 18-16. Recheck main rotor balance in a hover
per step 3.
7. Evaluate collective trim, longitudinal cyclic trim, and lateral cyclic trim. Adjust as
required. Recheck main rotor balance in a hover per step 3.
8. Remove track and balance equipment. Torque stripe fasteners. Reinstall removable
controls, as required.

APR 2017 Chapter 18 Track and Balance Page 18.5

FIGURE 18-3A C258-5 MAIN ROTOR PITCH LINK

Page 18.6 Chapter 18 Track and Balance APR 2017

18-13 Track Adjustment
A. Main Rotor Blade Pitch Link

NOTE
Shorten high pitch blade when adjusting track in a hover.
NOTE
During rigging, adjust both pitch links exactly the same for
collective adjustments.

1. For fine adjustment:

a. C258-5 Pitch Link: Adjust barrel assembly only per the following steps:
i. Refer to Figure 18-3A. Using backup wrench on barrel assembly, loosen
21FKF-813 nut at lower rod end, and upper rod end palnut and jam nut.
ii. Rotate barrel assembly to shorten or lengthen pitch link as required.
One-half turn of barrel changes blade track approximately 0.20 inch.
One-half turn of barrel changes blade angle approximately 0.20°. For
finer adjustment, rotate less than one-half turn as required.
iii. Refer to Figure 5-1. Verify rod end threaded shank blocks passage of
0.020-inch diameter lockwire through barrel assembly witness holes.
iv. Position rod ends to allow as much pitch link rotation as possible
without binding. Using backup wrench on barrel assembly, special
torque 21FKF-813 nut per § 20-33, and standard torque upper rod end
jam nut and palnut per § 20-32.
v. Repeat steps on opposite pitch link as required; torque stripe per Figure 5-1.
b. C258-1 Pitch Link: Adjust fitting only per the following:
i. Refer to Figure 18-3B. Cut and discard pitch link assembly safety wire.
Using backup wrench on link assembly, loosen 21FKF-813 nut; using
backup wrench on fitting, loosen upper rod end palnut and jam nut.
ii. Rotate fitting to shorten or lengthen pitch link as required. One-half turn
of fitting changes blade track approximately 0.20 inch. One-half turn of
fitting changes blade angle approximately 0.20°. For finer adjustment,
rotate less than one-half turn as required.
iii. Refer to Figure 5-1. Verify rod end threaded shank blocks passage of
0.020-inch diameter lockwire through pitch link witness holes.
iv. Using backup wrench on link assembly, special torque 21FKF-813 nut
per § 20-33. Using backup wrench on fitting, standard torque upper
rod end jam nut and palnut per § 20-32. Safety fitting to link assembly
using 0.032-inch diameter lockwire.
v. Repeat steps on opposite pitch link as required; torque stripe per Figure 5-1.

APR 2019 Chapter 18 Track and Balance Page 18.7

FIGURE 18-3B C258-1 MAIN ROTOR PITCH LINK

Page 18.7A Chapter 18 Track and Balance APR 2019

18-13 Track Adjustment (continued)
A. Main Rotor Blade Pitch Link (continued)
2. For medium length adjustment, adjust upper rod end per the following:
a. Refer to Figure 18-3A or 18-3B. Using backup wrench on barrel assembly or
fitting, loosen upper rod end palnut and jam nut. Remove hardware securing
rod end to pitch horn.
b. Rotate upper rod end to shorten or lengthen pitch link as required. One-half
turn of upper rod end changes blade track approximately 0.25 inch. One-
half turn of upper rod end changes blade angle by approximately 0.24°.
c. Refer to Figure 5-1. Verify rod end threaded shank blocks passage of 0.020-
inch diameter lockwire through barrel asssembly (upper), or fitting, witness
hole. Install hardware securing rod end to pitch horn and standard torque
fasteners per § 20-32.
d. Position rod ends to allow as much pitch link rotation as possible without
binding. Using backup wrench on barrel assembly or fitting, standard torque
upper rod end jam nut and palnut per § 20-32.
e. Repeat steps on opposite pitch link as required; torque stripe per Figure 5-1.

3. For coarse length adjustment:

a. C258-5 Pitch Link: Adjust lower rod end per the following:
i. Refer to Figure 18-3A. Using backup wrench on barrel assembly, loosen
21FKF-813 nut at lower rod end. Remove hardware securing lower rod
end to swashplate.
ii. Rotate lower rod end to shorten or lengthen pitch link as required. One-
half turn of lower rod end changes blade angle by approximately 0.44°.
iii. Refer to Figure 5-1. Verify rod end threaded shank blocks passage of
0.020-inch diameter lockwire through barrel asssembly (lower) witness
hole. Install hardware securing rod end to swashplate and standard
torque fasteners per § 20-32.
iv. Position rod ends to allow as much pitch link rotation as possible
without binding. Using backup wrench on barrel assembly, special
torque 21FKF-813 nut per § 20-33.
v. Repeat steps on opposite pitch link as required; torque stripe per Figure 5-1.

APR 2017 Chapter 18 Track and Balance Page 18.7B

18-13 Track Adjustment (continued)
A. Main Rotor Blade Pitch Link (continued)
3. b. C258-1 Pitch Link: Adjust link assembly per the following:
i. Refer to Figure 18-3B. Cut and discard pitch link assembly safety wire.
Using backup wrench on link assembly, loosen 21FKF-813 nut. Remove
hardware securing lower rod end to swashplate.
ii. Rotate link assembly to shorten or lengthen pitch link as required. One-
half turn of link assembly changes blade angle by approximately 0.44°.
iii. Refer to Figure 5-1. Verify rod end threaded shank blocks passage of 0.020-
inch diameter lockwire through link assembly witness hole. Install hardware
securing rod end to swashplate and standard torque fasteners per § 20-32.
iv. Position rod ends to allow as much pitch link rotation as possible without
binding. Using backup wrench on link assembly, special torque 21FKF-
813 nut per § 20-33. Safety fitting to link assembly using 0.032-inch
diameter lockwire.
v. Repeat steps on opposite pitch link as required; torque stripe per Figure 5-1.

Page 18.7C Chapter 18 Track and Balance APR 2017

Intentionally Blank

APR 2017 Chapter 18 Track and Balance Page 18.7D

FIGURE 18-4 MAIN ROTOR BLADE TRIM TAB

Page 18.8 Chapter 18 Track and Balance APR 2017

18-13 Track Adjustment (continued)
B. Main Rotor Blade Trim Tab

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 MT526-8 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.

1. Using felt tip marker, ink mark main rotor blade trim tab per Figure 18-4. Mark
line with a measuring point in the center of the tab (approximate).
2. Position MT352-1 gage chordwise across blade upper surface and tab trailing
edge. Zero dial indicator on measuring point.
3. Position MT526-8 bending tool on tab per Figure 18-4. Slide tool completely over
tab until tool stops contact blade trailing edge. 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 MT526-8 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).

APR 2017 Chapter 18 Track and Balance Page 18.9

FIGURE 18-4A MAIN ROTOR BLADE TIP

Page 18.10 Chapter 18 Track and Balance APR 2017

18-14 Balance Adjustment

WARNING
A rotor which is smooth after balancing but goes out of balance
within a few flights is suspect and must be examined by RHC
before further flight.

A. Tip Weights (Spanwise Balance Adjustment)

1. Remove screws securing tip cover to blade. Balance rotor assembly spanwise
by adjusting tip weights as required per Figure 18-2. Washers may be trimmed.
Refer to Figure 18-4A. 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.
(1) AN960-10 or NAS1149F0363P Washer = (2) AN960-10L or NAS1149F0332P Washers
(1) C298-2 Weight = (5) AN960-10 or NAS1149F0363P Washers
(1) C298-3 Weight = (11) AN960-10 or NAS1149F0363P Washers
(1) C298-4 Weight = (4) C298-3 Weights

B. Teeter Hinge Bolt Shims (Chordwise Balance Adjustment - Coarse Adjustment)

1. Remove and discard teeter hinge nut cotter pin. Remove nut, thrust washer, and
any shims.
2. Have two people cone the main rotor blades. Push out teeter hinge bolt (and any
shims) with another bolt.
3. Balance rotor assembly chordwise by moving (or exchanging) existing teeter
hinge shims to other side of bolt (under head or under nut) as required per Figure
18-2. Install teeter hinge bolt per § 62-10.

C. Chord Arm Weight (Chordwise Balance Adjustment - Fine Adjustment)

1. Balance rotor assembly chordwise by adjusting chord arm weights or washers per
Figure 18-2. Total weight not to exceed four A255-2 weights (or equivalent).
(1) A255-1 Weight = (8) AN970-4 Washers
(1) A255-2 Weight = (3) A255-1 Weights

APR 2017 Chapter 18 Track and Balance Page 18.10A

Intentionally Blank

Page 18.10B Chapter 18 Track and Balance APR 2017

18-15 Troubleshooting

The following are some of the symptoms and corrections which occur in the Track and Balance
operations of the helicopter. Decide on the various causes of a given trouble and then eliminate
causes one by one, beginning with the most probable.

Symptom Probable Cause Correction

1. Excessive Cyclic or Main rotor (MR) out of track. Track and balance per Section 18-10.
Stick Shake
Rough or binding A205-7 fork Replace or refer to Section 67-40.
assembly (upper swashplate).
Brinelled spindle bearing Send blade(s) to RHC for spindle bearing
(rough movement). replacement.
Rough blade surface (chipped paint). Repair blades per Section 62-60.
Rough or binding pitch links. Replace pitch link rod ends
MR blade boot misaligned. Realign or replace boot per Section 62-11.
MR teeter or coning hinge binding. Replace bearings per Section 62-21.
MR blade trim tabs bent upward. Bend trim tabs evenly down per Section 18-13.
Blade mismatch. Send blade(s) to RHC for replacement.

2. Excessive Ship MR out of track and balance. Track and balance per Section 18-10.
Vibration
MR teeter or coning hinge friction. Adjust hinge friction per Section 62-32.
MR teeter or coning hinge binding. Replace bearings per Section 62-21.
Brinelled spindle bearing Send blade(s) to RHC for spindle bearing
(rough movement). replacement.
MR teeter hinge bearings worn. Replace bearings per Section 62-21.

3. Excessive Cyclic Brinelled spindle bearing Send blade(s) to RHC for spindle bearing
Stick Forces (rough movement). replacement.

4. Intermittent Blade MR teeter or coning hinge friction Adjust hinge friction per Section 62-32.
Track Picture
MR coning hinge binding. Replace bearings per Section 62-21.
MR teeter hinge not "broken-in." Track and balance per Section 18-10. Adjust
track to minimize error.
Brinelled spindle bearing Send blade(s) to RHC for spindle bearing
(rough movement). replacement.

5. Radical Changes to MR teeter hinge bearings worn. Replace bearings per Section 62-21.
Cyclic Trim
Brinelled spindle bearing Send blade(s) to RHC for spindle bearing
(rough movement). replacement.

25 OCT 2010 R66 Maintenance Manual Chapter 18 Track and Balance Page 18.11
18-16 Autorotational RPM Adjustment

Use the following procedure for checking and adjusting autorotational RPM:

WARNING

Failure to properly adjust autorotational RPM (RPM too low)

may prevent the rotorcraft from achieving proper RPM at low
gross weights.

1. Perform autorotation RPM check at minimum practical gross weight (less than 1900
lb). Calculate the takeoff gross weight of the helicopter. Record the time on the
hourmeter.

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 # Reading OAT Altitude RPM

Page 18.12 Chapter 18 Track and Balance R66 Maintenance Manual 25 OCT 2010
18-16 Autorotational RPM Adjustment (continued)

3. After test flight, determine the following:

Test # 1 2 3 4 5

Elapsed Time (in-flight hourmeter reading

minus take-off hourmeter reading):

Pounds of Fuel Consumed

(elapsed time x 140 lb/hr):

Test Gross Weight

(take-off gross weight minus fuel consumed):

Test Longitudinal Center of Gravity:

Chart % RPM*:

Test % RPM (from in-flight data):

RPM Correction
(chart % RPM minus test % RPM):

*Perform step 4 to obtain value.

4. Refer to Figure 18-5. To find Chart % RPM, perform the following:

a. Start at outside air temperature, and draw a vertical line up to pressure altitude.

b. Draw a horizontal line from pressure altitude to rotorcraft gross weight at time of
autorotation.

c. Draw a vertical line down from autorotation gross weight to required auto RPM.

5. Adjust pitch links based on average RPM correction required. Lengthen both pitch links
to decrease RPM if test RPM is greater than chart RPM; shorten both pitch links to
increase RPM. One full rod end turn will change RPM approximately 3½%. Adjust both
pitch links exactly the same so track will not be affected.

6. Repeat previous steps as required until the RPM correction is ± 1% of chart RPM.

25 OCT 2010 R66 Maintenance Manual Chapter 18 Track and Balance Page 18.13
AUTOROTATION RPM
COLLECTIVE FULL DOWN

50 KIAS

One full turn of rod ends = approximately 3½% RPM change

One full turn of rod end = 1⅙ turns of barrel

Example: OAT=20°C, Hp=2000 ft, GW=1800 lb, RPM=103%

FIGURE 18-5 AUTOROTATION RPM ADJUSTMENT

Page 18.14 Chapter 18 Track and Balance R66 Maintenance Manual 25 OCT 2010
Intentionally Blank

25 OCT 2010 R66 Maintenance Manual Chapter 18 Track and Balance Page 18.15
FIGURE 18-6 TAIL ROTOR BALANCING EQUIPMENT INSTALLATION

Page 18.16 Chapter 18 Track and Balance R66 Maintenance Manual 25 OCT 2010
18-20 Tail Rotor Dynamic Balance

18-21 Preparing Helicopter for Tail Rotor Dynamic Balance

NOTE
Use the following balance procedures in conjunction with
approved equipment manufacturer’s balancing instructions.
WARNING
Ensure cable(s) cannot entangle tail rotor.

1. Clean tail rotor blades per § 20-10. Inspect tail rotor rod ends and elastomeric bearings
per §§ 5-33 and 5-34.
2. Track tail rotor blades per § 64-10.
3. Refer to Figure 18-6. If using photocell to obtain clock angle, install a target tape
spanwise on inboard side of one arm of tail rotor hub; if using Strobex, install a target
tape spanwise on outboard side of hub.
4. Using appropriate hardware, attach bracket(s) to vibration transducer, and photocell, if
used. Secure bracket to tail rotor gearbox output shaft cap at forward, top attachment
bolt. Orient vibration transducer vertically.
5. Connect cable(s) to transducer, and photocell, if used. Route cable(s) forward and
into cabin; wrap around tailcone several times, and secure with duct tape. If using
Strobex, route cable to a position located approximately 20 feet to left of tail rotor.
Place sandbags (or similar) on cable to prevent cable movement.
6. Connect cable(s) to balancer. Verify security of installation.

APR 2019 Chapter 18 Track and Balance Page 18.17

DATE SERIAL NO.
PAGE

PITCH HORN-TO-PITCH LINK FASTENER (CHORDWISE) WEIGHTS BLADE-TO-HUB OUTBOARD FASTENER (SPANWISE) WEIGHTS
(1) NAS1149F0463P Washer = (2) NAS1149F0432P Washers (1) C141-23 Washer = (3.5) NAS1149F0663P Washers
(1) A214-3 Washer = (3.5) NAS1149F0432P Washers (1) C141-24 Washer = (7) NAS1149F0663P Washers
(1) A141-14 Washer = (5) NAS1149F0432P Washers (2) NAS1149F0632P (1) NAS1149F0663P Washer

BALANCE
CLOCK IPS

ADJUSTMENT:
CLOCK IPS

ADJUSTMENT:

FIGURE 18-7 TAIL ROTOR DYNAMIC BALANCE CHART

Page 18.18 Chapter 18 Track and Balance APR 2019

18-22 Ground Checks

NOTE

Run-up and shutdown helicopter throughout procedure as

required per R66 Pilot's Operating Handbook (POH) Section 4.
NOTE

Use the following balancing procedures in conjunction with

approved equipment manufacturer’s balancing instructions.
WARNING

Tail rotor balancing equipment must be removed for flight.

1. Prepare helicopter for tail rotor dynamic balance per Section 18-21.
2. Make a photocopy of Figure 18-7; use copy to record ground check data. Check tail rotor
balance at 99-101% RPM on ground and record data. Maximum vibration allowance is
0.2 ips (inches per second). (If using Chadwick-Helmuth system, set Function Knob on
Balancer to appropriate channel, set balancer RPM Range knob to X10, and set RPM to
231. During ground run, view tail rotor assembly target tape through Strobex and tune
Balancer by adjusting RPM dial.)
3. Adjust balance per Section 18-23 as required, record change, and recheck balance.
Repeat steps 2 and 3 as required until tail rotor balance is within limits.
4. Remove track and balance equipment. Install tail rotor gearbox output shaft cap forward,
top attachment bolt and special torque per Section 20-33. Install 0.032-inch diameter
lockwire securing cap retaining hardware and safety in pairs.

WARNING

A rotor which is smooth after balancing but goes out of balance

within a few flights is suspect and must be examined by RHC
before further flight.
18-23 Balance Adjustment
Refer to R66 Illustrated Parts Catalog (IPC) Figure 64-1. Refer to Section 64-11 for tail
rotor assembly static balance procedure.
A. Pitch Horn-to-Pitch Link Fastener (Chordwise Balance Adjustment)
Chordwise dynamic balance is achieved by varying NAS6604 bolt length and nut-side
washers on tail rotor blade pitch horn-to-pitch link fastener. Select bolt length and
washers as required to balance tail rotor assembly chordwise per Figure 18-7, and
to meet torque requirements per Section 20-30. Standard torque nut and palnut per
Section 20-32, but do not torque stripe.
B. Blade-to-Hub Outboard Fastener (Spanwise Balance Adjustment)
Spanwise dynamic balance is achieved by varying nut-side washer size on tail rotor
blade-to-hub outboard fastener. Four washers are required under outboard nuts. Select
a combination of four washers to balance tail rotor assembly spanwise per Figure 18-7,
placing largest washers closest to hub assembly. Standard torque nuts and palnuts per
Section 20-32, but do not torque stripe.

25 OCT 2010 R66 Maintenance Manual Chapter 18 Track and Balance Page 18.19
FIGURE 18-8 SWASHPLATE AND COLLECTIVE CONTROL RIGGING

FIGURE 18-9 A205-5 SWASHPLATE FORK RIGGING

Page 18.20 Chapter 18 Track and Balance R66 Maintenance Manual 25 OCT 2010
18-30 Main Rotor Flight Control Rigging

NOTE

Refer to Section 5-33, and Figures 5-1 & 5-2 for standard rod
end adjustment procedures. Refer to Section 18-13 for main
rotor pitch link adjustment procedure.

For collective adjustments, both pitch links must be adjusted

exactly the same.

Track and balance helicopter per Sections 18-10 & 18-20 as

required after adjusting flight controls.
NOTE

Cyclic stick travel is non-adjustable. Travel is limited by A211-4

stop attached to the cyclic box assembly.

Collective stick travel is non-adjustable. Travel is limited by

A333-1 stop integral to the collective stick friction assembly.
Perform the following check to verify collective travel and
swashplate travel do not interfere.

1. Install MT559-1 rigging blocks inside A211-4 cyclic stick stop. Position collective stick
full down. Apply cyclic and collective stick frictions.

2. Rig the following push-pull tube assemblies and fork assembly, located between keel
panels, to the noted rod end center-to-center dimensions:

PART NUMBER DIMENSION

C121-1 = 51.15 ± 0.03 inches

F121-1 = 32.36 ± 0.03 inches
G205-1 = 5.40 ± 0.03 inches

3. Adjust length of F121-1 tube so that with collective full up, there is a 0.50 inch gap
between G205-1 yoke and F315-1 support.

4. Refer to Figure 18-8. Position MT146-4 swashplate rigging blocks between lower, non-
rotating swashplate and C281-1 fitting. Refer to Section 5-33, and adjust push-pull
tube rod ends until aligned with swashplate attachment holes.

5. Cut and discard ty-rap(s) as required to lift swashplate boot.

6. Position collective stick full up. Verify top of C201-1 ball assembly is flush with top
edge of C208-1 tube within 0.030 inch. Refer to Section 5-33, and adjust push-pull
tube rod ends in or out equally to raise or lower swashplate as required.

7. Refer to Figure 18-9. Adjust swashplate A205-5 lower fork assembly (non-rotating) to
3.70 ± 0.03 inch, and upper fork assembly (rotating) to 3.85 ± 0.03 inch.

25 OCT 2010 R66 Maintenance Manual Chapter 18 Track and Balance Page 18.21
FIGURE 18-10 MAIN ROTOR BLADE RIGGING

Page 18.22 Chapter 18 Track and Balance R66 Maintenance Manual 25 OCT 2010
18-40 Main Rotor Blade Angle Rigging

A. Procedure

NOTE

Refer to Section 5-33, and Figures 5-1 & 5-2 for standard rod
end adjustment procedures. Refer to Section 18-13 for main
rotor pitch link adjustment procedure.

1. Perform main rotor flight control rigging per Section 18-30.

2. Level helicopter laterally and longitudinally via main rotor hub per Section 8-12.

3. Perform collective travel rigging per Section 18-41 Parts A and B.

4. Perform cyclic travel rigging per Section 18-42 Parts A, B, C, and D.

5. Perform track and balance per Section 18-10 as required.

B. Measuring Blade Angles

NOTE

Hydraulic flight controls must be pressurized while measuring

blade angles.
WARNING

Never adjust flight controls while hydraulics are pressurized.

Hydraulic forces can cause injury.

1. Teeter main rotor hub until blade tips are approximately level. Place a tracking stick
at the end of one blade and mark the tip height. Rotate the rotor 180° and mark the
opposite blade’s tip height. Teeter main rotor hub as required until blade tips are level
within 1 inch.

2. Refer to Figure 18-10. Using felt tip marker, mark upper surface of both main rotor
blades 49.5 inches inboard of seam between blade tip and tip cover. Lay 1-inch wide
length of masking tape chordwise on each blade, centered over marking. Mark each
rotor blade with a different color designation, such as red and blue.

3. Hang a 6-inch length of masking tape from one blade tip for reference. Zero Kell-Strom
KS113 propeller protractor (or equivalent) on top of the main rotor hub, parallel to the
teeter hinge bolt, at location marked “LEVEL HERE”. During zeroing, point protractor
face toward the blade with hanging tape. When taking blade angle readings, always
point protractor face toward the blade with hanging tape.

4. Position MT525-1 fixture on top of the blade’s tape at 49.5 inches, and tight against
the leading edge. Position protractor on top of fixture, point protractor face toward the
blade with hanging tape, and take blade angle reading.

SEP 2012 R66 Maintenance Manual Chapter 18 Track and Balance Page 18.23
18-41 Collective Travel

NOTE

Lengthening pitch links increases blade angles.

NOTE

When making adjustments, keep pitch links as close to neutral

(mid-travel) position as possible to preserve the adjustment
range for flight checks.

A. Collective Down

1. Refer to Figure 18-8. Position collective stick full up and apply friction. Place
MT759-1 rigging blocks around cyclic stick in cyclic box assembly. Verify top of ball
is flush with tube within 0.030 inch. Adjust all swashplate push-pull tubes exactly
the same amount as required (one full turn = 0.48°).

2. Position collective stick full down and apply friction.

3. Rotate blades so pitch links are aligned with helicopter longitudinal axis.

4. Measure and record blade angles per Section 18-40 Part B to determine the values
below. Rotate blades 180° and align per step 3 as required.

BLUE BLADE RED BLADE

Pitch horn forward ° Pitch horn forward °
Pitch horn aft + ° Pitch horn aft + °
= ° = °
÷2= ° ÷2= °
5. Blade angles must average between 1.0° and 2.0° for collective down position.
(Final blade angle for collective down position is determined during autorotation rpm
adjustment.) Adjust main rotor blade pitch links per Section 18-13 as required (one
full barrel turn = 0.72°) until blade angles, when blades are positioned pitch horn
forward, are within 0.2°. Adjust pitch links until blade angles, when blades are
positioned pitch horn aft, are also within 0.2°.

NOTE

After making adjustments, position collective stick full up and

apply friction. Verify top of swashplate ball is flush with tube
within 0.030 inch per Figure 18-8. Adjust all swashplate push-
pull tubes exactly the same amount as required (one full turn =
0.48°). Lengthening all push-pull tubes increases blade angles.

Page 18.24 Chapter 18 Track and Balance R66 Maintenance Manual SEP 2012
18-41 Collective Travel

B . Collective Up

1. Position collective stick full up and apply friction. Place MT759-1 rigging blocks
around cyclic stick in cyclic box assembly.

2. Rotate blades so pitch links are aligned with helicopter longitudinal axis.

3. Measure and record blade angles per Section 18-40 Part B to determine the values
below. Rotate blades 180° and align per step 2 as required.

BLUE BLADE RED BLADE

Pitch horn forward ° Pitch horn forward °
Pitch horn aft + ° Pitch horn aft + °
= ° = °
÷2= ° ÷2= °
4. For collective up position, blade angles must average between 12.5° and 13.5°
more than collective down position average. Adjust main rotor blade pitch links per
Section 18-13 as required (one full barrel turn = 0.72°) until blade angles, when
blades are positioned pitch horn forward, are within 0.2°. Adjust pitch links until
blade angles, when blades are positioned pitch horn aft, are also within 0.2°.

NOTE

Remeasure collective down blade angles after making adjustment

for collective up blade angles.
NOTE

After making adjustments, position collective stick full up and

SEP 2012 R66 Maintenance Manual Chapter 18 Track and Balance Page 18.25
18-42 Cyclic Travel

A. Cyclic Left

1. Position collective stick full down. Position cyclic stick in the longitudinal neutral
(mid travel) position, and against left stop. Apply control frictions; sandbag cyclic
stick as required.

2. Rotate blades so pitch links are aligned with helicopter lateral axis.

3. Measure and record blade angles per Section 18-40 Part B to determine the values
below. Rotate blades 180° and align per step 2 as required.

BLUE BLADE RED BLADE

Pitch horn right ° Pitch horn right °
Pitch horn left + ° Pitch horn left + °
= ° = °
÷2= ° ÷2= °
4. Blade angles must average between 7.5° and 8.5° for cyclic left position. Adjust
swashplate forward left or right push-pull tube as required (one full turn = 0.6°).

B. Cyclic Right

1. Position collective stick full down. Position cyclic stick in the longitudinal neutral
(mid travel) position, and against right stop. Apply control frictions; sandbag cyclic
stick as required.

2. Rotate blades so pitch links are aligned with helicopter lateral axis.

3. Measure and record blade angles per Section 18-40 Part B to determine the values
below. Rotate blades 180° and align per step 2 as required.

BLUE BLADE RED BLADE

Pitch horn right ° Pitch horn right °
Pitch horn left + ° Pitch horn left + °
= ° = °
÷2= ° ÷2= °
4. Blade angles must average between 6.0° and 7.0° for cyclic right position. Adjust
swashplate forward left or right push-pull tube as required (one full turn = 0.6°).

NOTE

Remeasure cyclic left blade angles after making adjustment for

cyclic right blade angles.

Page 18.26 Chapter 18 Track and Balance R66 Maintenance Manual SEP 2012
18-42 Cyclic Travel (continued)
C. Cyclic Forward
1. Position collective stick full down. Position cyclic stick in the lateral neutral (5
inches to left of right stop) position, and against forward stop. Apply control
frictions; sandbag cyclic stick as required.
2. Rotate blades so pitch links are aligned with helicopter longitudinal axis.
3. Measure and record blade angles per § 18-40 Part B to determine the values below.
Rotate blades 180° and align per step 2 as required.
BLUE BLADE RED BLADE
Pitch horn forward ° Pitch horn forward °
Pitch horn aft + ° Pitch horn aft + °
= ° = °
÷2= ° ÷2= °
4. Blade angles must average between 13.50° and 14.25° for cyclic forward position.
Adjust swashplate aft push-pull tube as required (one full turn = 0.44°). A coarse
adjustment can be made by adjusting swashplate forward push-pull tubes exactly
the same amount (one full turn = 0.6°).
D. Cyclic Aft
1. Position collective stick full down. Position cyclic stick in the lateral neutral (5
inches to left of right stop) position, and against aft stop. Apply control frictions;
sandbag cyclic stick as required.
2. Rotate blades so pitch links are aligned with helicopter longitudinal axis.
3. Measure and record blade angles per § 18-40 Part B to determine the values below.
Rotate blades 180° and align per step 2 as required.
BLUE BLADE RED BLADE
Pitch horn forward ° Pitch horn forward °
Pitch horn aft + ° Pitch horn aft + °
= ° = °
÷2= ° ÷2= °
4. Blade angles must average between 13.50° and 14.25° for cyclic aft position.
Adjust swashplate aft push-pull tube as required (one full turn = 0.44°). A coarse
adjustment can be made by adjusting swashplate forward push-pull tubes exactly
the same amount (one full turn = 0.6°).

NOTE
Remeasure cyclic forward blade angles after making adjustment
for cyclic aft blade angles.

MAY 2015 Chapter 18 Track and Balance Page 18.27

18-50 Tail Rotor Flight Control Rigging

Refer to R66 Illustrated Parts Catalog (IPC) Figures 67-29 thru 67-39.

18-51 Pedals

1. Refer to Figure 67-4. Insert a 3/16-inch diameter rigging pin through the hole in the
right-hand keel panel and the rigging pin holes in the C317-7 bellcrank.

2. Adjust the F121-9 push-pull tube as required to obtain a dimension of 5.24 ± 0.03 in.
from the lower forward NAS6604-9 bolt in C317-5 or C317-9 bellcrank and horizontal
pedal torque tube.

18-52 Forward Bellcrank

Remove the rigging pin and place the left pedal against its stop. Adjust the F121-11 push-
pull tube to obtain 1.08 - 1.18 inches between the end of the rod end and the bulkhead.

18-53 Intermediate Bellcrank

With left pedal at stop, adjust the C121-17 push-pull tube length as required to obtain
0.35 ± 0.03 inch between two faces of pitch control assembly and the housing.

FIGURE 18-11 TAIL ROTOR BLADE RIGGING

Page 18.28 Chapter 18 Track and Balance MAY 2015

18-60 Tail Rotor Blade Rigging

1. Level helicopter laterally, and longitudinally via main rotor hub, per § 8-12.

2. Place left (or right) pedal against its stop. Position tail rotor blades parallel to the
tailcone.

3. Refer to Figure 18-11. Tape a tracking stick to tailcone at blade tip. A tracking stick
can be made using a 1” x 12” strip of aluminum with a 90º bend 2 inches from one end.

4. Rotate tail rotor shaft weldment and mark tracking stick where each blade tip drain hole
passes. Adjust (teeter) tail rotor hub on output shaft until both blade tips pass the same
point on the tracking stick.

5. Using felt tip marker, mark inboard surface of both tail rotor blades 7.25 inches from
each blade tip. Lay 1-inch wide strip of masking tape chordwise on each blade, centered
over marking. Mark each blade with a different color designation, such as red or blue.

6. Have a second person hold one blade tip at the left pedal track mark with the left pedal
against its stop. Position MT525-2 rigging fixture on the aft blade, against the inboard
surface. Position propeller protractor against the fixture, measure the blade angle, and
record data below. Rotate the tail rotor 180°, and record the opposite blade angle.
Pedals Full Left
Blue Blade °
Red Blade + °
= °
÷2= ° (18.5/19.0° required)
7. Difference between blue and red blade angles may not exceed 0.4°. If blade angles
exceed this limit, remove tail rotor assembly per § 64-10, rotate assembly one-half
revolution, and install assembly per § 64-10. Repeat previous steps. If blade angles still
exceed relative limit, contact RHC Technical Support for replacement blade assistance.

8. Adjust C121-17 push-pull tube rod ends per § 5-33 and Figures 5-1 & 5-2 as required to
obtain blade angle between 18.5° and 19.0°. One full turn of the rod end will change
the blade angle 0.33°.

9. Have a second person hold one blade tip at the right pedal track park with the right pedal
against its stop. Position MT525-2 rigging fixture on the aft blade, against the inboard
surface. Position propeller protractor against the fixture, measure the blade angle, and
record data below. Rotate the tail rotor 180°, and record the opposite blade angle.
Pedals Full Right
Blue Blade °
Red Blade + °
= °
÷2= ° (15.5/16.5° required)
10. Adjust C121-17 push-pull tube rod ends per § 5-33 and Figures 5-1 & 5-2 as required
to obtain blade angle between 15.5° and 16.5°. If adjusted, recheck left pedal blade
angles per previous steps.

MAY 2015 Chapter 18 Track and Balance Page 18.29

18-60 Tail Rotor Blade Rigging (continued)

11. If the blade angle range for left and right pedal settings cannot be obtained using the
preceding steps, pedal total travel is either too great or too small. Use the following
procedure to check and adjust pedal travel:

a. Add right and left pedal blade angles together. If total is less than 34.0°, pedal total
travel is too small. If total is greater than 35.5°, pedal total travel is too great.

b. If pedal total travel is too small, increase C343-11 push-pull tube length and/or
decrease C343-13 push-pull tube length.

c. If pedal total travel is too great, decrease C343-11 push-pull tube length and/or
increase C343-13 push-pull tube length.

d. Recheck left and right pedal blade angles per previous steps.

12. Balance tail rotor per § 18-20.

Page 18.30 Chapter 18 Track and Balance MAY 2015

Intentionally Blank

MAY 2015 Chapter 18 Track and Balance Page 18.31

FIGURE 18-12 FAN SHAFT AND ENGINE SHAFT BALANCING

Page 18.32 Chapter 18 Track and Balance MAY 2015

18-70 Fan Shaft and Engine Shaft Balancing

18-71 Preparing Helicopter for Fan Shaft and Engine Shaft Balancing

NOTE
Use the following balance procedures in conjunction with
approved equipment manufacturer’s balancing instructions.

1. Remove tailcone cowling per § 53-23. Clean F196-1 fan shaft weldment, G174-
1 fanwheel assembly, and F642 shaft weldment. Inspect condition of flex plates,
weldment flanges, and adjacent yokes. Verify proper fastener installation and unbroken
torque stripe.
2. Refer to Figure 18-12.
a. Fan Shaft: Using a #8 screw, attach vibration transducer and photocell (cables
pointed up) to mounting bracket(s). Secure bracket(s) to top of tailcone at the
forward nutplate, aiming photocell toward center of shaft.
b. Engine Shaft: Using appropriate hardware, attach photocell (cable pointed
outboard toward access door) to mounting bracket. Secure bracket to F020-1
frame assembly using MS21919WDG16 clamp and associated hardware, aiming
photocell toward center of shaft.
3. Install a target tape on each shaft weldment and align tape with a flange arm. Verify
photocell beam will hit target tape. (Tape becomes the 12 o'clock position.)
4. Route cable(s) forward into cabin; secure cables to cabin with duct tape.
5. Connect cable(s) to balancer. Verify security of installation.

APR 2019 Chapter 18 Track and Balance Page 18.33

FIGURE 18-13 FAN SHAFT BALANCING CHART

Page 18.34 Chapter 18 Track and Balance APR 2019

18-72 Ground Checks

NOTE
Run-up and shutdown helicopter throughout procedure as
required per R66 Pilot's Operating Handbook (POH) Section 4.
NOTE
Use the following balancing procedures in conjunction with
approved equipment manufacturer’s balancing instructions.
WARNING
Fan shaft and engine shaft balancing equipment must be
removed for flight.

1. Prepare helicopter for fan shaft and engine shaft balance per § 18-71.
2. Configure balance equipment per manufacturer's instructions.
3. Ground run helicopter at 100% RPM (2114 fan shaft RPM and 6016 engine shaft
RPM). Verify cyclic stick and tail rotor pedals are in neutral position.
4. Determine vibration level per balance equipment manufacturer's instructions. Maximum
vibration allowance is 0.2 IPS (inches per second). If reading is over 0.2 IPS:
a. Fan Shaft: Refer to Figure 18-13. Adjust balance by selecting one or more
NAS1149D0463J, NAS1149F0432P, NAS1149F0463P, A214-3, or A141-14
washers as required and install under one nut of intermediate flex plate (tail rotor
driveline) fastener.
b. Engine Shaft: Refer to Figure 18-14. Adjust balance by selecting one or more
NAS1149D0463J, NAS1149F0432P, NAS1149F0463P, A214-3, or A141-14
washers as required and install under one nut of aft flex plate (engine driveline)
fastener. After first adjustment, if engine shaft does not respond correctly to
balance weight, verify TIR of F018 clutch’s housing is less than 0.004 inch
(rotate TR backwards by hand to rotate clutch housing) before making further
weight changes. If TIR exceeds limit, contact RHC Technical Support.

NOTE
If a large diameter washer is installed at a shaft flange, also
install one NAS1149F0432P washer against flange to prevent
flange damage (not required for flat flange). Additionally, an
NAS6604-5, -6, -7, or -8 bolt may be substituted for a bolt at
a flex plate fastener; verify thread engagement meets torque
requirements per § 20-30.

5. Adjust as required until reading is 0.2 IPS or less.

APR 2019 Chapter 18 Track and Balance Page 18.35

FIGURE 18-14 ENGINE SHAFT BALANCING CHART

Page 18.36 Chapter 18 Track and Balance APR 2019

CHAPTER 20

STANDARD PRACTICES
Section Title Page

20-10 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.1

20-20 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.2A
20-30 Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.3
20-31 Torque Stripe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.5
20-32 Standard Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.6
20-33 Special Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.7
20-34 Push-Pull Tube Rod End Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 20.11B
20-35 D210-series Nuts on Critical Fasteners . . . . . . . . . . . . . . . . . . . . . . . . 20.11B
20-36 A880 Flared Tube Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.11C
20-40 Non-Destructive Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.12
20-41 Magnetic Particle Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.12
20-42 Fluorescent Penetrant Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.13
20-50 Corrosion Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.13
20-60 Priming and Painting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.13
20-70 Approved Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.16
20-71 Paint Strippers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.16
20-72 Solvents and Cleaners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.16
20-73 Fillers and Putty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.17
20-74 Torque Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.17
20-75 Primers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.18
20-76 Powder Coat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.18A
20-77 Paints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.18B
20-78 Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.21
20-79 Adhesives and Sealants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.22
20-80 Storage Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.24
20-90 Miscellaneous Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.25
20-91 Part Interchangeability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.25
20-92 Thermal Fitting Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.25
20-93 Replacement Component Identification (Data) Plates . . . . . . . . . . . . . . . 20.25
20-94 Crimp Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.26

JUL 2020 Chapter 20 Standard Practices Page 20.i

Intentionally Blank

Page 20.ii Chapter 20 Standard Practices JUL 2020

CHAPTER 20

STANDARD PRACTICES

20-10 Cleaning

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

A. Cleaning Exterior Surfaces

NOTE
Remove turbine exhaust stains from engine cowling, tailcone,
empennage, and tail rotor blades after every flight to prevent
permanent discoloration.
CAUTION
Refer to § 20-10 Part B for cleaning windshield and windows.
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.
CAUTION
Wash helicopter exterior surfaces 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.

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.

JUL 2020 Chapter 20 Standard Practices Page 20.1

20-10 Cleaning (continued)
B. Cleaning Windshield and Windows
1. Remove dirt, mud, and other loose particles from exterior surfaces with clean water.
2. Wash with mild soap and warm water or with aircraft plastic cleaner. Use a soft
cloth or sponge in a straight back and forth motion. Do not rub harshly.
3. Remove oil and grease with a cloth moistened with isopropyl alcohol (rubbing
alcohol) or aliphatic naphtha.

CAUTION
Do not use gasoline, other alcohols, benzene, carbon tetrachloride,
thinner, acetone, or window (glass) cleaning sprays.

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. Scratches can be removed from acrylic windshields by rubbing with jeweler’s rouge
followed by hand polishing with commercial plastic polish. Use a figure eight motion
with polishing. Polishing optional, polycarbonate (impact-resistant) windshields is
not recommended as it may thin the protective hardcoat finish.
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.
E. Cleaning or Rinsing RR300 Engine
Follow published Rolls-Royce guidance (subject to revision) to maximize RR300 engine
corrosion prevention:
• RR300 Operation and Maintenance Manual (OMM) Task 05-50-00-100-801, Clean
the Engine after Operation in a Corrosive Environment, and
• NTO (Notice To Operators) No. RR300-020, RR300 Engine Wash Procedures.
Refer to § 12-71 for drainage spotface inspection during cleaning or rinsing of RR300
engine.

Page 20.2 Chapter 20 Standard Practices JUL 2020

20-20 Lubrication

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

All R66 bearings are sealed or self-lubricating and do not require periodic lubrication.
The engine oil tank, the main and tail rotor gearboxes, and the hydraulic reservoir require
servicing when indicated by sight gage level. Additionally, change engine, gearbox, or
hydraulic oil and clean respective sight gage when oil becomes so dirty its level cannot be
determined. Change hydraulic oil if notedly odorous.
When installing a new or overhauled main rotor gearbox, replace filter at first 100-hour
inspection after installation. Thereafter, replace filter at scheduled intervals per § 5-20.
When installing a new or overhauled tail rotor gearbox, drain and flush after first 4 hours
of flight or first chip light, whichever occurs first. Thereafter, drain and flush gearbox at
scheduled intervals per § 5-20.
Servicing procedures are located in Chapter 12.

JUL 2020 Chapter 20 Standard Practices Page20.2A

Intentionally Blank

Page 20.2B Chapter 20 Standard Practices JUL 2020

20-30 Torque Requirements

A. Tool Calibration

Dimensions and tolerances given in this manual are critical. Calibrate measuring tools per
manufacturers recommendation at least once a year, when tool is dropped, misused, or
calibration is suspect. This includes torque wrenches, micrometers, calipers, dial indicators,
and spring scales.

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 Section 20-32 unless otherwise specified.
If torque is applied by rotating bolt, increase torque value by 10% to account for higher
friction at bolthead and shank.

For example, the torque wrench setting for an NAS1305 bolt used with a NAS1068 nutplate
is determined as follows:

NAS1305 bolt (5 indicates 5/16 inch size) dry torque per Section 20-32 240 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 secondary locking mechanisms in most areas on the helicopter, and are
torqued per Section 20-32. The R66 Illustrated Parts Catalog (IPC) lists secondary locking
mechanisms for specific fasteners.

D. Critical Fastener

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.

WARNING

Assembly of flight controls is critical and requires inspection

by a qualified person. If a second person is not available,
RHC recommends the installer take a 5-minute break prior to
inspecting flight control connections he has assembled.

25 OCT 2010 R66 Maintenance Manual Chapter 20 Standard Practices Page 20.3
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 20-1 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 20-2 SHORTENING TORQUE WRENCH EFFECTIVE LENGTH

Page 20.4 Chapter 20 Standard Practices R66 Maintenance Manual 25 OCT 2010
20-30 Torque Requirements (continued)
E. Torque Requirements

CAUTION
Never substitute AN bolts for NAS bolts. NAS bolts have higher
tensile strength.

1. Any self-locking nut whose drag has deteriorated appreciably must be replaced.
Damaged hardware must be replaced.
2. Bolt and nut are to be clean and dry except when assembly procedure specifies
anti-seize or thread-locking compound.
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 20-1 and 20-2.
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.

20-31 Torque Stripe

WARNING
Refer to Safety Data Sheet (SDS) and observe precautions
when working in proximity to hazardous materials.

Refer to Figure 5-1. Apply lacquer-paint Torque Seal® 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 § 20-74.
If, during inspection, the remaining torque stripe on a fastener is insufficient to determine
joint integrity, then remove accompanying palnut as required and apply specified torque
to fastener. If fastener moves, disassemble joint and inspect parts for damage such as
fretting, thread deformation, hole elongation, etc.; replace damaged parts. If fastener
does not move, install new palnut as required & standard torque per § 20-32. Torque
stripe fastener per § 20-31.

APR 2019 Chapter 20 Standard Practices Page 20.5

20-32 Standard Torques
NOTE
1. Torque values are in inch-pounds unless otherwise specified.
2. Torque values include nut self-locking torque.
3. Increase torque values 10% if torqued at bolt head.
4. Wet indicates threads lubricated with A257-9 anti-seize.
5. For elbow and tee fittings which require alignment, torque to indicated
value, then tighten to desired position.
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

Page 20.6 Chapter 20 Standard Practices APR 2019

20-33 Special Torques
Special torques supersede standard torques listed in § 20-32.

NOTE
1. Torque values are in inch-pounds unless otherwise specified.
2. Torque values include nut self-locking torque.
3. Increase torque values 10% if torqued at bolt head.
4. Wet indicates threads lubricated with A257-9 anti-seize.
5. 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.

TORQUE
AREA FASTENER (IN.-LB)
(1) D795-8 line assembly, B-nuts 150
(1) D799-2 switch assembly 90
(1) D799-3 switch assembly 90
(1) D799-9 switch assembly 90
(1) G783 condenser, dessicant cap 100
(1) G784-1 evaporator assembly, inlet B-nut to TXV 210
AIR CONDITIONING (1) G794-1 hose assembly, B-nuts 210
(OPTIONAL
EQUIPMENT) (1) G794-2 hose assembly, B-nuts 210
(1) G794-3 hose assembly, B-nuts 150
(1) G810-1 line assembly, B-nuts 210
(1) G811-1 line assembly, B-nuts 150
(2) AN924-8D nuts 360
(8) MS27039C1-07 screws at condenser fans 30
(2) 91292A135 screws 70
CABIN (1) D210-5 nut, ground handling ball 240
(1) B289-2 bolt, drain 70
(1) B563-2 sight gage 150
(1) D205-19 hose assembly, B-nuts 285
(1) D205-20 hose assembly, B-nuts 285
(1) F723-1 line assembly, B-nuts 675
COOLING SYSTEM (1) F723-2 line assembly, B-nuts 245
(ENGINE AND MAIN
(1) F723-3 line assembly, B-nuts 245
ROTOR GEARBOX
OILS) (1) F723-4 line assembly, B-nuts 245
(1) F724-1 line assembly, B-nuts 120
(1) F724-2 line assembly, B-nuts 285
(1) F724-3 line assembly, B-nuts 285
(2) AN815-8D unions, on F649-1 oil cooler 300
(2) AN832-8D unions, at firewall 230-260

JUL 2020 Chapter 20 Standard Practices Page 20.7

20-33 Special Torques (continued)

TORQUE
AREA FASTENER
(IN.-LB)
COOLING (1) AN832-10D union, at firewall 330-360
SYSTEM (2) AN924-8D nuts, at firewall 150
(ENGINE (1) AN924-10D nut, at firewall 180
& MAIN
GEARBOX (2) AN924-6D nuts, securing F823-1 thermostat assembly to firewall 120
OILS) (2) AS5169D04L fitting, on F649-1 oil cooler 58
(Cont’d) (1) MS28034-1 oil temperature sender, to tank 120
(16) MS51861-37C screws, securing door hinge assemblies 36
DOOR (2) 94830A030 nuts, securing G904-1 gas spring ball studs at
100
HINGES baggage compartment door
AND GAS (2) 94830A030 nuts, securing D575-1 gas spring ball studs at aft doors 100
SPRINGS (2) C394-2 ball stud, at forward doors, to frame 150 wet
(2) D575-2 and (2) D575-3 ball joints, at forward doors' D573-4 rods 37
(2) F650-1 bolt, forward main rotor gearbox and G201 frame mounts 50 FT-LB wet
DRIVE Bolt head or nut
SYSTEM (2) F650-2 bolt, aft main rotor gearbox and G201 frame mounts 50 FT-LB wet
Bolt head or nut
(2) MS21044B5 nut, securing A780 cable to B415-2 relay 80
ELECTRICAL
SYSTEM (1) NAS6605-3 bolt, securing B237-8 battery ground cable to G131-5
70
terminal assembly
(8) NAS6604-6 bolts, securing vertical stabilizers to upper horizontal
185
stabilizer
EMPENNAGE
(1) NAS1352-3-14P screw, securing guard assembly blocks to lower
40
vertical stabilizer
(1) Fuel control unit (FCU) lever nut 40-50
ENGINE
(1) Power turbine governor (PTG) lever nut 40-60
CONTROLS
(4) MS21042L3 nut, securing control wires 25-30
(1) A457-16 and (1) A457-17 fittings, IBF filter FMA line 60
ENGINE (1) G738-1 nozzle, compressor service 30
INDUCTION (1) AN316-7R nut, compressor service line 150
(1) AN929-4 cap, compressor service line 60
(1) A761-2 valve, sump 60
(1) B254-3 strainer, fuel bladder outlet 150
(1) B283-12 hose assembly, fuel valve to fuel pump inlet, B-nuts 110-130
(5) B289 bolts, fuel sender 37
FUEL (1) F550 fuel sender center stud nut 11
SYSTEM (1) F550 fuel sender ground stud nut 9
(1) D205-21 hose assembly, fuel bladder outlet to fuel valve, B-nuts 110-130
(1) G254-2 fitting, vent assembly 200
(1) G254-6 retainer, vent assembly 200
(1) A880-1005 or AN924-5D nut, low fuel warning switch assembly 150

Page 20.8 Chapter 20 Standard Practices JUL 2020

20-33 Special Torques (continued)

TORQUE
AREA FASTENER
(IN.-LB)
FUEL SYSTEM
(1) D210-3 nut, securing control wire 27
(Cont’d)
(5) B289-4 bolts, fuel sender 37
(1) D205-35 hose assembly, nuts (large tank; drain) 120
(2) D205-36 hose assembly, nuts 120
AUXILIARY
(1) D205-37 hose assembly, nuts (small tank; drain) 120
FUEL SYSTEM
(2) G764-5 fittings 200
(1) G768-3 sensor assembly 85
(2) A880-906 or AN815-6D fitting 200
(1) 564601 tube assembly, at AS4824N08 seal 325
FUEL FLOW (1) 564601 tube assembly, at AS4824N04 seal 145
METER (1) SS6565-8-4 fitting, at AS4824N08 seal 325
INSTALLATION (1) SS6565-8-4 fitting, at AS4824N04 seal 245
(1) AS5178J04 nut, at G155-1 (aft) bracket 145
(1) G391-1 line assembly B-nuts (apply A257-9 to upper nut threads) 245 wet
(1) G391-2 line assembly B-nuts 100
(1) G391-3 line assembly B-nuts 100
HEATER (1) G391-4 line assembly B-nuts 100
(1) G391-5 line assembly B-nuts 230-260
(2) G392-3 diffuser assembly B-nuts 100
(1) D210-3 nut, securing control wire 25–30
(2) AN815-3D union 95–105
(2) AN815-4D union 135–150
(1) AN820-4 cap, on reservoir AN804D4 T-fitting 60
(1) AN820-6 cap, on reservoir AN834-6D T-fitting 120
(2) D452-3 nuts, on aft and left hand servos 60
(3) D452-4 nuts, on aft and left hand servos and on reservoir 90
(1) D452-6 nut, on reservoir 150
(2) B330-19 palnut, on aft and left hand servos 30
HYDRAULIC (3) B330-21 palnut, on aft and left servos and on reservoir 45
HOSES &
FITTINGS (1) B330-25 palnut, on reservoir 75
(1) D205-14 line assembly B-nuts 95–105
(1) D205-17 line assembly B-nuts 95–105
(1) D205-18 line assembly B-nuts 135–150
(1) D205-22 line assembly B-nuts 95–105
(1) D205-23 line assembly B-nuts 135–150
(1) D205-24 line assembly B-nuts 135–150
(2) F902-1 line assembly B-nuts 135–150
(2) F902-2 line assembly B-nuts 110–130

JUL 2020 Chapter 20 Standard Practices Page 20.9

20-33 Special Torques (continued)

TORQUE
AREA FASTENER
(IN.-LB)
(1) D487-3, filler-vent 100
HYDRAULIC
(1) D516-1, filter cap 150
RESERVOIR
(1) B563-2, sight gage 150
HYDRAULIC (1) D210-08 nut, attaching D200-2 scissors 25
SERVOS (1) B330-6 palnut on D200-2 scissor apex fastener 5-10
(4) NAS6604-46 bolts, securing ground handling wheel
70
support weldments to skid tubes
LANDING (4) NAS6607P20 bolt, securing landing gear to fuselage
66 FT-LB
GEAR supports and shackles
(2) NAS6607P44 bolt, securing shackles to fuselage 66 FT-LB
(4) B277-28 clamp, securing fairings to struts 15
(2) D674-2 hose assembly, B-nuts 245
(4) D674-6 hose assembly, B-nuts 245
(2) D674-7 hose assembly, B-nuts 120
(1) D674-9 hose assembly, B-nuts 245
(2) D674-10 hose assembly, B-nuts 245
(2) D674-11 hose assembly, B-nuts 245
POP-OUT
FLOATS (1) D674-12 hose assembly, B-nuts 245
(OPTIONAL (1) D674-13 hose assembly, B-nuts 245
EQUIPMENT)
(2) D770-1 valve assembly 40
(2) D770-2 valve assembly 40
(2) D770-3 valve assembly 40
(2) D770-4 valve assembly 40
(2) D770-5 valve assembly 40
(2) D770-6 valve assembly 40
(2) B289-2 bolts, per blade, self-sealing 70
MAIN ROTOR
(2) A722-4 screws, per blade, tip balance weight 40 wet
BLADE
(2) NAS1351N3-12P screws, per blade, tip cover 40 wet
MAIN ROTOR
FLIGHT (2) MS21042L04 nut, low rotor horn V3-1 switch 4-5
CONTROLS
(1) B254-3 strainer, main rotor gearbox sump 200
(1) B563-2 sight gage 150
(1) B566-1 chip detector, main rotor gearbox 150
MAIN ROTOR (1) D205-25 hose assembly, sump to pump B-nuts 120
GEARBOX
(8) D210-3 nuts, securing D500-2 (hydraulic) and D500-3
37
(main gearbox oil) pumps to main gearbox
(1) F904-1 pinion plug, securing tail rotor output yoke to 60 FT-LB wet
main gearbox Apply A257-9 to threads

Page 20.10 Chapter 20 Standard Practices JUL 2020

20-33 Special Torques (continued)

TORQUE
AREA FASTENER
(IN.-LB)
MAIN ROTOR (1) A880-1208 or AN814-8D plug, main rotor gearbox filler plug 150
GEARBOX (1) MS21245L8 nut, securing input yoke to main gearbox 40 FT-LB
(Cont’d) (1) chip detector wire terminal nut 5
New bolt: 0.021-
0.022 inch
elongation, wet
(1) NAS634-105 bolt, teeter hinge and
MAIN ROTOR HUB Used bolt: 0.020-
(2) NAS634-105 bolt, coning hinges 0.022 inch
elongation, wet,
and cotter pin
holes must align
MAST TUBE (1) B277-064 clamp, lower rib to mast tube 50
(2) 21FKF-813 or 27FKF-813 self-locking jam nuts, main
PITCH LINKS 300
rotor pitch links
(1) D745-3 (pressure) switch assembly 65
(1) F147-1 screw, FCU minimum throttle stop 20
(1) F170 fitting, engine gearbox vent 100
(1) F727-1 line assembly, fuel pump drain 50-65
(1) F727-2 line assembly, horizontal turbine-firewall shield
50-65
assembly drain
(1) F741-1 line assembly, fuel differential pressure switch 80
(1) G200-1 engine lifting lug (optional) 110
(1) G426-1 (fuel differential pressure) switch assembly 100
(2) nuts, securing harness wire to MGT thermocouple studs,
20
engine-supplied
(2) nuts, securing harness wires to starter-generator small
20
terminals, starter-generator supplied
POWERPLANT
(2) nuts, securing harness wires to starter-generator large
180
terminals, starter-generator supplied
(1) nut, securing harness wire to ignition exciter box, engine-
15
supplied
(2) nuts, securing harness and (2) MS21919WCH4 clamps to
40
engine accesory gearbox, engine-supplied
(4) nuts, securing F577-1 bracket assembly, engine-supplied 40
(2) tee bolts, securing F173-1 struts to engine, engine-supplied 35-40
(2) A880-908 or AN815-8D unions, engine oil outlet & oil tank
250
vent
(1) A880-910 or AN815-10D union, engine oil inlet 375
(1) AN919-0D reducer and (1) AN919-2D reducer 100
(2) NAS6605-3 bolt, securing G200-1 lug to engine (optional) 110

JUL 2020 Chapter 20 Standard Practices Page 20.11

20-33 Special Torques (continued)
TORQUE
AREA FASTENER
(IN.-LB)
(6) NAS6605H3 bolts, securing (2) F593-1 support assemblies to
110
engine
POWERPLANT
(2) NAS6605H4 bolts and (1) NAS6605H2 bolt, securing F174-1
(Cont’d) 110
weldment and F593-3 plate to engine
(1) CV26-77 check valve, engine oil outlet (superseded; early R66s) 250
(26) NAS1352N08-8 screws, securing spacers, sleeve assembly,
35 wet
SWASHPLATE shield, and retainers
(2) NAS1352N08-4 screws, securing B769-2 bracket 35
(1) D210-4 nut, securing C119-2 bumper 120
TAIL ROTOR
(1) NAS6606-53 bolt, teeter hinge 380
TAIL ROTOR
FLIGHT (1) D210-4 nut, outboard of F316-1 bellcrank assembly 90
CONTROLS
(1) A610-1 vent assembly 100
(1) B563-4 sight gage 150
(1) B566-2 chip detector 100
TAIL ROTOR (1) D210-5 nut, pitch control housing 240
GEARBOX (1) AN320-8 nut, input yoke 35-45 FT-LB
(4) MS20074-04-06 bolts, input cap 60
(8) MS20074-04-06 bolts, input housing and output cap 100
(4) NAS1352-5-12P bolts (undrilled), gearbox-to-tailcone attachment 260
TAIL ROTOR
(1) NAS1352-3-14P screw, securing block assembly to stabilizer 40
GUARD
(22) AN526C832R12 screw, thru center brace 16
(74) B526-6 screw, polycarbonate windshield fasteners 24
WINDSHIELD (4) B526-8 screw, polycarbonate windshield fasteners 24
(24) NAS1352-08-12P screw, polycarbonate windshield
30
fasteners, with wire strike provisions

Page 20.11A Chapter 20 Standard Practices JUL 2020

20-34 Push-Pull Tube Rod End Adjustment

NOTE
Refer to § 18-13 to adjust C258 main rotor pitch links.

The following procedure is standard for adjusting push-pull tube rod ends:
1. Loosen palnut and jam nut on rod end shank.
2. Remove hardware securing push-pull tube rod end to attachment point per respective
instructions.
3. Screw rod end in or out of push-pull tube as required to obtain proper rigging
adjustment. Apply B270-21 (corrosion) protectant to exposed threads.
4. After any rod end adjustment, verify rod end threaded shank blocks passage of 0.020-
inch diameter wire thru the witness hole in the push-pull tube per Figure 5-1. When
no witness hole is provided, refer to Figure 5-1 for maximum rod end extension.
5. Install fastener securing push-pull tube to attachment point per respective instructions.
6. Refer to Figure 5-2. Position rod ends to allow as much push-pull tube rotation as
possible without binding. Standard torque jam nuts & palnuts per § 20-32 & torque
stripe per Figure 5-1.

20-35 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 MS21042L3 nut or NAS1291-3 nut with D210-3 nut,
replace MS21042L4 nut or NAS1291-4 nut with D210-4 nut,
replace MS21042L5 nut or NAS1291-5 nut with D210-5 nut,
replace MS21042L6 nut or NAS1291-6 nut with D210-6 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.

JUL 2020 Chapter 20 Standard Practices Page 20.11B

20-36 A880 Flared Tube Components

A. Nuts – Flare

Dash
Allowable Part Numbers Material REF Tube OD REF
Numbers
-102 AN818-2D, AN818-2W, AS5175W02 AL 1/8-inch
-103 AN818-3D, AN818-3W, AS5175W03 AL 3/16-inch
-104 AN818-4D, AN818-4W, AS5175W04 AL 1/4-inch
-105 AN818-5D, AN818-5W, AS5175W05 AL 5/16-inch
-106 AN818-6D, AN818-6W, AS5175W06 AL 3/8-inch
-108 AN818-8D, AN818-8W, AS5175W08 AL 1/2-inch
-110 AN818-10D, AN818-10W, AS5175W10 AL 5/8-inch
-202 AN818-2J, AS5175J02 CRES 1/8-inch
-203 AN818-3J, AS5175J03 CRES 3/16-inch
-204 AN818-4J, AS5175J04 CRES 1/4-inch
-205 AN818-5J, AS5175J05 CRES 5/16-inch
-206 AN818-6J, AS5175J06 CRES 3/8-inch
-208 AN818-8J, AS5175J08 CRES 1/2-inch
-210 AN818-10J, AS5175J10 CRES 5/8-inch

Page 20.11C Chapter 20 Standard Practices JUL 2020

20-36 A880 Flared Tube Components (continued)

B. Sleeves

Dash
Allowable Part Numbers Material REF Tube OD REF
Numbers
-302 MS20819-2D, AS3220D02, AS3220W02 AL 1/8-inch
-303 MS20819-3D, AS3220D03, AS3220W03 AL 3/16-inch
-304 MS20819-4D, AS3220D04, AS3220W04 AL 1/4-inch
-305 MS20819-5D, AS3220D05, AS3220W05 AL 5/16-inch
-306 MS20819-6D, AS3220D06, AS3220W06 AL 3/8-inch
-308 MS20819-8D, AS3220D08, AS3220W08 AL 1/2-inch
-310 MS20819-10D, AS3220D10, AS3220W10 AL 5/8-inch
-402 MS20819-2J, AS5176J02 CRES 1/8-inch
-403 MS20819-3J, AS5176J03 CRES 3/16-inch
-404 MS20819-4J, AS5176J04 CRES 1/4-inch
-405 MS20819-5J, AS5176J05 CRES 5/16-inch
-406 MS20819-6J, AS5176J06 CRES 3/8-inch
-408 MS20819-8J, AS5176J08 CRES 1/2-inch
-410 MS20819-10J, AS5176J10 CRES 5/8-inch

JUL 2020 Chapter 20 Standard Practices Page 20.11D

20-36 A880 Flared Tube Components (continued)

C. Adapters – NPT to Flare

Dash
Allowable Part Numbers Material REF Tube OD REF
Numbers
-502 AN816-2D, AS5194D0202 AL 1/8-inch
-503 AN816-3D, AS5194D0302 AL 3/16-inch
-504 AN816-4D, AS5194D0402 AL 1/4-inch
-505 AN816-5D, AS5194D0502 AL 5/16-inch
-506 AN816-6D, AS5194D0604 AL 3/8-inch
-508 AN816-8D, AS5194D0806 AL 1/2-inch
-510 AN816-10D, AS5194D1008 AL 5/8-inch
-532 AN816-2J, AS5194J0202 CRES 1/8-inch
-533 AN816-3J, AS5194J0302 CRES 3/16-inch
-534 AN816-4J, AS5194J0402 CRES 1/4-inch
-535 AN816-5J, AS5194J0502 CRES 5/16-inch
-536 AN816-6J, AS5194J0604 CRES 3/8-inch
-538 AN816-8J, AS5194J0806 CRES 1/2-inch
-540 AN816-10J, AS5194J1008 CRES 5/8-inch
-562 AN816-2, AS5194-0202 STL 1/8-inch
-563 AN816-3, AS5194-0302 STL 3/16-inch
-564 AN816-4, AS5194-0402 STL 1/4-inch
-565 AN816-5, AS5194-0502 STL 5/16-inch
-566 AN816-6, AS5194-0604 STL 3/8-inch
-568 AN816-8, AS5194-0806 STL 1/2-inch
-570 AN816-10, AS5194-1008 STL 5/8-inch

Page 20.11E Chapter 20 Standard Practices JUL 2020

20-36 A880 Flared Tube Components (continued)

D. Elbows – 90°, NPT to Flare

Dash
Allowable Part Numbers Material REF Tube OD REF
Numbers
-602 AN822-2D, MS20822-2D, AS5195W0202 AL 1/8-inch
-603 AN822-3D, MS20822-3D, AS5195W0302 AL 3/16-inch
-604 AN822-4D, MS20822-4D, AS5195W0402 AL 1/4-inch
-605 AN822-5D, MS20822-5D, AS5195W0502 AL 5/16-inch
-606 AN822-6D, MS20822-6D, AS5195W0604 AL 3/8-inch
-608 AN822-8D, MS20822-8D, AS5195W0806 AL 1/2-inch
-610 AN822-10D, MS20822-10D, AS5195W1008 AL 5/8-inch
-632 AN822-2J, MS20822-2J, AS5195J0202 CRES 1/8-inch
-633 AN822-3J, MS20822-3J, AS5195J0302 CRES 3/16-inch
-634 AN822-4J, MS20822-4J, AS5195J0402 CRES 1/4-inch
-635 AN822-5J, MS20822-5J, AS5195J0502 CRES 5/16-inch
-636 AN822-6J, MS20822-6J, AS5195J0604 CRES 3/8-inch
-638 AN822-8J, MS20822-8J, AS5195J0806 CRES 1/2-inch
-640 AN822-10J, MS20822-10J, AS5195J1008 CRES 5/8-inch
-662 AN822-2, MS20822-2, AS5195-0202 STL 1/8-inch
-663 AN822-3, MS20822-3, AS5195-0302 STL 3/16-inch
-664 AN822-4, MS20822-4, AS5195-0402 STL 1/4-inch
-665 AN822-5, MS20822-5, AS5195-0502 STL 5/16-inch
-666 AN822-6, MS20822-6, AS5195-0604 STL 3/8-inch
-668 AN822-8, MS20822-8, AS5195-0806 STL 1/2-inch
-670 AN822-10, MS20822-10, AS5195-1008 STL 5/8-inch

JUL 2020 Chapter 20 Standard Practices Page 20.11F

20-36 A880 Flared Tube Components (continued)

E. Elbows – 45°, NPT to Flare

Dash
Allowable Part Numbers Material REF Tube OD REF
Numbers
-702 AN823-2D, MS20823-2D, AS5196W0202 AL 1/8-inch
-703 AN823-3D, MS20823-3D, AS5196W0302 AL 3/16-inch
-704 AN823-4D, MS20823-4D, AS5196W0402 AL 1/4-inch
-705 AN823-5D, MS20823-5D, AS5196W0502 AL 5/16-inch
-706 AN823-6D, MS20823-6D, AS5196W0604 AL 3/8-inch
-708 AN823-8D, MS20823-8D, AS5196W0806 AL 1/2-inch
-710 AN823-10D, MS20823-10D, AS5196W1008 AL 5/8-inch
-732 AN823-2J, MS20823-2J, AS5196J0202 CRES 1/8-inch
-733 AN823-3J, MS20823-3J, AS5196J0302 CRES 3/16-inch
-734 AN823-4J, MS20823-4J, AS5196J0402 CRES 1/4-inch
-735 AN823-5J, MS20823-5J, AS5196J0502 CRES 5/16-inch
-736 AN823-6J, MS20823-6J, AS5196J0604 CRES 3/8-inch
-738 AN823-8J, MS20823-8J, AS5196J0806 CRES 1/2-inch
-740 AN823-10J, MS20823-10J, AS5196J1008 CRES 5/8-inch
-762 AN823-2, MS20823-2, AS5196-0202 STL 1/8-inch
-763 AN823-3, MS20823-3, AS5196-0302 STL 3/16-inch
-764 AN823-4, MS20823-4, AS5196-0402 STL 1/4-inch
-765 AN823-5, MS20823-5, AS5196-0502 STL 5/16-inch
-766 AN823-6, MS20823-6, AS5196-0604 STL 3/8-inch
-768 AN823-8, MS20823-8, AS5196-0806 STL 1/2-inch
-770 AN823-10, MS20823-10, AS5196-1008 STL 5/8-inch

Page 20.11G Chapter 20 Standard Practices JUL 2020

20-36 A880 Flared Tube Components (continued)

F. Elbows – 90°, Bulkhead Flare to Flare

Dash
Allowable Part Numbers Material REF Tube OD REF
Numbers
-802 AN833-2D, AS1038D0202, AS1038W0202 AL 1/8-inch
-803 AN833-3D, AS1038D0303, AS1038W0303 AL 3/16-inch
-804 AN833-4D, AS1038D0404, AS1038W0404 AL 1/4-inch
-805 AN833-5D, AS1038D0505, AS1038W0505 AL 5/16-inch
-806 AN833-6D, AS1038D0606, AS1038W0606 AL 3/8-inch
-808 AN833-8D, AS1038D0808, AS1038W0808 AL 1/2-inch
-810 AN833-10D, AS1038D1010, AS1038W1010 AL 5/8-inch
-832 AN833-2J, AS1038J0202 CRES 1/8-inch
-833 AN833-3J, AS1038J0303 CRES 3/16-inch
-834 AN833-4J, AS1038J0404 CRES 1/4-inch
-835 AN833-5J, AS1038J0505 CRES 5/16-inch
-836 AN833-6J, AS1038J0606 CRES 3/8-inch
-838 AN833-8J, AS1038J0808 CRES 1/2-inch
-840 AN833-10J, AS1038J1010 CRES 5/8-inch
-862 AN833-2, AS1038-0202 STL 1/8-inch
-863 AN833-3, AS1038-0303 STL 3/16-inch
-864 AN833-4, AS1038-0404 STL 1/4-inch
-865 AN833-5, AS1038-0505 STL 5/16-inch
-866 AN833-6, AS1038-0606 STL 3/8-inch
-868 AN833-8, AS1038-0808 STL 1/2-inch
-870 AN833-10, AS1038-1010 STL 5/8-inch

JUL 2020 Chapter 20 Standard Practices Page 20.11H

20-36 A880 Flared Tube Components (continued)

G. Unions – Flare to Flare

Dash
Allowable Part Numbers Material REF Tube OD REF
Numbers
-902 AN815-2D, AS5174D0202, AS5174W0202 AL 1/8-inch
-903 AN815-3D, AS5174D0303, AS5174W0303 AL 3/16-inch
-904 AN815-4D, AS5174D0404, AS5174W0404 AL 1/4-inch
-905 AN815-5D, AS5174D0505, AS5174W0505 AL 5/16-inch
-906 AN815-6D, AS5174D0606, AS5174W0606 AL 3/8-inch
-908 AN815-8D, AS5174D0808, AS5174W0808 AL 1/2-inch
-910 AN815-10D, AS5174D1010, AS5174W1010 AL 5/8-inch
-932 AN815-2J, AS5174J0202 CRES 1/8-inch
-933 AN815-3J, AS5174J0303 CRES 3/16-inch
-934 AN815-4J, AS5174J0404 CRES 1/4-inch
-935 AN815-5J, AS5174J0505 CRES 5/16-inch
-936 AN815-6J, AS5174J0606 CRES 3/8-inch
-938 AN815-8J, AS5174J0808 CRES 1/2-inch
-940 AN815-10J, AS5174J1010 CRES 5/8-inch
-962 AN815-2, AS5174-0202 STL 1/8-inch
-963 AN815-3, AS5174-0303 STL 3/16-inch
-964 AN815-4, AS5174-0404 STL 1/4-inch
-965 AN815-5, AS5174-0505 STL 5/16-inch
-966 AN815-6, AS5174-0606 STL 3/8-inch
-968 AN815-8, AS5174-0808 STL 1/2-inch
-970 AN815-10, AS5174-1010 STL 5/8-inch

Page 20.11I Chapter 20 Standard Practices JUL 2020

20-36 A880 Flared Tube Components (continued)

H. Nuts – Hex

Dash
Allowable Part Numbers Material REF Tube OD REF
Numbers
-1002 AN924-2D, AN924-2W, AS5178W02 AL 1/8-inch
-1003 AN924-3D, AN924-3W, AS5178W03 AL 3/16-inch
-1004 AN924-4D, AN924-4W, AS5178W04 AL 1/4-inch
-1005 AN924-5D, AN924-5W, AS5178W05 AL 5/16-inch
-1006 AN924-6D, AN924-6W, AS5178W06 AL 3/8-inch
-1008 AN924-8D, AN924-8W, AS5178W08 AL 1/2-inch
-1010 AN924-10D, AN924-10W, AS5178W10 AL 5/8-inch
-1032 AN924-2J, AS5178J02 CRES 1/8-inch
-1033 AN924-3J, AS5178J03 CRES 3/16-inch
-1034 AN924-4J, AS5178J04 CRES 1/4-inch
-1035 AN924-5J, AS5178J05 CRES 5/16-inch
-1036 AN924-6J, AS5178J06 CRES 3/8-inch
-1038 AN924-8J, AS5178J08 CRES 1/2-inch
-1040 AN924-10J, AS5178J10 CRES 5/8-inch
-1062 AN924-2, AS5178-02 STL 1/8-inch
-1063 AN924-3, AS5178-03 STL 3/16-inch
-1064 AN924-4, AS5178-04 STL 1/4-inch
-1065 AN924-5, AS5178-05 STL 5/16-inch
-1066 AN924-6, AS5178-06 STL 3/8-inch
-1068 AN924-8, AS5178-08 STL 1/2-inch
-1070 AN924-10, AS5178-10 STL 5/8-inch

JUL 2020 Chapter 20 Standard Practices Page 20.11J

20-36 A880 Flared Tube Components (continued)

I. Tees – NPT to Flare

Dash
Allowable Part Numbers Material REF Tube OD REF
Numbers
-1102 AN826-2D, MS20826-2D, AS5198W020202 AL 1/8-inch
-1103 AN826-3D, MS20826-3D, AS5198W030203 AL 3/16-inch
-1104 AN826-4D, MS20826-4D, AS5198W040204 AL 1/4-inch
-1105 AN826-5D, MS20826-5D, AS5198W050205 AL 5/16-inch
-1106 AN826-6D, MS20826-6D, AS5198W060406 AL 3/8-inch
-1108 AN826-8D, MS20826-8D, AS5198W080608 AL 1/2-inch
-1110 AN826-10D, MS20826-10D, AS5198W100810 AL 5/8-inch
-1132 AN826-2J, MS20826-2J, AS5198J020202 CRES 1/8-inch
-1133 AN826-3J, MS20826-3J, AS5198J030203 CRES 3/16-inch
-1134 AN826-4J, MS20826-4J, AS5198J040204 CRES 1/4-inch
-1135 AN826-5J, MS20826-5J, AS5198J050205 CRES 5/16-inch
-1136 AN826-6J, MS20826-6J, AS5198J060406 CRES 3/8-inch
-1138 AN826-8J, MS20826-8J, AS5198J080608 CRES 1/2-inch
-1140 AN826-10J, MS20826-10J, AS5198J100810 CRES 5/8-inch
-1162 AN826-2, MS20826-2, AS5198-020202 STL 1/8-inch
-1163 AN826-3, MS20826-3, AS5198-030203 STL 3/16-inch
-1164 AN826-4, MS20826-4, AS5198-040204 STL 1/4-inch
-1165 AN826-5, MS20826-5, AS5198-050205 STL 5/16-inch
-1166 AN826-6, MS20826-6, AS5198-060406 STL 3/8-inch
-1168 AN826-8, MS20826-8, AS5198-080608 STL 1/2-inch
-1170 AN826-10, MS20826-10, AS5198-100810 STL 5/8-inch

Page 20.11K Chapter 20 Standard Practices JUL 2020

20-36 A880 Flared Tube Components (continued)

J. Plugs without Holes

Dash
Allowable Part Numbers Material REF Tube OD REF
Numbers
-1202 AN814-2D, AN814-2W, AS5169D02, AS5169W02 AL 1/8-inch
-1203 AN814-3D, AN814-3W, AS5169D03, AS5169W03 AL 3/16-inch
-1204 AN814-4D, AN814-4W, AS5169D04, AS5169W04 AL 1/4-inch
-1205 AN814-5D, AN814-5W, AS5169D05, AS5169W05 AL 5/16-inch
-1206 AN814-6D, AN814-6W, AS5169D06, AS5169W06 AL 3/8-inch
-1208 AN814-8D, AN814-8W, AS5169D08, AS5169W08 AL 1/2-inch
-1210 AN814-10D, AN814-10W, AS5169D10, AS5169W10 AL 5/8-inch
-1232 AN814-2J, AS5169J02 CRES 1/8-inch
-1233 AN814-3J, AS5169J03 CRES 3/16-inch
-1234 AN814-4J, AS5169J04 CRES 1/4-inch
-1235 AN814-5J, AS5169J05 CRES 5/16-inch
-1236 AN814-6J, AS5169J06 CRES 3/8-inch
-1238 AN814-8J, AS5169J08 CRES 1/2-inch
-1240 AN814-10J, AS5169J10 CRES 5/8-inch
-1262 AN814-2, AS5169-02 STL 1/8-inch
-1263 AN814-3, AS5169-03 STL 3/16-inch
-1264 AN814-4, AS5169-04 STL 1/4-inch
-1265 AN814-5, AS5169-05 STL 5/16-inch
-1266 AN814-6, AS5169-06 STL 3/8-inch
-1268 AN814-8, AS5169-08 STL 1/2-inch
-1270 AN814-10, AS5169-10 STL 5/8-inch

JUL 2020 Chapter 20 Standard Practices Page 20.11L

20-36 A880 Flared Tube Components (continued)

K. Plugs with Holes

Dash Material Tube OD

Allowable Part Numbers
Numbers REF REF
-1302 AN814-2DL, AN814-2WL, AS5169D02L, AS5169W02L AL 1/8-inch
-1303 AN814-3DL, AN814-3WL, AS5169D03L, AS5169W03L AL 3/16-inch
-1304 AN814-4DL, AN814-4 WL, AS5169D04L, AS5169W04L AL 1/4-inch
-1305 AN814-5DL, AN814-5WL, AS5169D05L, AS5169W05L AL 5/16-inch
-1306 AN814-6DL, AN814-6WL, AS5169D06L, AS5169W06L AL 3/8-inch
-1308 AN814-8DL, AN814-8WL, AS5169D08L, AS5169W08L AL 1/2-inch
-1310 AN814-10DL, AN814-10WL, AS5169D10L, AS5169W10L AL 5/8-inch
-1332 AN814-2JL, AS5169J02L CRES 1/8-inch
-1333 AN814-3JL, AS5169J03L CRES 3/16-inch
-1334 AN814-4JL, AS5169J04L CRES 1/4-inch
-1335 AN814-5JL, AS5169J0SL CRES 5/16-inch
-1336 AN814-6JL, AS5169J06L CRES 3/8-inch
-1338 AN814-8JL, AS5169J0BL CRES 1/2-inch
-1340 AN814-10JL, AS5169J10L CRES 5/8-inch
-1362 AN814-2L, AS5169-02L STL 1/8-inch
-1363 AN814-3L, AS5169-03L STL 3/16-inch
-1364 AN814-4L, AS5169-04L STL 1/4-inch
-1365 AN814-5L, AS5169-05L STL 5/16-inch
-1366 AN814-6L, AS5169-06L STL 3/8-inch
-1368 AN814-8L, AS5169-08L STL 1/2-inch
-1370 AN814-10L, AS5169-10L STL 5/8-inch

Page 20.11M Chapter 20 Standard Practices JUL 2020

Intentionally Blank

JUL 2020 Chapter 20 Standard Practices Page 20.11N

20-40 Non-Destructive Testing

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

20-41 Magnetic Particle Inspection

Ferromagnetic steel parts must be inspected for structural defects using magnetic particle
inspection.
Steel parts covered by this specification shall be inspected per ASTM E 1444 wet process
with ultra‑violet light. Applicable requirements and limitations of the above standard shall
apply. Parts shall be thoroughly demagnetized and cleaned after inspections. Record the
size and location of all rejectable indications.
Procedures and equipment used to perform the inspection shall conform to requirements
of ASTM E 1444. Whenever possible, parts shall be inspected with both circular and
longitudinal magnetization.
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:
y Indications smaller than 0.015 inch are not considered ratable.
y Indications caused by sharp changes in cross‑section or part geometry.
Rejectable indications:
y Indications interpreted as cracks, seams, laps, shuts, or any flaws which are
open to the surface.
y Indications oriented at an angle of more than 15 degrees from the longitudinal
axis with length exceeding 0.125 inch.
y Circumferential indications on any shoulder or fillet (changes in diameter).
y Any indications which break over an edge, shoulder, fillet radius, keyway,
spline, or an adjacent area of part more than 0.015 inch.
y Indications caused by undercuts at the toe of a weld.
y Indications caused by cracks in the weld or parent metal.
y Indications caused by inclusions in weld material exceeding 0.1 inch in length.

Page 20.12 Chapter 20 Standard Practices JUL 2020

20-42 Fluorescent Penetrant Inspection
This specification provides for surface inspection of parts fabricated from nonmagnetic
materials to detect discontinuities open to the surface, such as cracks, cold shuts, laps,
porosity and other surface defects.
Applicable requirements and limitations of ASTM E 1417 shall apply. After inspection is
complete, solvent clean parts.
The step‑by‑step procedure and equipment used to perform the inspection shall be
accomplished per ASTM E 1417.
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.

20-50 Corrosion Control

[Reserved].

20-60 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 § 20-70.
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).

APR 2017 Chapter 20 Standard Practices Page 20.13

20-60 Priming and Painting (continued)

WARNING
Refer to appropriate Material Safety Data Sheet (MSDS) and
take necessary safety precautions when working in proximity
to hazardous materials.

A. Priming
1. Preparing Aluminum
Unless otherwise specified, chemical conversion coating using Alodine 1201 is the
standard treatment before priming aluminum. Follow manufacturers instructions
for application of Alodine. 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 an
approved 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 an
approved solvent.
d. Air dry. Do not touch parts with bare hands until primed.
2. Preparing Steel
Alkaline clean is the preferred method for cleaning stainless steel. Alternately,
stainless steel may be cleaned using an approved solvent.
Steel parts should only be cleaned using an approved solvent; using an alkaline
cleaning process on steel may cause a corrosive reaction.
Where immersion is not practical or for extremely greasy or dirty parts, a preclean
in a solvent vapor degreaser may be used.
Air or blow dry using filtered, dry, compressed air.
3. Application
Apply primer after mixing per manufacturer’s recommendations. Primer coating
is not to exceed 0.0005–0.0020 inch thickness 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 (6) hours before using.

Page 20.14 Chapter 20 Standard Practices APR 2017

20-60 Priming and Painting (continued)
A. Priming (continued)
4. Inspection
Inspect for complete coverage and excessive thickness. If primer is excessively
thick, strip part and re-prime. Refer to § 20-70 for approved materials.
B. Painting
Prior to liquid topcoat application, ensure surfaces have been cleaned and primed. In
general, most parts will be cleaned and primed as detail parts. 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 sandpaper.
2. Lightly scuff with Scotch Brite pads (optional).
3. Wipe with clean cloth and approved solvent.
4. Wipe with tack cloth.
5. Apply topcoat.

JUL 2020 Chapter 20 Standard Practices Page 20.15

20-70 Approved Materials
The following items are available from the noted manufacturer(s) or their distributor(s).
Check with appropriate regulatory authority(s) for allowable usage of materials.

WARNING
Review appropriate Safety Data Sheet (SDS) when working in
proximity to hazardous materials. Specific recommendations
for use of personal protective equipment are located in the SDS.
CAUTION
Follow product manufacturer’s instructions for handling and
storage.

20-71 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.

20-72 Solvents and Cleaners

PRODUCT MANUFACTURER/SUPPLIER APPLICATION

QSOL 220 Safety-Kleen Systems, Inc. General use 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 Removing 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)

Page 20.16 Chapter 20 Standard Practices JUL 2020

20-72 Solvents and Cleaners (continued)

PRODUCT MANUFACTURER/SUPPLIER APPLICATION

815 GD Brulin Corporation Ultrasonic cleaning, general
Indianapolis, IN use.**
SF50 L&R Mfg. Co. ““
Kearny, NJ
#112 Ammoniated or L&R Mfg. Co. Ultrasonic cleaning, avionics
#222 Nonammoniated cleaning Kearny, NJ components only.
& rinse solution
Cleanup Wipe E-4365 Sontara Cleaning and drying.
Candler, NC
Snoop Liquid Leak Detector Swagelok Leak detector.
Salon, OH
* May be used on acrylic plastic.
** Mix 5%–20% by volume; titration not required.
*** Acetone and PCBTF may be mixed 50–50.

20-73 Fillers and Putty

PRODUCT MANUFACTURER/SUPPLIER APPLICATION

05960 Glazing Putty 3M Minor surface imperfections.
05860 Dry Guide Coat St. Paul, MN
31180 Finishing Glaze
SBF1191 Gearhead Products ““
Indianapolis, IN
FE-351 Cream Hardener Catalyst Systems ““
Gnadenhutten, OH

20-74 Torque Seal

PRODUCT MANUFACTURER/SUPPLIER APPLICATION

F-900 Organic Products Co. Torque seal.
(Any color except red) Irving, TX

JUL 2020 Chapter 20 Standard Practices Page 20.17

20-75 Primers

A. Non-chromate Primers

Corlar 13580S* Desoprime CA7502* Desoprime CA7422*

Manufacturer Axalta PPG PPG
Corlar 13580S
Base CA7502A CA7422A
Epoxy Primer
Corlar 13180S
Activator CA7502B CA7422B
Epoxy Activator
13756S VOC-Exempt
Reducer CA7502C CA7422C
Reducer
Base: Activator: Reducer 4:1:1 4:4:1 4:4:1
Viscosity 17-21 sec in Zahn #2 15-19 sec in Zahn #2 15-19 sec in Zahn #2
2 hours at 55–70°F
2 hours at 55–68°F
Induction time 30 minutes 1 hour at 71–80°F
1 hour at 69–95°F
30 minutes > 70°F
Pot life 8 hours at 70°F 4 hours at 70°F 4 hours at 70°F
Flash off time None 30 minutes 30 minutes
2 hours at 70°F 3 hours at 70°F 3 hours at 70°F
Dry time
1 hour at 130°F 30 minutes at 120°F 30 minutes at 120°F
Recoat window 48 hours 48 hours 48 hours
* Shelf life per manufacturer's recommendation.

B. Chromate Primers

44GN007* 10P20-44*
Manufacturer PPG AkzoNobel
Base 44GN007 10P20-44
Activator 44GN007CAT EC-265 or EC-273
Reducer Distilled or deionized water TR-114 or TR-102
Base: Activator: Reducer 3:1:8 3:1:1
Viscosity 18–22 seconds in Zahn #2 13–19 seconds in Zahn #2
Induction time None None
Pot life 4 hours at 70°F 4 hours at 77°F
Flash off time 15 minutes 30 minutes
2 hours at 70°F
Dry time 30 minutes at 140°F
45 minutes at 120°F
Recoat window 24 hours 24 hours
* Shelf life per manufacturer's recommendation.

Page 20.18 Chapter 20 Standard Practices JUL 2020

20-76 Powder Coat

PRODUCT MANUFACTURER
Interpon 100-AL101QF Gray AkzoNobel
Zinc Rich Epoxy Powder* Santa Fe Springs, CA
81-2158 Vitralon Grey Pratt & Lambert Chemical Coatings
Zinc Rich Epoxy Powder* Buffalo, NY
39/80020 Smooth Matte Tiger Drylac USA
Black Cucamonga, CA
Polyester Topcoat Powder*
49/72460 Smooth Glossy Tiger Drylac USA
Gray RAL 7043 Cucamonga, CA
Polyester Topcoat Powder*
49/22460 Smooth Glossy ““
Yellow RAL 1028
Polyester Topcoat Powder*
PFWF104S9 White Dupont Co.
Polyester Topcoat Powder* Wilmington, DE
* Shelf life is 12 months from date of manufacture at ambient temperature.

JUL 2020 Chapter 20 Standard Practices Page 20.18A

FIGURE 20-3 PAINT CODES
(Refer to Chapter 62 for rotor blade paint dimensions. Exterior surface codes are D & F unless otherwise specified.)

20-77 Paints
Refer to Figures 20-3 & 20-4 for paint code application. Paint codes for specific helicopter
serial numbers are listed on the inside cover of Airframe Maintenance Record (logbook).

FINISH
MATERIAL* ADDITIVES MANUFACTURER RHC PART NO. APPLICATION
CODE
18BK006CAT
Flat Black 18BK006 PPG Aerospace; Irvine, CA 18BK006
Catalyst
A1 Abrasion Resistant PC-216 Curing
Blade black
AkzoNobel; Waukegan, IL 23T3-90
23T3-90 Black Solution
FR2-55 Mat Top Coat Thinner: water Mapaero Pamiers, France 557Z7038B005 Interior and
A2 Aerofine 8250 Topcoat Thinner: water AkzoNobel; Waukegan, IL 8250 skid tube black
Dark gray Imron 13100S Activator
B AF400/AF700 13110S Activator
Axalta; Wilmington, DE DS020EP Dark grey

Page 20.18B Chapter 20 Standard Practices JUL 2020

20-77 Paints (continued)

FINISH
MATERIAL* ADDITIVES MANUFACTURER RHC PART NO. APPLICATION
CODE
White Imron 13100S Activator
D AF400/AF700 13110S Activator
Axalta; Wilmington, DE N0774EP White

Yellow Imron 13100S Activator

E AF400/AF700 13110S Activator
Axalta; Wilmington, DE N0680EP Yellow

Imron AF400/AF700 13100S Activator

F Colors 13110S Activator
Axalta; Wilmington, DE / Exterior

13100S Activator
Clear Imron
13110S Activator Axalta; Wilmington, DE AF740 Clear coat
AF740
G 13930S Reducer
1311 Matte Clear coat
/ Krylon; Columbus, OH 1311
Clear Coat aerosol
9T00 Activator 9T00-A
D-121 Tint D121
J White Imron 2.1 FT D-101 Tint Axalta; Wilmington, DE D101 Floats
2100-P 2.1 Binder 2100-P
9T20 Flattener 9T20
Printcolor White Ink
750-9005 Printcolor Glass
Printcolor Black Ink Hardener 700 7509005
750-8005 Gensolve Thinner Deco; 7508005
K Printcolor Maize Yellow GS-017L Orance, CA 7501205,
Silkscreen
Ink 750-1205 Slow Retarder 7503005
Printcolor Carnation 10-03432
Red 750-3005
Red Imron 13100S Activator
L AF400/AF700 13110S Activator
Axalta; Wilmington, DE N0759EP Red

Light Gray Imron 13100S Activator Baggage

O AF400/AF700 13110S Activator
Axalta; Wilmington, DE N0020
compartment
Silver Bullet AM Tracer
16-CURE-F4 Burke; R66 Middle
P Black
Activator Ridgefield, WA
20-452AM-F1
seat
20-452AM-F1
Cardinal A-2000 Cardinal; A2000-
/ Interior and
Flat Black Cleveland, OH BKE-30-903
A3 Krylon 1613 Krylon;
Skid Touch Up
/ 1613 Aerosol
Semi-Flat Black Colombus, OH

* Shelf life per manufacturer's recommendation.

JUL 2020 Chapter 20 Standard Practices Page 20.19

FIGURE 20-4 PAINT CODES

Page 20.20 Chapter 20 Standard Practices JUL 2020

20-78 Lubricants

RHC MANUFACTURER’S
LUBRICANT TYPE MANUFACTURER
PART NO. PART NO.
A257-1 Grease 101 Southwestern Petroleum Corp.
(general purpose) Fort Worth, TX
A257-3 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
A257-12 Grease MobilGrease 28 Exxon Mobil Corp.,
MIL-PRF-81322
A257-15 Hydraulic fluid Per MIL-PRF-5606 Any
A257-17 Substitute A257-19
A257-18 O-ring lubricant 55 Dow Corning Corp.
Midland, MI
A257-19 Valve lubricant and 111 Dow Corning Corp.
sealant compound Midland, MI
A257-20 Pag oil 3420025-049 Idemitsu Lubricants America
(Daphne Hermetic PR) or Southfield, MI
3420025-067 (Nissan
Type R)
A257-21 Petrolatum P-16 Panef Corp.
lubricant Milwaukee, WI
A257-22 Gear oil Mobil SHC 629 Exxon Mobil Corp.
synthetic
A257-23 Turbine oil Per AS5780 Any
Class HPC

JUL 2020 Chapter 20 Standard Practices Page 20.21

20-79 Adhesives and Sealants

RHC
DESCRIPTION COLOR MFR. PART NO. MANUFACTURER
PART NO.
B270-1 Sealant – manganese-cured, Gray AC-730 B-* 3M Co.
fuel resistant (2-part) St. Paul, MN
B270-2 Substitute B270-1
B270-4 Substitute B270-13
B270-5 Sealant - synthetic rubber putty White Q4-2805 Dow Corning Corp.
(1-part) Light Gray 94-031 Midland, MI
B270-6 Sealant & lubricant - thread Gray 80631, 80632, Permatex, Inc.
(1-part) 80633 Solon, OH
Titeseal 55 Radiator Spec. Co.
Charlotte, NC
B270-7 Substitute B270-14
B270-8 Adhesive - rubber, nitrile/acetone Tan C 160 Stabond Corp.
(1-part) Gardena, CA
Dark 847 3M Co.
Brown 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, Translu- 3145 Dow Corning Corp.
noncorrosive (1-part) cent Midland, MI
B270-14 Substitute B270-8
B270-15 Adhesive - plastic, for vinyl Clear 2262 3M Co.
(1-part) St. Paul, MN
B270-16 Substitute B270-14
B270-17 Adhesive - cyanoacrylate, instant Clear Super Bonder Henkel Loctite Corp.
(1-part) 495 Rocky Hill, CT
B270-18 Adhesive - weather strip (1-part) Black 051135-08008 3M Co.
St. Paul, MN
B270-19 Adhesive - epoxy structural, rigid Green 1838 B/A 3M Co.
(2-part) St. Paul, MN
B270-20 Adhesive/sealant - threadlocker, Purple 222 or 222MS Henkel Loctite Corp.
anaerobic, non-permanent (1-part) Rocky Hill, CT

Page 20.22 Chapter 20 Standard Practices JUL 2020

20-79 Adhesives and Sealants (continued)

RHC PART
DESCRIPTION COLOR MFR. PART NO. MANUFACTURER
NO.
B270-21 Protectant – corrosion, non- Amber Max Wax Corrosion
drying (1-part) Technologies Corp.
Garland, TX
Lt. Amber LPS 3 LPS Laboratories, Inc.
Tucker, GA
B270-22 Substitute B270-21
Protectant – corrosion, drying Amber LPS Hardcoat LPS Laboratories, Inc.
(1-part) Tucker, GA
B270-23 Sealant – gasket (1-part) Purple 515 Henkel Loctite Corp.
Rocky Hill, CT
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 Automotivetouchup
up, brush in bottle (1-part) Touch up Bottle Harahan, LA
B270-26 Sealant – Polysulfide, window Black AC-251B-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
B270-28 Substitute B270-27

* Dash number for minimum hours application life may be –½, –2, –6, or –12.

JUL 2020 Chapter 20 Standard Practices Page 20.23

20-80 Storage Limits
1. B283 hoses have a shelf storage life of 5 years. Hose service life is “on condition”,
with a maximum of 12 years or 2000 hours, whichever occurs first.
2. Elastic cords have a shelf storage life of 5 years. Elastic cord service life is “on
condition”, with a maximum of 12 years. 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 8130-3 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 (20) quarter, five (5) year shelf life from the
indicated cure date. Flourocarbon (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.

Page 20.24 Chapter 20 Standard Practices JUL 2020

20-90 Miscellaneous Practices

20-91 Part Interchangeability

Refer to R66 Illustrated Parts Catalog for part interchangeability information.

20-92 Thermal Fitting Parts

General Procedures for using heat to fit parts during assembly or evaluating parts that
may have been overheated in service:
Aluminum parts must not be heated above 200ºF for more than 5 minutes. Higher
temperatures or longer times adversely affect strength and corrosion properties. Scrap
any aluminum parts suspected of going above 325ºF regardless of time at temperature.
Steel parts (bare) – Maximum temperature 300ºF. Higher temperature can reduce the
strength or cause temper brittleness in some alloys.
Steel parts (cadmium plated) – Maximum temperature 300ºF. 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 300ºF. 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.

20-93 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.

APR 2017 Chapter 20 Standard Practices Page 20.25

20-94 Crimp Inspection
Refer to Figure 20-5.

FIGURE 20-5 CRIMP INSPECTION

Page 20.26 Chapter 20 Standard Practices APR 2017

CHAPTER 21

ENVIRONMENT CONTROL

Section Title Page

21-00 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.1
21-10 Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.3
21-11 Nose Vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.3
21-20 Air Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.5
21-21 Compressor Assembly . . . . . . . . . . . . . . . . . . . . . . . . 21.5
21-22 Condenser and Fan Assemblies . . . . . . . . . . . . . . . . . . 21.7
21-23 Evaporator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 21.8
21-24 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.9
21-30 Cabin Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.11
21-31 Valve Assembly and Control Rigging . . . . . . . . . . . . . . 21.11
21-32 Muffler Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.12
21-33 Diffuser and Tee Assemblies . . . . . . . . . . . . . . . . . . . . 21.12

SEP 2012 R66 Maintenance Manual Chapter 21 Environment Control Page 21.i
Intentionally Blank

Page 21.ii Chapter 21 Environment Control R66 Maintenance Manual SEP 2012
CHAPTER 21

ENVIRONMENT CONTROL

21-00 Description
Fresh air vents are located in each door and in the nose. Door vents are opened and closed
using the knob near the vent door hinge. A rotating knob is provided to seal and lock vents
closed. 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.
See Chapter 52 for door vent maintenance instructions.
The fresh air inlet in the nose is opened by pulling the vent handle on the console face.
Rotating the vent handle clockwise will lock its position. Air from the nose inlet is directed
along the inside surface of the windshield for defogging as well as for ventilation.
The optional cabin air conditioning system, shown schematically in Figure 21-2, is similar to
conventional automotive and light aircraft systems. The system consists of a compressor
mounted immediately aft of the main gearbox, a condenser mounted to the vertical firewall
in the engine compartment, an evaporator mounted to the front of the center seat support,
a blower, an overhead outlet duct, and interconnecting lines and hoses. The system uses
R134a refrigerant.
The compressor is belt-driven, by a pulley mounted to the main gearbox tail rotor drive yoke
assembly, and is equipped with an electromagnetic clutch. When the system is off, the
compressor clutch is disengaged, allowing the compressor pulley to freewheel.
Cooling air for the condenser is supplied via an opening in the belly. The engine cowling air
scoop collects the necessary cooling air for the condenser during forward flight. In a hover,
electric fans help to draw cooling air through the condenser.
The evaporator blower draws warm cabin air though the evaporator inlet grill and evaporator,
where the air is cooled. Cool air is drawn through the blower and blown through ducts under
the center seat, up the cabin aft wall, and to the overhead duct.
The system is controlled by a toggle switch on the overhead duct which allows selection of
off, low, and high fan settings. The compressor requires main rotor gearbox oil pressure to
engage. The compressor is automatically engaged by switching the fan on. A temperature
(freeze) switch disengages the compressor when evaporator temperature drops below
freezing. Safety (pressure) switches disengage the compressor if excessive refrigerant
leakage occurs or if refrigerant pressure is excessive. When the collective is lowered to the
full-down position another switch disengages the compressor for 10 seconds to ensure that
aircraft performance is not affected. All circuits are protected by the 25 amp A/C circuit
breaker; the evaporator blower, the condenser fans, and the compressor clutch circuits are
further protected by fuses.
Bleed air from the engine compressor is used for cabin heat. Tubing routes hot air from the
engine to outlets forward of the tail rotor pedals and in the rear footwells. A heater control
knob located to the left of the cyclic stick actuates a valve in the aft end of the control
tunnel through a push-pull cable to control cabin heat. Because the cabin heat uses engine
compressor air, some performance degradation occurs with heat ON.

CAUTION
In case of engine fire, cabin heat should be turned off.

MAY 2015 Chapter 21 Environment Control Page 21.1

FIGURE 21-1 NOSE VENT

Page 21.2 Chapter 21 Environment Control MAY 2015

21-10 Ventilation

21-11 Nose Vent

Refer to R66 Illustrated Parts Catalog (IPC) Figures 21-1.

A. Removal

1. Remove hardware securing avionics face to F033-1 lower console and remove face.
Unscrew and remove radios. Remove hardware securing radio trays to lower console
and remove trays. Disconnect OAT wiring.

2. Refer to Figure 21-1. Remove screws attaching upper console to lower console and
hinge console aft. Protect instrument face with foam support or equivalent.

3. Remove and discard cotter pin securing clevis pin and C522-5 (air vent) control inner
wire to C062-1 vent box assembly channel. Remove and retain clevis pin.

4. Remove hardware securing AN742-3 clamp and control housing to vent box angle.

5. Cut and discard ty-rap securing control housing to lower console angle.

6. Remove screws securing C365-13 mount assembly to lower console and remove
control. As required, remove MS35489-4 grommet and clamp; remove jam nut
& lockwashers securing mount assembly to control housing, and remove mount
assembly.

B. Installation

1. Refer to Figure 21-1. As required, install C365-12 mount assembly, lockwashers,

and jam nut on C522-5 (air vent) control housing, but do not tighten jam nut. Install
AN742-3 clamp and (new, as required) MS35489-4 grommet on control housing.

2. Position control in lower console and install screws securing mount assembly to
lower console. Verify security.

3. Rotate control knob until horizontal within 15° when locked; tighten jam nut against
mount assembly. Verify security.

4. Route control inner wire through C062-1 vent box assembly channel. Adjust grommet
position as required, and install clevis pin through channel and control inner wire.
Install cotter pin. Verify security.

5. Install clamp and hardware securing clamp and control housing to vent box angle.

6. Install ty-rap around control housing through hole in lower console angle. Cinch ty-
rap until snug without over-tightening, and trim tip flush with head.

7. 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.

8. Close and secure upper console. Connect OAT wiring. Install radio trays and
hardware securing trays to lower console. Verify security. Install and secure radios.
Install avionics face and hardware securing face to lower console.

SEP 2012 R66 Maintenance Manual Chapter 21 Environment Control Page 21.3
FIGURE 21-2 AIR CONDITIONING SCHEMATIC

Page 21.4 Chapter 21 Environment Control R66 Maintenance Manual SEP 2012
21-20 Air Conditioning

21-21 Compressor Assembly

Refer to R66 Illustrated Parts Catalog (IPC) Figure 21-3.

A. Belt Replacement

1. Remove tailcone cowling per § 53-23.

2. Remove hardware securing F196-1 tail rotor drive fan shaft to C947-3 plate
assemblies, noting hardware removed.

3. Loosen hardware securing G777-1 compressor assembly to G781-1 arm weldment.

CAUTION

Do not use refrigerant hose assemblies or fittings to rotate

compressor. Do not rotate compressor further than necessary,
to avoid damaging system wiring and refrigerant hoses or
fittings.

4. Rotate compressor down and inboard as required to disengage B173-5 v-belt from
pulleys. Route belt around drive shaft flange and remove belt.

5. Route new B173-5 v-belt around drive shaft flange and fit belt onto G779-1 pulley
and compressor pulley.

6. Rotate compressor up and outboard to tension belt, then tighten hardware securing
compressor to weldment. Adjust belt until 4.5-5.5 lb of force applied mid-span
deflects belt 0.16-inch. Standard torque bolts per § 20-32 and torque stripe per
Figure 5-1.

7. Install hardware securing drive shaft to plate assemblies, as removed. Standard

torque bolts per § 20-32 and torque stripe per Figure 5-1.

8. Install tailcone cowling per § 53-23.

MAY 2015 Chapter 21 Environment Control Page 21.5

21-21 Compressor Assembly (continued)

B. Removal

1. Remove tailcone cowling per § 53-23.

2. Turn BATTERY switch OFF. Cut and discard ty-raps as required and disconnect
compressor assembly wiring from airframe harness at connectors.

3. Recover refrigerant per § 12-81. Remove hardware securing refrigerant hose

assemblies to G777-1 compressor assembly. Cap fittings.

4. Remove hardware securing compressor to G781-1 arm weldment and G782-1

mount weldment and remove compressor.

C. Installation

1. Remove G777-1 compressor assembly service port caps and completely drain oil.
Using a syringe, service compressor with 120±10 cc A257-20 pag oil into the
high pressure port. Install service port caps; verify security.

2. Refer to § 5-45. Inspect B173-5 v-belt condition and replace as required. Fit
belt around G779-1 pulley and compressor pulley, and install hardware securing
compressor to G782-1 mount weldment. Standard torque bolts per § 20-32.

3. Install hardware securing compressor to G781-1 arm weldment. Rotate compressor

up and outboard to tension belt, then tighten hardware securing compressor to
weldment. Adjust belt until 4.5-5.5 lb of force applied mid-span deflects belt
0.16-inch. Standard torque bolts per § 20-32, and torque stripe all compressor
mounting hardware per Figure 5-1.

4. Remove caps and install refrigerant hose assemblies and hardware securing hoses
to compressor. Special torque screws per § 20-33 and torque stripe per Figure
5-1.

5. Connect compressor assembly wiring to airframe harness at connectors and install

ty-raps as required. Cinch ty-raps until snug without over-tightening, and trim tips
flush with heads.

6. Perform leak detection per § 12-83.

7. Charge system with refrigerant per § 12-82.

8. Install tailcone cowling per § 53-23.

Page 21.6 Chapter 21 Environment Control MAY 2015

21-22 Condenser and Fan Assemblies

Refer to R66 Illustrated Parts Catalog (IPC) Figure 21-7.

A. Removal

1. Recover refrigerant per Section 12-82.

2. Remove engine cowling per Section 53-21.

3. Turn BATTERY switch OFF. Cut and discard ty-raps as required and disconnect
G780-1 fan assembly wiring from airframe harness at connectors.

4. Remove hardware securing G786-1 box assembly to G783-1 condenser.

5. Using backup wrench, disconnect G810-1 and G811-1 line assembly b-nuts from
condenser fittings.

6. Supporting condenser, remove hardware securing condenser to G787 support

assemblies. Taking care not to damage line assemblies and condenser fittings,
carefully remove condenser. Cap fittings.

B. Installation

1. Remove caps. Install hardware securing G783-1 condenser to G787 support

assemblies. Verify security.

2. Connect G810-1 and G811-1 line assembly b-nuts to condenser fittings. Using
backup wrench, special torque b-nuts per Section 20-33, and torque stripe per Figure
5-1.

3. Install hardware securing G786-1 box assembly to condenser. Verify security.

4. Connect G780-1 fan assembly wiring to airframe harness at connectors and install
ty-raps as required. Cinch ty-raps until snug without over-tightening, and trim tips
flush with heads.

5. Perform leak detection per Section 12-83.

6. Charge system with refrigerant per Section 12-82.

7. Install engine cowling per Section 53-21.

SEP 2012 R66 Maintenance Manual Chapter 21 Environment Control Page 21.7
21-23 Evaporator Assembly

Refer to R66 Illustrated Parts Catalog (IPC) Figure 21-11.

A. Removal

1. Recover refrigerant per Section 12-82.

2. Refer to Section 6-70. Detach F931-1 seat assembly (secured via hook and loop
tape) from F474-1 cover assembly and remove seat. Remove hardware securing
cover assembly and F380-8 angle to F377-1 middle seat assembly; remove cover
and angle.

3. Cut and discard ty-raps as required and disconnect D799-7 (freeze) switch assembly
wiring from airframe harness at connector.

4. Remove screws securing G798-1 cover assembly to seat assembly. Remove

hardware securing G784-1 evaporator assembly and switch to seat assembly.

5. Using backup wrench, disconnect D795-8 line assembly and evaporator line b-nuts
from G794 hose assemblies.

6. Remove aluminum tape securing F380-7 cover to middle seat (if installed). Detach
grommet from seat assembly and carefully remove evaporator and attached
components forward through seat assembly vertical wall relief. Cap fittings.

B. Installation

1. Remove caps. Position G784-1 evaporator assembly and associated components

in F377-1 middle seat assembly. Install screws securing evaporator and D799-7
(freeze) switch assembly to seat assembly. Install screws securing G798-1 cover
assembly to seat assembly.

2. Connect D795-8 line assembly and evaporator line b-nuts to G794 hose assemblies.
Using backup wrench, special torque hose b-nuts per Section 20-33, and torque
stripe per Figure 5-1.

3. Connect freeze switch wiring to airframe harness at connector and install ty-raps as
required. Cinch ty-raps until snug without over-tightening, and trim tips flush with
heads.

4. Perform leak detection per Section 12-83.

5. Charge system with refrigerant per Section 12-82.

6. Install screws securing F474-1 cover assembly and F380-8 angle to middle seat.
Attach F931-1 seat assembly (secured via hook and loop tape) to cover.

Page 21.8 Chapter 21 Environment Control R66 Maintenance Manual SEP 2012
21-24 Troubleshooting
1. If air exiting overhead duct is not cold:

POSSIBLE CAUSE TROUBLESHOOT/CORRECTIVE ACTION

Low Refrigerant Recover refrigerant per § 12-82. System should operate normally on
Charge/ Refrigerant approximately 2.5 lb refrigerant.
Leak
If less than 2.5 refrigerant is recovered, perform leak detection per § 12-83,
repair leaks if any, and charge system with refrigerant per § 12-82.

Switch or Wiring With aircraft not running, temporarily connect a jumper from ground to wire
Problem Interrupting 1898 at main gearbox oil pressure switch. Raise collective to full-up position.
Compressor Power Turn on Master switch and A/C switch on overhead duct (low or high setting
ok). Have observer listen to and observe compressor clutch through cowl door.
Clutch should engage (click and snap against pulley) whenever A/C is switched
on. Remove temporary jumper.
Check wiring at freeze switch (refer to § 21-23), high and low pressure
switches (near compressor assembly), and full-down collective switch. Repair
any damaged wiring or connectors. Check continuity through each switch. All
switches should be closed with a properly charged system and aircraft at rest
on ground. Replace any defective switch.

Failed Compressor Inspect belt.

V-Belt
Replace belt per § 21-21 as required.

Insufficient Inspect condenser installation. Verify no blockage and all seals in place.
Condenser Airflow
Remove blockage and/or repair seals to ensure airflow through core.

Extreme Extreme temperature and humidity may result in cooling effect less than a
Environmental typical automobile.
Conditions
No corrective action available.

2. If excessive condensation is found near evaporator assembly:

POSSIBLE CAUSE TROUBLESHOOT/CORRECTIVE ACTION

Blocked or Kinked Verify system is draining normally. After several minutes ground run in humid
Evaporator Drain conditions with A/C on, water should be seen draining from the drain tube.
If water drainage is not observed, inspect drain line (refer to § 5-45). Correct
any damaged or kinked lines. Clean sediment trap as required. Verify proper
function of check ball.

Extreme Humidity Some condensation is unavoidable in extreme humidity.

Ensure all fresh air vents closed. Limit opening and closing cabin doors as
much as practical to limit humidity entering cabin.

JUL 2020 Chapter 21 Environment Control Page 21.9

FIGURE 21-3 CABIN HEAT

Page 21.10 Chapter 21 Environment Control JUL 2020

21-30 Cabin Heat
21-31 Valve Assembly and Control Rigging
Refer to R66 Illustrated Parts Catalog (IPC) Figures 21-31 and 21-35.
A. Removal
1. Refer to Section 6-70. Remove hardware securing F794-1 and F794-2 (belly cover)
panels and remove panels. Remove engine cowling per Section 53-21.
2. Refer to Figure 21-3. Remove hardware securing A522-14 (heater valve) control
inner wire to G019-1 (heater) valve assembly arm.
3. Remove hardware securing AN742-3 clamps and control housing to F621-2 bracket.
4. Hinge aft right seat forward. Remove clamps, spacers, and hardware securing G391-2
and G391-5 line assemblies to aft right keel panel. Hinge seat back.
5. Loosen line assembly B-nuts from G400-2 muffler assembly & G396-1 union; disconnect
lines from valve assembly fittings and remove valve. Plug lines & cap fittings.
B. Installation
1. Refer to Figure 21-3. Remove caps and plugs, install G019-1 (heater) valve assembly
and connect G391-2 and G391-5 line assembly B-nuts to valve assembly fittings.
Hand-tighten B-nuts at valve assembly, G400-2 muffler assembly, and G396-1 union,
but do not torque.
2. Hinge aft right seat forward. Install clamps, spacers, and hardware securing line
assemblies to aft right keel panel. Verify security. Hinge seat back.
3. Position valve assembly so F621-2 bracket is vertical within 5°; special torque line
assembly B-nuts at valve assembly, muffler assembly, and union, and torque stripe
per Figure 5-1.
4. Perform control rigging per Part C, steps 3 thru 6.
5. Install engine cowling per Section 53-21.
C. Control Rigging
1. Refer to Section 6-70. Remove hardware securing F794-1 and F794-2 (belly cover)
panels and remove panels.
2. Refer to Figure 21-3. Remove palnut and loosen nut securing A462-4 fitting and
A522-14 (heater valve) control inner wire to G019-1 (heater) valve assembly arm.
3. As required, loosen hardware securing AN742-3 clamps and control housing to
F621-2 bracket. Position end of control housing flush-0.25 inch at or beyond edge
of aft clamp and install fasteners. Verify security.
4. Refer to detail in Figure 76-3. Push heater valve knob ON then pull up slightly to
create 0.03-0.10 inch clearance under knob. Position valve assembly arm in full
open detent. Verify sufficient inner wire beyond aft edge of fitting and special
torque fitting nut per Section 20-33.
5. Install fitting palnut, standard torque per Section 20-32, and torque stripe per Figure
5-1. Trim control wire 0.10-0.30 inch beyond aft edge of fitting.
6. Install (belly cover) panels, and install hardware. Verify security.

SEP 2012 R66 Maintenance Manual Chapter 21 Environment Control Page 21.11
21-32 Muffler Assembly

Refer to R66 Illustrated Parts Catalog (IPC) Figure 21-35.

A. Removal

1. Refer to Section 6-70. Remove hardware securing F794-1 and F794-2 (belly cover)
panels and remove panels.

2. Refer to Figure 21-3. Loosen B277-12 clamp and pull A785-39 hose off of G400-2
muffler assembly. Install temporary covers on muffler and hose openings.

3. Loosen G391-4 line assembly B-nut at AN824-8D tee; disconnect G391-2 and -4
line assemblies from muffler.

4. Remove hardware securing MS21919WCH32 clamps and muffler to forward right

keel panel and remove muffler. Plug & cap fittings. As required, remove clamps
from muffler.

B. Installation

1. Refer to Figure 21-3. As required, install MS21919WCH32 clamps on G400-2

muffler assembly. Install hardware securing clamps and muffler to forward right keel
panel. Verify security.

2. Remove caps and plugs and connect G341-2 and G341-4 line assembly B-nuts
to muffler assembly fittings. Special torque B-nuts at AN824-8D tee and muffler
assembly, and torque stripe per Figure 5-1.

3. Remove temporary covers and slide B277-12 clamp and A785-39 hose onto muffler
assembly and tighten clamp. Verify security.

4. Install (belly cover) panels, and install hardware. Verify security.

21-33 Diffuser and Tee Assemblies

Refer to R66 Illustrated Parts Catalog (IPC) Figure 21-33.

A. Forward Diffuser and Tee Assembly Removal

1. Refer to Figure 21-3. Remove screws attaching upper console to lower console and
hinge console aft. Protect instrument face with foam support or equivalent.

2. Loosen two B277-24 clamps securing G400-1 tee assembly collars to G400-7 and
G400-8 diffuser assemblies. Slide diffusers outboard from tee and lower console
assembly.

3. Loosen B277-12 clamp securing A785-39 hose to tee assembly can weldment and
pull hose and clamp off of can.

4. Remove hardware securing MS21919WCH16 clamp and tee assembly to angle and
remove tee. As required, remove clamps from tee.

Page 21.12 Chapter 21 Environment Control R66 Maintenance Manual SEP 2012
21-33 Diffuser and Tee Assemblies (continued)

B. Forward Diffuser and Tee Assembly Installation

1. Refer to Figure 21-3. As required, install MS21919WCH16 and (two) B277-24

clamps on G400-1 tee assembly. Install tee with clamps, and install hardware
securing MS21919WCH16 clamp and tee to angle.

2. Insert G400-7 and G400-8 diffuser assemblies through lower console and into tee
assembly. Orient diffuser holes vertically within 5°, and tighten clamps (against
spacers) securing tee assembly collars to diffusers. Verify security.

3. Slide A785-39 hose and B277-12 clamp onto tee assembly can weldment and tighten
clamp. Verify security.

4. Close and secure upper console.

C. Aft Diffuser Assemblies and Tee Removal

1. Refer to Section 6-70. Remove hardware securing F794-1 (belly cover) forward
panel and remove panel.

2. Refer to Figure 21-3. Hinge aft right and left seats forward. Remove hardware
securing G394-1 guards and G392-3 diffuser assemblies to aft seat assemblies and
remove guards. Hinge seats back.

3. Disconnect diffuser assembly B-nuts from AN824-8D tee and remove diffusers. As
required, disconnect G391-4 line assembly B-nut from tee and remove tee. Cap
fittings.

D. Aft Diffuser Assemblies and Tee Installation

1. Refer to Figure 21-3. As required, remove caps, install AN824-8D tee, and connect
G391-4 line assembly B-nut, but do not torque.

2. Remove caps and install G392-3 diffuser assemblies; connect diffuser assembly
B-nuts to tee, but do not torque. Hinge aft right and left seats forward and install
hardware securing diffusers to aft seat assemblies. Special torque line assembly and
diffuser B-nuts per Section 20-33, and torque stripe per Figure 5-1.

3. Install G394-1 guards and hardware securing guards to aft seat assemblies. Verify
security. Hinge seats back.

4. Install (belly cover) panel, and install hardware. Verify security.

SEP 2012 R66 Maintenance Manual Chapter 21 Environment Control Page 21.13
Intentionally Blank

Page 21.14 Chapter 21 Environment Control R66 Maintenance Manual SEP 2012
CHAPTER 22

AUTOPILOT
Section Title Page

22-00 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.1

22-10 (Pitch) Servo Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.3
22-20 (Roll) Servo Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.4
22-30 Flight Control Computer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.5
22-40 Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.6
22-50 Cyclic Grip Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.7
22-60 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.8
22-61 Scheduled Maintenance and Inspections . . . . . . . . . . . . . . . . . . . . . . . . 22.8
22-62 Special Maintenance and Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.10

MAY 2015 Chapter 22 Autopilot Page 22.i

Intentionally Blank

Page 22.ii Chapter 22 Autopilot MAY 2015

CHAPTER 22

AUTOPILOT

22-00 Description

The optional, factory-installed autopilot system consists of two electric servo assemblies, a
flight control computer, a control panel, and control buttons on the pilot’s cyclic grip.

The autopilot system also utilizes the Attitude Heading Reference System (AHRS; refer to §
97-13).

Two electric servo assemblies attach via push-pull tubes to the bottom of the cyclic stick.
One servo controls pitch and is installed in the control tunnel forward of the cyclic stick.
The other servo controls roll and is installed under the pilot’s seat. Electromagnetic clutches
engage or disengage servo inputs from the cyclic control system when selected by the pilot.

The flight control computer is located on a forward panel under the pilot's seat. The control
panel is located below the GPS in the instrument console.

The primary autopilot mode is Stability Augmentation System (SAS) mode. In SAS mode
the autopilot senses aircraft attitude from the flight control computer and the AHRS. The
computer controls servo inputs to the cyclic to maintain attitude.

Additional modes, which may be used simultaneously when in SAS mode, are described
in the Normal Procedures section of the R66 Pilot's Operating Handbook (POH) Autopilot
Supplement.

The control panel has a row of buttons to control autopilot modes and annunciators to
indicate mode status. A dark annunciator indicates that a mode is off, a white annunciator
indicates that a mode is armed or on standby, and a green annunciator indicates that a mode
is active. The annunciators flash alternating white and green during start up.

The cyclic grip-mounted buttons are the TRIM and AP OFF buttons. The TRIM button is
used to reset the trim attitude. The autopilot tries to maintain the attitude at which the
button is released. In addition, holding the TRIM button for more than 1.25 seconds engages
the system from standby mode. The AP OFF button allows disengagement with hands on
controls.

Safety monitors automatically disengage individual modes or the entire system if a

malfunction is detected. Audio warnings consisting of beeps in the headset accompany the
safety monitors and are described in the Normal Procedures section of the POH Autopilot
Supplement.

The autopilot is protected by a dedicated circuit breaker on the avionics bus (autopilot is not
powered with the avionics master switch off).

A. Schematic

Refer to MM Figure 98-8 for autopilot installation electrical schematic.

MAY 2015 Chapter 22 Autopilot Page 22.1

FIGURE 22-1 AUTOPILOT SYSTEM

Page 22.2 Chapter 22 Autopilot MAY 2015

22-10 (Pitch) Servo Assembly
A. Removal
1. Turn battery & avionics switches off and pull out AUTOPILOT (5 amp) circuit breaker
at panel.
2. Remove F680-3 and F445-1 collective covers and F444-1 cyclic cover. Hinge front
right seat forward. Remove G702-7 cover assembly under pilot's seat.
3. Remove avionics and avionics trays as required from lower console.

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

4. Position cyclic stick full aft and apply cyclic friction. Remove hardware (and C130-50
spacer) securing D354-3 (pitch) servo assembly arm to A336-8 push-pull tube's rod end.
5. Disconnect servo harness from 01311-03-11 flight control computer's J1 PITCH
receptacle. Cut and discard ty-rap securing harness to M23190/1-2 clamp and pull
harness through access holes into control tunnel.
6. Support servo and remove hardware securing servo's D353-4 brace to cyclic box and
keel panels. Carefully remove servo from control tunnel.
B. Installation
1. Turn battery & avionics switches off and pull out AUTOPILOT (5 amp) circuit breaker
at panel. Position cyclic stick full aft and apply cyclic friction.
2. Position D354-3 (pitch) servo assembly in control tunnel and install hardware securing
servo's D353-4 brace to cyclic box. Standard torque bolts per § 20-32 and torque
stripe per Figure 5-1. Install screws securing brace to keel panels. Verify security.
3. Route servo harness through access holes and connect harness to 01311-03-11 flight
control computer's J1 PITCH receptacle. Install ty-rap securing harness to M23190/1-
2 clamp. Cinch ty-rap until snug without over-tightening, and trim tip flush with head.
Verify harness security.
4. Install hardware (and C130-50 spacer) securing servo arm to A336-8 push-pull tube's rod
end. Standard torque bolt per § 20-32 and torque stripe per Figure 5-1. Verify security.
5. Verify length of A336-8 push-pull tube and A127-3 rod ends center-to-center dimension
is 4.27–4.33 inches.
6. Verify freedom of flight controls through full travel with and without friction applied.
7. Install avionics trays and avionics if removed. Verify security.
8. Push in AUTOPILOT circuit breaker (5 amp) at panel. Perform ground checks as
appropriate per § 22-61.
9. Install G702-7 cover assembly under pilot's seat. Install F444-1 cyclic cover, and
F445-1 and F680-3 collective covers. Verify security.

JUL 2020 Chapter 22 Autopilot Page 22.3

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

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

3. Position cyclic stick full left and apply cyclic friction. Remove hardware securing
D354-4 (roll) servo assembly arm to A336-8 push-pull tube's rod end.
4. Disconnect servo harness from 01311-03-11 flight control computer's J3 ROLL
receptacle. Cut and discard ty-raps securing servo harness to autopilot harnesses.
5. Support servo and remove hardware securing servo's D352-14 block assembly to
keel panel and D353-5 brace assembly. Carefully remove servo from under pilot's
seat.
B. Installation
1. Turn battery & avionics switches off and pull out AUTOPILOT (5 amp) circuit
breaker at panel. Position cyclic stick full left and apply cyclic friction.
2. Position D354-4 (roll) servo assembly under pilot's seat and install hardware
securing servo's D352-14 block assembly to keel panel and D353-5 brace assembly.
Tighten screws. Verify security.
3. Connect servo harness to 01311-03-11 flight control computer's J3 ROLL
receptacle. Install ty-raps securing servo harness to autopilot harnesses as required.
Cinch ty-raps until snug without over-tightening, and trim tips flush with heads.
Verify harness security.
4. Install hardware securing servo arm to A336-8 push-pull tube's rod end. Standard
torque bolt per § 20-32 and torque stripe per Figure 5-1. Verify security.
5. Verify length of A336-8 push-pull tube and A127-3 rod ends center-to-center
dimension is 4.17–4.23 inches.
6. Verify freedom of flight controls through full travel with and without friction applied.
7. Push in AUTOPILOT circuit breaker (5 amp) at panel. Perform ground checks as
appropriate per § 22-61.
8. Install G702-7 cover assembly under pilot's seat. Install F445-1 and F680-3
collective covers. Verify security.

Page 22.4 Chapter 22 Autopilot JUL 2020

FIGURE 22-2 FLIGHT CONTROL COMPUTER

22-30 Flight Control Computer

A. Removal
1. Turn battery & avionics switches off and pull out AUTOPILOT (5 amp) circuit
breaker at panel.
2. Remove G702-7 cover assembly under pilot's seat.
3. Disconnect D323 harness assemblies and D354 servo assembly harnesses from
01311-03-11 flight control computer's J1 PITCH, J2, J3 ROLL, and J4 receptacles.
4. Disconnect pitot and static tubes from computer. Plug elbows and tubes.
5. Support computer and remove screws securing computer to D358-1 support
assemblies. Carefully remove computer from under pilot's seat.

APR 2017 Chapter 22 Autopilot Page 22.5

22-30 Flight Control Computer (continued)
B. Installation
1. Turn battery & avionics switches off and pull out AUTOPILOT (5 amp) circuit
breaker at panel.
2. Position 01311-03-11 flight control computer under pilot's seat and install screws
securing computer to D358-1 support assemblies. Tighten screws. Verify security.
3. Remove plugs and connect pitot and static tubes to computer. Perform pitot and
static system leak checks per § 95-10.
4. Connect D323 harness assemblies and D354 servo assembly harnesses to
computer's J1 PITCH, J2, J3 ROLL, and J4 receptacles. Install ty-raps securing
harnesses as required. Cinch ty-raps until snug without over-tightening, and trim
tips flush with heads. Verify harness security.
5. Verify freedom of flight controls through full travel with and without friction applied.
6. Push in AUTOPILOT circuit breaker (5 amp) at panel. Perform ground checks as
appropriate per § 22-61.
7. Install G702-7 cover assembly under pilot's seat.

22-40 Control Panel

A. Removal
1. Turn battery & avionics switches off and pull out AUTOPILOT (5 amp) circuit
breaker at panel.
2. Loosen radio keys securing 01309-01-01 control panel from avionics tray.
3. Carefully unplug/remove control panel from tray.
B. Installation
1. Turn battery & avionics switches off and pull out AUTOPILOT (5 amp) circuit
breaker at panel.
2. Carefully plug-in/install 01309-01-01 control panel in avionics tray.
3. Tighten radio keys securing control panel to tray. Verify security.
4. Push in AUTOPILOT circuit breaker (5 amp) at panel. Perform ground checks as
appropriate per § 22-61.

Page 22.6 Chapter 22 Autopilot APR 2017

22-50 Cyclic Grip Assembly

Refer to R66 Illustrated Parts Catalog (IPC) Figures 22-1 & 67-11.

A. Grip Angle Adjustment

1. Loosen cap screws securing pilot's cyclic grip, block assembly, and bar to grip
weldment.

2. Rotate grip about weldment to desired angle. Special torque cap screws to 40 in.-lb.

B. Removal and Installation

Refer to § 67-12 for cyclic grip assembly removal and installation procedures.

To access grip switches:

1. Remove MS24693-S1 screws securing C214-27 plate to D379-1 grip. Remove switch
nuts and lockwashers to free switches from plate.

2. Install switch lockwashers (new) and nuts and tighten switches to plate; verify switch
security. Install screws securing plate to grip.

3. Turn battery switch on and perform ground checks as appropriate per § 22-61.

C. Schematic

Refer to MM Figure 98-1 for F024 electrical system schematic.

MAY 2015 Chapter 22 Autopilot Page 22.7

22-60 Maintenance

22-61 Scheduled Maintenance and Inspections

A. Ground Checks

NOTE

Perform the following ground checks after component replacement

or other repairs have been performed on the autopilot system.
Perform ground checks after an accident or incident that may have
affected autopilot or related equipment prior to return to service.
NOTE

Refer to § 22-62 for troubleshooting if any of the following ground

checks cannot be verified.

1. Turn battery & avionics switches on. Verify four beeps in headset and control
panel LEDS alternate white/green:

FOUR BEEPS LEDs ALTERNATE

IN HEADSET WHITE/GREEN

2. Verify SAS enters standby mode approximately 6 seconds after attitude indicator
caging flag exits window (pull and release caging knob if instrument bank angle
exceeds 6 degrees). Verify no sound in headset and control panel SAS LED is
white, other LEDs are dark:

SAS LED IS WHITE,

NO SOUND
OTHER LEDs DARK

3. Visually verify servo assembly arms do not move when moving cyclic.
4. Engage SAS mode (cyclic should feel "energized). Verify no sound in headset and
control panel SAS LED is green, other LEDs are dark:

SAS LED IS GREEN,

NO SOUND
OTHER LEDS DARK

5. Install & activate hydraulic test pump (to simulate hydraulics-on operation) per § 12-34.

a. With SAS engaged, displace cyclic at least 1 inch from neutral position and
verify SAS returns cyclic to neutral within ± 0.25 inch. Perform check for roll
& pitch axes.

b. With SAS engaged, displace cyclic full deflection, and verify 2.5–3.5 lb force
when displaced more than 1 inch from neutral position. Perform check for roll &
pitch axes.

Page 22.8 Chapter 22 Autopilot MAY 2015

22-61 Scheduled Maintenance and Inspections (continued)

A. Ground Checks (continued)

6. Refer to step 2. Engage SAS and verify SAS disengages when control panel's SAS
button is depressed or when AP OFF button on the cyclic grip is depressed. Verify
four beeps in headset and control panel SAS LED is white, other LEDs are dark:

FOUR BEEPS SAS LED IS WHITE,

IN HEADSET OTHER LEDS DARK

7. Pressurize pitot system per § 95-10. Engage SAS and ALT modes. Verify no
sound in headset and SAS & ALT LEDs are green, other LEDs are dark:

SAS & ALT LEDs ARE

NO SOUND GREEN, OTHER LEDS
DARK

8. Disengage ALT mode. Verify no sound in headset and SAS LED is green, other
LEDs are dark:

SAS LED IS GREEN,

NO SOUND
OTHER LEDS DARK

9. Refer to steps 7 & 8. Engage SAS and HDG modes. Verify no sound in headset
and SAS & HDG LEDs are green, other LEDs are dark. Disengage HDG mode.
Verify no sound in headset and SAS LED is green, other LEDs are dark.

10. Engage SAS, HDG, and ALT modes. Verify no sound in headset and SAS, HDG,
and ALT LEDs are green, other LEDs are dark. Press AP OFF button on cyclic grip.
Verify no sound in headset and SAS LED is green, other LEDs are dark.

11. Engage SAS, HDG, and ALT modes. Verify no sound in headset and SAS, HDG,
and ALT LEDs are green, other LEDs are dark. Press AP OFF button twice on cyclic
grip. Verify four beeps in headset and SAS LED is white, other LEDs are dark.

B. Scheduled Maintenance and Inspections

Every 100-hour or annual inspection:

1. Inspect condition of associated equipment. Verify proper installation and security of

equipment.

2. Inspect wiring condition. Verify no loose, chafed, or broken wires or terminals. Verify
neatness, proper routing and installation, and security.

3. Inspect pitot and static lines for obstructions, cracking, chafing, pinching or kinking.
Verify integrity of pitot and static line connections. Verify line security.

4. Perform ground checks per Part A.

MAY 2015 Chapter 22 Autopilot Page 22.9

22-62 Special Maintenance and Inspections

A. Troubleshooting

CAUTION

Adjustment to autopilot equipment is not permitted.

PROBLEM ACTION
Control panel lights do not illuminate or Verify computer is getting power.
flash when master switch is turned on. Return computer to RHC.
System does not enter standby-mode Verify attitude indicator bank angle less
(lights flash continuously). than 6 degrees.
Verify attitude indicator output between
13 and 14 pins is less than 0.3 volts at
connector.
Check wiring between attitude indicator
and computer.
Contact RHC Technical Support.
SAS does not engage when TRIM button Check wiring between TRIM button and
depressed for longer than 1.25 seconds; computer.
pressing TRIM button does not reset Verify integrity of TRIM button.
reference attitude; pressing TRIM button
does not reset reference altitude in Return computer to RHC.
altitude hold.
SAS does not disengage when cyclic grip Check wiring between AP OFF button and
AP OFF button depressed. computer.
Verify integrity of AP OFF button.
Return computer to RHC.
SAS does not engage or disengage when Engage and/or disengage SAS using cyclic
control panel buttons pressed. grip buttons. If system responds properly,
failure is in control panel or associated
wiring to computer.
Contact RHC Technical Support.
SAS does not hold pitch attitude, but Check servo-to-cyclic linkage.
holds roll attitude or vice versa. Check wiring between faulty servo and
computer.
Return faulty servo and computer to RHC.
SAS disengages unintentionally Contact RHC Technical Support.
(accompanied by four beeps in headset).
Autopilot mode disengages Determine if navigation signal may have
unintentionally, and reverts to SAS mode gone invalid due to operational reason.
(accompanied by single beep in headset). Check wiring between appropriate
instrument/avionics and computer.
Check instrument/avionics for failure flags
(steady and intermittent).

Page 22.10 Chapter 22 Autopilot MAY 2015

22-62 Special Maintenance and Inspections (continued)

A. Troubleshooting (continued)

PROBLEM ACTION
Cyclic vibrates erratically, SAS does not Manually override SAS, system should
disengage. disengage automatically.
Contact RHC Technical Support.
Helicopter enters low frequency pitch Return computer to RHC.
oscillation when ALT engaged; helicopter
diverges nose-up or nose-down when ALT
engaged.
ILS glideslope tracking performance is Check for excessive friction in longitudinal
poor. cyclic.
Check GPS output to computer.
Cyclic force seems higher than normal Verify servo clutches are disengaged, and
with SAS disengaged. clutch arms do not move when SAS is Off
or in standby-mode.
No aural warning in headset when SAS is Check wiring to unswitched audio input to
disengaged. audio panel.

MAY 2015 Chapter 22 Autopilot Page 22.11

Intentionally Blank

Page 22.12 Chapter 22 Autopilot MAY 2015

CHAPTER 25

FURNISHINGS

Section Title Page

25-00 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.1

25-10 Seat Harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.3
25-11 Seat Harness Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.3
25-12 Seat Harness Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.4
25-20 Seat Assemblies and Back Rests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.5
25-21 Seat Assembly Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . 25.5
25-22 Back Rest Assembly Removal and Installation . . . . . . . . . . . . . . . . . . . . . 25.6
25-23 Back Rest Cushion Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.7
25-24 Heated Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.8
25-30 Carpet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.11
25-40 Insulation (Foam and Headliner) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.12
25-50 General Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.12
25-51 Pilot’s Operating Handbook (POH) Strap Replacement . . . . . . . . . . . . . . . . 25.12
25-52 License Holder Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.13
25-53 Map Pocket Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.13
25-60 Emergency Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.14
25-61 Emergency Locator Transmitter (ELT) . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.14
25-62 Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.15
25-70 Cargo Hook Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.16
25-71 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.16
25-72 Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.17
25-73 Cargo Hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.18
25-74 Cyclic Grips, Electric Cargo Hook Release, Remote Equipment Provisions,
and Left-Seat Collective . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.22
25-75 Mechanical Cargo Hook Release Control Rigging . . . . . . . . . . . . . . . . . . . 25.25
25-76 Load Cell and Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.26
25-77 Left-Seat Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.27
25-78 Doors with Bubble Windows and Fans . . . . . . . . . . . . . . . . . . . . . . . . . . 25.28
25-79 Skid-Mounted Mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.30
25-80 Cabin Interior Hardpoint Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.31
25-81 Arm Rest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.31

APR 2019 Chapter 25 Furnishings Page 25.i

Intentionally Blank

Page 25.ii Chapter 25 Furnishings APR 2019

CHAPTER 25

FURNISHINGS

25-00 Description

The seats are not adjustable but the pilot-side pedals are adjustable. Each helicopter is supplied
with a cushion which can be placed behind the pilot to position him forward. This allows
shorter pilots to reach the pedals, the cyclic stick in its most forward position, and the controls
on the center console.

Each seat is equipped with a combined seat 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.

Five-point harnesses are optional for the front seats. The five-point harness is equipped with
a webbing stop located above the inertia reel. The stop limits shoulder strap retraction and
should be adjusted so the straps are comfortable without excessive slack.

The main baggage compartment is located between the cabin and the engine compartment. It
is accessed via a large door on the aircraft right side. The cowl door annunciator illuminates
to warn the pilot when the door is not latched. A light illuminates the compartment when
the battery switch is ON. Tie down anchors are provided for securing items in the baggage
compartment. Observe placarded weight limits. Placard locations and illustrations are given
in Chapter 11.

Additional compartments are located under each seat except the center rear seat. Seat cushions
hinge forward for access to these compartments. Do not load these compartments above
the maximum fill lines. The lines indicate required crush space for the seats in an accident.
Baggage compartment dimensions are given in Chapter 6.

WARNING

Never repair or modify seat assemblies, including seat assembly

fabric, seat pans, or hook and loop tape (Velcro) securing fabric
to seat pans. Seat assembly energy-absorption design is critical
to occupant safety. To preserve crashworthiness, maintenance
is limited to seat assembly replacement.

SEP 2012 R66 Maintenance Manual Chapter 25 Furnishings Page 25.1

FIGURE 25-1 SEAT HARNESSES, SEAT ASSEMBLIES, AND BACK RESTS

Page 25.2 Chapter 25 Furnishings R66 Maintenance Manual SEP 2012

25-10 Seat Harnesses
Refer to R66 Illustrated Parts Catalog (IPC) Figures 25-3 and 25-5. Refer to Figures 25-9, 25-
11, and 25-13 for optional Five-Point Harness Installation.
25-11 Seat Harness Removal
A. Forward Seat Harness (Standard)
1. Refer to Figure 25-1. Remove F680-1 and F680-3 collective cover assemblies; hinge
seat assemblies forward.
2. Remove hardware securing each F628-5 buckle assembly to inboard anchor, and
hardware securing each lap belt fitting to outboard anchor.
3. Remove shoulder strap guide covers and hardware securing guides to door frames.
4. Remove right side inertia reel cover and hardware securing reels to F369 and F370
forward seat backs. Remove seat harnesses.
B. Five-Point Harness (Optional, not shown; for forward seats only)
1. Remove screws securing F424-1 bumper assembly to F423-4 tube assembly and
remove bumper.
2. Refer to Figure 25-1. Remove F680-1 and F680-3 collective cover assemblies; hinge
seat assemblies forward.
3. Remove hardware securing lap belts to inboard and outboard anchors. Remove
hardware securing fifth-point belts to seat boxes.
4. Remove hole plugs, then remove inertia reel covers and hardware securing reels to
F369 and F370 forward seat backs. Remove five-point harnesses.
C. Aft Left and Right Seat Harness
1. Refer to Figure 25-1. Remove F931-1 seat assembly; hinge left and right seat
assemblies forward.
2. Remove hardware securing each F628-6 buckle assembly to inboard anchor, and
hardware securing each lap belt fitting to outboard anchor.
3. Remove shoulder strap guide covers and hardware securing guides to door frames.
4. Remove inertia reel covers and hardware securing reels to cabin bulkhead.
D. Center Seat Harness
1. Remove tailcone cowling per Section 53-23.
2. Refer to Figure 25-1. Remove F931-1 seat assembly; hinge left and right seat
assemblies forward.
3. Remove hardware securing F628-6 buckle assembly to inboard right side anchor and
hardware securing lap belt fitting to inboard left side anchor.
4. Remove shoulder strap guide cover and hardware securing guide to cabin bulkhead
and upper frame.
5. Remove F436-1 (headset jack) cover assembly and hardware securing inertia reel to
cabin bulkhead.

SEP 2012 R66 Maintenance Manual Chapter 25 Furnishings Page 25.3

25-12 Seat Harness Installation
A. Forward Seat Harness (Standard)
1. Refer to Figure 25-1. Install hardware securing inertia reels to F369 and F370
forward seat backs. Install right side reel cover.
2. Install hardware securing shoulder strap guides to door frames. Standard torque
bolts per Section 20-32. Install guide covers.
3. Install hardware securing F628-5 buckle assemblies to inboard anchors, and lap belt
fittings to outboard anchors. Position buckle swage between two forward rivets.
Standard torque bolts per Section 20-32.
4. Install F680-1 and F680-3 collective cover assemblies.
B. Five-Point Harness (Optional, not shown; for forward seats only)
1. Attach inertia reels to F369 and F370 forward seat backs. Install covers and hole
plugs. Verify security.
2. Attach lap belt fittings to inboard and outboard anchors. Standard torque bolts per
Section 20-32.
3. Attach fifth point belts to seat boxes.
4. Refer to Figure 25-1. Install F680-1 and F680-3 collective cover assemblies; hinge
seat assemblies forward.
5. Position F424-1 bumper assembly on F423-4 tube assembly and install screws.
Verify security.
C. Aft Left and Right Seat Harness
1. Refer to Figure 25-1. Install hardware securing inertia reels to cabin bulkhead.
Install reel covers.
2. Install hardware securing shoulder strap guides to door frames. Standard torque
bolts per Section 20-32. Install guide covers.
3. Install hardware securing F628-6 buckle assemblies to inboard anchors, and lap belt
fittings to outboard anchors. Standard torque bolts per Section 20-32.
4. Install F931-1 seat assembly.
D. Center Seat Harness
1. Refer to Figure 25-1. Install hardware securing inertia reel to cabin bulkhead. Install
F436-1 (headset jack) cover assembly. Verify security.
2. Install hardware securing shoulder strap guide to cabin bulkhead and upper frame.
Standard torque bolt per Section 20-32. Install guide cover.
3. Install hardware securing F628-6 buckle assembly to inboard right side anchor, and lap
belt fitting to outboard left side anchor. Standard torque bolts per Section 20-32.
4. Install F931-1 seat assembly.
5. Install tailcone cowling per Section 53-23.

Page 25.4 Chapter 25 Furnishings R66 Maintenance Manual SEP 2012

25-20 Seat Assemblies and Back Rests

25-21 Seat Assembly Removal and Installation

WARNING
Never modify seat assemblies, including seat assembly fabric,
seat pans, or hook and loop tape (Velcro) securing fabric to
seat pans. Seat assembly energy-absorption design is critical
to occupant safety.

A. Left and Right Seat Assembly Removal

1. If heated seats are installed, turn battery switch off and pull out SEAT HEATERS
circuit breaker (20 amp) on circuit breaker panel. Disconnect F940-3 (forward seats)
or F940-4 (aft seats) wire harness from F940-1 module assembly wiring at connector.
2. Refer to Figure 25-1. Remove hardware securing seat assembly hinge to seat
box and remove seat assembly.
B. Left and Right Seat Assembly Installation
1. If heated seats are installed, turn battery switch off and pull out SEAT HEATERS
circuit breaker (20 amp) on circuit breaker panel.
2. Refer to Figure 25-1. Position seat assembly on seat box and install hardware
securing hinge to box. Verify security.
3. If heated seats are installed, connect F940-3 (forward seats) or F940-4 (aft seats)
wire harness to F940-1 module assembly wiring at connector. Verify security.
Push in circuit breaker on circuit breaker panel and turn battery switch on. Verify
proper function of switches at control panel. Verify temperature setting system
functionality by toggling between high/low/off heat positions.
C. Center Seat Assembly
Refer to Figure 25-1. Attach or detach center seat assembly to or from the seat box
via hook and loop tape (Velcro).

APR 2019 Chapter 25 Furnishings Page 25.5

25-22 Back Rest Assembly Removal and Installation
A. Aft Left and Right Back Rest Assembly Removal
1. If heated seats are installed, turn battery switch off and pull out SEAT HEATERS
circuit breaker (20 amp) on circuit breaker panel.
2. Refer to Figure 25-1. Remove hardware securing back rest assembly to cabin
bulkhead.
3. If heated seats are installed, disconnect F940-3 (forward seats) or F940-4 (aft
seats) wire harness from F939-2 pad assembly wiring at connector.
4. Remove back rest assembly.
B. Aft Left and Right Back Rest Assembly Installation
1. If heated seats are installed, turn battery switch off and pull out SEAT HEATERS
circuit breaker (20 amp) on circuit breaker panel. Connect F940-3 (forward seats)
or F940-4 (aft seats) wire harness to F939-2 pad assembly wiring at connector.
Verify security.
2. Refer to Figure 25-1. Install hardware securing back rest assembly to cabin
bulkhead. Verify security.
3. If heated seats are installed, push in circuit breaker on circuit breaker panel and
turn battery switch on. Verify proper function of switches at control panel.
Verify temperature setting system functionality by toggling between high/low/off
heat positions.
C. Center Back Rest Assembly Removal
Refer to Figure 25-1. Detach back rest assembly hook and loop tape (Velcro) at
bottom; slide back rest assembly up and out of keyhole slots.
D. Center Back Rest Assembly Installation
Refer to Figure 25-1. Install back rest assembly in keyhole slots and slide down. Press
firmly on back rest assembly hook and loop tape (Velcro) at bottom. Verify security.

Page 25.6 Chapter 25 Furnishings APR 2019

25-23 Back Rest Cushion Replacement
A. Forward Back Rest
1. If heated seats are installed, turn battery switch off and pull out SEAT HEATERS
circuit breaker (20 amp) on circuit breaker panel. Disconnect F940-3 wire harness
from F939-2 pad assembly wiring at connector.
2. Refer to Figure 25-1. Drill out rivets securing back rest cushion to seat back
panel and deburr holes. Remove cushion.
3. Remove old adhesive residue from back rest support tube with plastic wedge.
Wipe surface with clean cloth, wet with acetone.
4. Center and straighten new cushion on seat back panel. Match drill seat back
panel #30 holes through cushion panel and deburr. Clean up debris.
5. Attach back rest cushion to seat back panel with B204-2 rivets.
6. Apply B270-18 adhesive to underside of back rest cushion flap and to mating
portion of support tube. Pull flap around tube, smooth wrinkles, and trim excess
flap. Remove excess adhesive prior to curing.
7. If heated seats are installed, push in circuit breaker on circuit breaker panel and
turn battery switch on. Verify proper function of switches at control panel.
Verify temperature setting system functionality by toggling between high/low/off
heat positions.
B. Aft Left and Right Back Rest
1. Remove back rest assembly per § 25-22.
2. Drill out rivets securing back rest cushion to seat back panel and deburr holes.
Remove cushion.
3. Center and straighten new cushion on seat back panel. Match drill seat back
panel #30 holes through cushion panel and deburr. Clean up debris.
4. Attach back rest cushion to seat back panel with B204-2 rivets.
5. Install back rest assembly per § 25-22.

APR 2019 Chapter 25 Furnishings Page 25.7

25-24 Heated Seats
A. Description
Heated seat bottoms and backrests for the forward seats and outboard rear seats are
an option. Switches to control low and high heat settings for all four heated seats
are located on the panel above the right-side collective boot.
The seat heaters operate only when the generator switch is in the ON position to
reduce the likelihood of inadvertently draining the battery before the engine is started.
B. Schematics
Refer to Figure 98-28 for heated seats installation electrical schematic.
C. Removal and Installation
Seat Assemblies
Remove and install seat assemblies per § 25-21 Part A.
(Circuit Board) Module Assembly Replacement
1. Remove seat assembly per § 25-21 Part A.
2. Disconnect F940 harness from F941-1 module assembly at connector.
3. Drill out rivets securing module to seat assembly pan and remove module. Clean
up debris.
4. Cleco (sheet metal fastener) new module to seat assembly pan. Progressively
remove clecos and install B204-1 rivets securing module to pan. Verify security.
5. Connect F940 harness to module at connector. Verify security.
6. Install seat assembly per § 25-21 Part A.
D. Scheduled Maintenance and Inspections
Refer to § 5-45 100-Hour/Annual Inspection.
F. Special Maintenance and Inspections
1. Open circuit breaker panel and applicable access panels.
2. Verify correct fuses are installed in circuits: F940-2 harness assembly requires (4)
AGC-5 fuses, one for each heated seat.
3. Inspect condition of and verify no obvious damage to F941-1 module assemblies,
F940-1 switch assembly, wire harnesses, copper bus bars, circuit breaker, or
circuit breaker wiring. Verify no loose, chafed, or broken wires or terminals.
Verify no evidence of arcing. Verify installed equipment security.
4. Secure circuit breaker panel and removed access panels.
5. Verify proper function of switches at control panel. Verify temperature setting
system functionality by toggling between high/low/off heat positions.

Page 25.8 Chapter 25 Furnishings APR 2019

Intentionally Blank

APR 2019 Chapter 25 Furnishings Page 25.9

FIGURE 25-2 CARPET AND INSULATION

Page 25.10 Chapter 25 Furnishings APR 2019

25-30 Carpet
A. Forward (Floor) Carpet Assembly Removal
1. Refer to Figure 25-2. Remove adjustable and/or removable pedals, as required.
2. Remove hardware securing scuff plates (and carpet) to cabin floor. Detach carpet
from floor via hook and loop tape (Velcro).
B. Forward (Floor) Carpet Assembly Installation
1. Refer to Figure 25-2. Attach carpet to floor via hook and loop tape (Velcro).
2. Install scuff plates; install B392-3 left-side cover (may be installed when pedals are
removed), as required.
3. Install adjustable and/or removable pedals, as required.
C. Aft (Floor) Carpet Assembly Removal and Installation
1. Refer to Figure 25-2. Attach or detach carpet to and from floor via hook and loop
tape (Velcro).
D. Carpet and Liner

CAUTION
Use caution when removing adhered carpet if carpet is intended
for reuse.

1. Removal
a. Starting at corners, gently peel back carpet by hand, or with plastic wedge or
putty knife.
b. Dampen old adhesive with Dupont Prep-Sol (or equivalent) to facilitate removal.
2. Installation
a. Verify proper carpet fit. Trim as required (do not trim carpet welt).
b. Apply B270-8 adhesive to bonding surface and carpet backing. Press carpet
to surface, smooth wrinkles, and remove excess adhesive prior to curing.

APR 2019 Chapter 25 Furnishings Page 25.11

25-40 Insulation (Foam and Headliner)
A. Removal

NOTE
Use caution not to damage surface underneath insulation when
removing insulation with tools.
NOTE
Insulation is installed using adhesive, except under seat
assemblies. Order new insulation as required; reuse of removed
insulation is not recommended.

1. 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.

25-50 General Maintenance

25-51 Pilot's Operating Handbook (POH) Strap Replacement

A. Removal
1. Remove POH.
2. Drill out rivets securing POH retaining strap to cabin right side and remove strap.
Deburr holes and clean up debris.
B. Installation
1. Cleco POH retaining strap to cabin right side holes. Remove clecos and install
rivets. Verify security.
2. Install POH.

Page 25.12 Chapter 25 Furnishings APR 2019

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

25-53 Map Pocket Replacement

A. Removal
1. Drill out rivets securing map pocket to front wall of forward seat box. 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. Remove clecos and install washers and rivets.

APR 2019 Chapter 25 Furnishings Page 25.13

25-60 Emergency Equipment

25-61 Emergency Locator Transmitter (ELT)

A. Description
The ELT activates when subjected to a significant change in velocity (as in a crash),
by remote control switch located on the cyclic control panel, or by a switch on the
ELT transmitter. Refer to § 96-90 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 § 5-20 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.

Page 25.14 Chapter 25 Furnishings APR 2019

25-62 Fire Extinguisher

CAUTION
Extinguisher is rated for a max storage and operating temperature
of 120°F (49°C). If operating conditions would expose
extinguisher to higher temperatures (e.g. long term parking in
the sun in a hot climate), remove extinguisher and store it in a
cooler area between flights.

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
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.

APR 2019 Chapter 25 Furnishings Page 25.15

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Page 25.16 Chapter 25 Furnishings APR 2019

25-70 Cargo Hook Installation

25-71 Description
See R66 Pilot’s Operating Handbook Cargo Hook Supplement (Section 9) for complete
system description.
The cargo hook installation includes a cargo hook, electric release buttons on left and
right side cyclic, mechanical release knobs at left and right front seat, hydraulic and
radio buttons and switches on left side cyclic, a start button on left side collective, a
load meter, gas temperature gauge, and torque meter at left front seat, and provisions
for remote control of external load equipment on left and right side cyclic. Optional
equipment includes forward doors with large bubble windows and skid-mounted mirrors.
Doors with large bubble windows are designed such that pilots may lean their head into
the bubble in order to look straight down at an external load. The left door contains a
second, lower window that allows the pilot to look back inside at the load meter, gas
temperature gauge, and torque meter. Each door contains an electric fan to aid with
defogging.
A padded elbow rest is provided above the left side collective. This allows the pilot to
brace his elbow for stability while leaning out to see external loads. The elbow rest is
adjustable up and down via a friction knob.
A cabin interior hardpoint installation is for use with safety harnesses.
The cargo hook is suspended from a hard point on the helicopter belly. For overhaul
requirements for the cargo hook itself, refer to Onboard Systems overhaul manual (refer
to § 25-73 Part D).
The load weigh system consists of a load cell incorporated in the hook attaching hardware
and a load meter installed at left front seat.
A <12 GAL FUEL indicator light illuminates with approximately 12 gallons of usable
fuel remaining. The light is activated by a second float switch in the fuel tank and is
independent of the standard (5 gallon) LOW FUEL caution light. At moderate to high
power settings, the 12 gallon light will turn on approximately 15 to 20 minutes flying time
prior to the LOW FUEL annunciator.

25-72 Configurations
See R66 Pilot’s Operating Handbook Cargo Hook Supplement (Section 9) for approved
flight configurations.

APR 2019 Chapter 25 Furnishings Page 25.17

25-73 Cargo Hook
A. Schematic
Refer to Figure 98-29 for cargo hook wiring schematic.
B. Removal
1. Turn battery switch off and pull out (10 amp) HOOK RELEASE and (10 amp) EXT
LOAD (if installed) circuit breaker(s) on circuit breaker panel.
2. Disconnect G140-6 (installations without load cell) or G140-7 (installations with
load cell) harness assembly from 528-029-00 cargo hook at hook connectors.
3. Remove cotter pin, castellated nut, washers, and bolt (G132-1) or load cell (G132-
2 or G132-4) securing hook to hard point’s D136-2 support. Remove hook.
4. Remove screws securing (mechanical release) cover to hook and remove cover.
Disconnect D676-3 (control) cable assembly’s ball from mechanical release’s fork.
5. Loosen jam nut and unthread hook from cable assembly.
6. Configure helicopter for flight with hook removed per Part F as required.
C. Installation
1. Turn battery switch off and pull out (10 amp) HOOK RELEASE and (10 amp) EXT
LOAD (if installed) circuit breaker(s) on circuit breaker panel.
2. Configure helicopter for flight with hook installed per Part F as required.
3. Loosen jam nut and thread 528-029-00 cargo hook onto D676-3 cable assembly.
Verify threads protrude beyond plate flange.
4. Insert bolt and washer (G132-1) or load cell (G132-2 or G132-4) securing hook
to hard point’s D136-2 support. Install washers and castellated nut, and tighten
nut finger tight (back off as required to align cotter pin holes, but do not install
cotter pin). Verify security.

CAUTION
Overtightening castellated nut can damage load cell.

5. Rig mechanical release control per § 25-75.

6. Install cotter pin at hook-to-hard point fastener.
7. Connect G140-6 (installations without load cell) or G140-7 (installations with
load cell) harness assembly to hook at hook connectors. Verify security.

Page 25.18 Chapter 25 Furnishings APR 2019

25-73 Cargo Hook (continued)
C. Installation (continued)

CAUTION
The cargo hook must be able to swing freely in all directions.
Incorrect restraining of the mechanical release control cable
could cause uncommanded cargo hook release if hook were to
strain against cable’s inner wire.

8. Maneuver cargo hook and verify wire harness and control cable have sufficient
slack through full range of travel.
9. Refer to Figure 25-3. Push-in (10 amp) HOOK RELEASE and (10 amp) EXT LOAD
(if installed) circuit breaker(s) on circuit breaker panel. Turn battery switch on.
Verify proper function of electrical release. Reset load beam by hand. Verify lock
indicator returns to locked position. Turn battery switch off.
10. Verify proper function of mechanical release control. Reset load beam by hand.
Verify lock indicator returns to locked position.
D. Scheduled Inspections

NOTE
Track time of external load operations when anything is attached
to the cargo hook and the helicopter is flying.
Every 100 hours of external load operations or annually, whichever occurs first:
1. Push-in (10 amp) HOOK RELEASE and (10 amp) EXT LOAD (if installed) circuit
breaker(s) on circuit breaker panel. Turn battery switch on. Refer to Figure 25-
3. Verify proper function of electrical hook release. Reset load beam by hand.
Verify lock indicator returns to locked position. Turn battery switch off.
2. Verify proper function of mechanical release control. Reset load beam by hand.
Verify lock indicator returns to locked position.
3. Maneuver cargo hook and verify wire harness and control cable have sufficient
slack through full range of travel.
4. Verify proper routing and security of mechanical release control cable; verify
smooth actuation without binding.
5. Remove screws securing (mechanical release) cover to 528-029-00 cargo hook
and remove cover. Refer to Figure 25-4. Rotate release lever clockwise to
remove free play (lock indicator will begin to move) and measure gap between
fork and ball as shown. Adjust gap per § 25-75 as required to obtain measurement
between 0.15–0.25 inch.
6. Inspect condition of cargo hook equipment for damage. Verify equipment security.

APR 2019 Chapter 25 Furnishings Page 25.19

25-73 Cargo Hook (continued)
D. Scheduled Inspections (continued)
Every 1000 hours of external load operations or 5 years, whichever occurs first:
1. Overhaul cargo hook per Onboard Systems Component Maintenance Manual
Document No. 122-017-00. Contact Onboard Systems for assistance locating
authorized overhaul facilities.
E. Special Inspections
For troubleshooting of the cargo hook only, refer to Onboard Systems Troubleshooting
Guide Document No. 125-004-00 available for download on their website at www.
onboardsystems.com.
F. Configurations for Flight
1. Configuration for Flight with Cargo Hook Removed
a. Remove cargo hook per Part B.
b. Disconnect G140-6 (installations without load cell) or G140-7 (installations
with load cell) harness assembly at connector on belly. Install FTC-4 caps
(labeled “FC-4”) over open belly receptacle(s); verify cap security. Cut and
discard ty-raps as required and remove harness assembly (leave D676-3
[control] cable assembly looped to A215-149 o-ring).
c. Remove hardware securing D136-3 bumpers and D136-2 support to G137-1
hardpoint installation rod ends and remove bumpers and support.
d. Remove (2) B526-6 (or MS27039C0806) screws (select two fasteners
spaced apart to provide best cable security) securing F794-2 (access) panel
to belly; install (2) MS27039C0816 screws, (2) AN742-4 clamps, and (2)
A130-38 spacers to secure control cable assembly to belly. Verify cable and
hardware security.
e. Revise Weight and Balance Record in R66 Pilot’s Operating Handbook (POH)
Section 6 to incorporate the following data:
Subtract:
Weight Long. Arm Long. Moment Lat. Arm Lat. Moment
3.90 lb 90.84 in. 354.28 in.-lb –4.10 in. –15.99 in.-lb

Page 25.20 Chapter 25 Furnishings APR 2019

25-73 Cargo Hook (continued)
F. Configurations for Flight (continued)
2. Configuration for Flight with Cargo Hook Installed
a. Remove (2) MS27039C0816 screws, (2) AN742-4 clamps, and (2) A130-
38 spacers securing D676-3 (control) cable assembly to F794-2 (access)
panel and belly; install (2) B526-6 (or MS27039C0806) screws. Verify
security.
b. Install hardware securing D136-3 bumpers and D136-2 support to G137-1
hardpoint installation rod ends. Standard torque fastener per § 20-32 and
torque stripe per Figure 5-1.
c. Remove FTC-4 cap (labeled “FC-4”) from hook harness assembly receptacle
on belly. Connect G140-6 (installations without load cell) or G140-7
(installations with load cell) harness assembly to receptacle; verify security.
Loop A215-149 o-ring around harness and control cable assembly. Install
ty-raps as required; cinch ty-raps until snug without over-tightening, and
trim tips flush with heads.
d. Install cargo hook per Part C steps 3 thru 10.
e. Revise Weight and Balance Record in R66 Pilot’s Operating Handbook (POH)
Section 6 to incorporate the following data:
Add:
Weight Long. Arm Long. Moment Lat. Arm Lat. Moment
3.90 lb 90.84 in. 354.28 in.-lb –4.10 in. –15.99 in.-lb

APR 2019 Chapter 25 Furnishings Page 25.21

25-74 Cyclic Grips, Electric Cargo Hook Release, Remote Equipment Provisions, and Left-
Seat Collective
A. Schematics
Refer to Figure 98-29 for cargo hook wiring schematic.
Refer to Figure 98-30 for external load controls wiring schematic.
Refer to Figure 98-31 for copilot instrument installation wiring schematic.
B. Removal and Installation
Refer to § 67-12 for cyclic grip assembly removal and installation procedures.
For removable cyclic grip, disconnect the electrical connectors located near the quick
release pin before removing the left cyclic grip. Reconnect the connectors when
installing the left cyclic grip.
For removable collective stick:
a. Removal: Unplug push-to-start button cable from jack. Unbutton boot and depress
locking pins to disengage and remove collective stick.
b. Installation: Depress locking pins and insert collective stick in control. Verify
both locking pins engage holes to secure stick; re-button boot. Plug in push-to-
start button cable to jack.
C. Scheduled Inspections
Refer to § 5-45 100-Hour/Annual inspection.

Page 25.22 Chapter 25 Furnishings APR 2019

Intentionally Blank

APR 2019 Chapter 25 Furnishings Page 25.23

FIGURE 25-3 LOCK INDICATOR

FIGURE 25-4 MECHANICAL RELEASE CONTROL RIGGING

(Shown with cover removed)

Page 25.24 Chapter 25 Furnishings APR 2019

25-75 Mechanical Cargo Hook Release Control Rigging

CAUTION
Cargo hook load beam must be closed and locked when rigging
mechanical release control.

1. Verify HOOK RELEASE knob adjacent to collective stick is positioned full down. Verify
cargo hook load beam is closed and locked.
2. If not previously accomplished, remove screws securing (mechanical release) cover to
528-029-00 cargo hook and remove cover.
3. Refer to Figure 25-4. If not previously accomplished, connect D676-3 (control) cable
assembly’s ball to mechanical release’s fork. Rotate release lever clockwise to remove
free play (lock indicator will begin to move) and measure gap between fork and ball as
shown.
4. Adjust gap as required to obtain measurement between 0.15–0.25 inch. To adjust
gap:
a. Disconnect cable assembly’s ball from release lever assembly’s fork.
b. Remove cotter pin (if installed), castellated nut, washers, and bolt (G132-1) or
load cell (G132-2 or G132-4) securing hook to hard point’s D136-2 support.
Remove hook.
c. Thread or unthread hook onto cable as required to meet gap dimensions. Verify
threads protrude beyond plate flange.
d. Reassemble hook to hardpoint per § 25-73 Part C step 3.
e. Repeat steps 3 and 4.
5. Special torque jam nut to 80 in.-lb. Install screws securing release lever assembly’s
cover to hook. Verify security.
6. Finish hook installation per § 25-73 Part C steps 6 thru 10.

APR 2019 Chapter 25 Furnishings Page 25.25

25-76 Load Cell and Meter
A. Schematic
Refer to Figure 98-29 for cargo hook wiring schematic.
B. Removal
Load Cell
Remove load cell per § 25-73 Part B steps 1 thru 3. Insert thru bolt temporarily to
support cargo hook while load cell is removed. Remove G140-7 harness assembly
as required; do not adjust control cable.
Load Meter
1. Turn battery switch off & pull out (10 amp) HOOK RELEASE circuit breaker on
circuit breaker panel.
2. Remove hardware securing G135-5 cover (copilot installation only) and G138
face to F353 panel and remove face with attached 210-095-00 load meter.
3. Disconnect G140-2 (RH or LH Solo PIC) or G140-8 (RH Solo PIC) harness
assembly from load meter. Remove hardware securing load meter to face and
remove load meter.
C. Installation
Load Cell
1. Install G140-7 harness assembly if removed; loop A215-149 o-ring around
harness and D676-3 (control) cable assembly. Install ty-raps as required; cinch
ty-raps until snug without over-tightening, and trim tips flush with heads.
2. Remove temporary thru bolt & install load cell per § 25-73 Part C steps 4 thru 10.
Load Meter
1. Turn battery switch off & pull out (10 amp) HOOK RELEASE circuit breaker on
circuit breaker panel.
2. Install hardware securing 210-095-00 load meter to G138 face. Connect G140-
2 (RH or LH Solo PIC) or G140-8 (RH Solo PIC) harness assembly to load meter.
Verify security.
3. Install hardware securing face with attached load meter to F353 panel; install
hardware securing G135-5 cover (copilot installation only) to face and panel.
Verify security.
D. Scheduled Inspections
Refer to § 25-73 Part D for scheduled inspections.
E. Special Inspections
Refer to Onboard Systems Owners Manual C-39 Indicator Document No. 120-095-
00 available for download on their website at www.onboardsystems.com.

Page 25.26 Chapter 25 Furnishings APR 2019

25-77 Left-Seat Instruments
A. Schematic
Refer to Figure 98-31 for copilot instruments installation wiring schematic.
B. Removal
1. Turn battery switch off and pull out (10 amp) HOOK RELEASE circuit breaker on
circuit breaker panel.
2. Remove hardware securing G135-5 cover and G138-4 face to F353-1 panel and
remove face with attached F600-2 torquemeter and T1221MK900C010 MGT
gage (and 210-095-00 load meter).
3. Disconnect G140 harness assembly from torquemeter and/or MGT gage, as
required. Remove hardware securing torquemeter and/or MGT gage to face, as
required, and remove torquemeter and/or MGT gage.
C. Installation
1. Turn battery switch off and pull out (10 amp) HOOK RELEASE circuit breaker on
circuit breaker panel.
2. Install hardware securing F600-2 torquemeter and T1221MK900C010 MGT gage
to G138-4 face. Connect G140 harness assembly to torquemeter and/or MGT
gage, as required. Verify security.
3. Install hardware securing face with attached torquemeter and MGT gage (and
210-095-00 load meter) to F353-1 panel; install hardware securing G135-5 cover
to face and panel. Verify security.
D. Scheduled Inspections
Refer to § 5-45 100-Hour/Annual inspection.
E. Special Inspections
Refer to § 95-25 Part F for torquemeter and § 95-31 Part F for MGT gage special
inspections.

APR 2019 Chapter 25 Furnishings Page 25.27

25-78 Doors with Bubble Windows and Fans
A. Schematic
Refer to Figure 98-32 for bubble door fans installation wiring schematic.
B. Removal
Bubble Door
1. Turn battery switch off and pull out AUX PWR (10 amp) circuit breaker on
circuit breaker panel.
2. Disconnect D580 fan assembly wiring from G140-9 harness assembly at connectors.
3. Refer to § 52-10. Pull D573-4 rod up and off of arm assembly ball joint.
4. Remove rings from door hinge pins, lift pins up from door frame hinge assemblies,
and remove door.
5. Perform weight and balance for doors off operation per Part E as required.
Fan Assembly
1. Turn battery switch off and pull out AUX PWR (10 amp) circuit breaker on
circuit breaker panel.
2. Disconnect D580 fan assembly wiring from G140-9 harness assembly at
connectors.
3. Remove hardware securing fan assembly to door stiffener and remove fan.
C. Installation
Bubble Door

WARNING
Failure to install a ring in each door’s two hinge pins may allow
door to depart aircraft in flight.

1. Turn battery switch off and pull out AUX PWR (10 amp) circuit breaker on
circuit breaker panel.
2. Refer to § 52-10. Align and insert door hinge pins in door frame hinge assemblies.
3. Align D573-4 rod with arm assembly ball joint and push down to lock.
4. Install rings in door hinge pins.
5. Connect D580 fan assembly wiring to G140-9 harness assembly at connectors;
verify security.
6. Push in AUX PWR (10 amp) circuit breaker on circuit breaker panel and turn
battery switch on. Verify proper operation of fan. Turn battery switch off.
7. Perform weight and balance for doors on operation per Part E as required.

Page 25.28 Chapter 25 Furnishings APR 2019

25-78 Doors with Bubble Windows and Fans (continued)
C. Installation (continued)
Fan Assembly
1. Turn battery switch off and pull out AUX PWR (10 amp) circuit breaker on
circuit breaker panel.
2. Install hardware securing fan assembly to door stiffener; verify security.
3. Connect D580 fan assembly wiring to G140-9 harness assembly at connectors;
verify security.
4. Push in AUX PWR (10 amp) circuit breaker on circuit breaker panel and turn
battery switch on. Verify proper operation of fan. Turn battery switch off.
D. Scheduled Inspections
Refer to § 5-45 100-Hour/Annual inspection.
E. Configurations for Flight
1. Door(s) Off Operation
a. Remove bubble door(s) per Part B.
b. Revise Weight and Balance Record in R66 Pilot’s Operating Handbook (POH)
Section 6 to incorporate the following data:
Right Door Subtract:
Weight Long. Arm Long. Moment Lat. Arm Lat. Moment
Weigh door (lb) 49.50 in. (Weight x Long. Arm) 26.80 in. (Weight x Lat. Arm)

Left Door Subtract:

Weight Long. Arm Long. Moment Lat. Arm Lat. Moment
Weigh door (lb) 49.50 in. (Weight x Long. Arm) –26.80 in. (Weight x Lat. Arm)

2. Door(s) On Operation
a. Install bubble door(s) per Part C.
b. Revise Weight and Balance Record in R66 Pilot’s Operating Handbook (POH)
Section 6 to incorporate the following data:
Right Door Add:
Weight Long. Arm Long. Moment Lat. Arm Lat. Moment
Weigh door (lb) 49.50 in. (Weight x Long. Arm) 26.80 in. (Weight x Lat. Arm)

Left Door Add:

Weight Long. Arm Long. Moment Lat. Arm Lat. Moment
Weigh door (lb) 49.50 in. (Weight x Long. Arm) –26.80 in. (Weight x Lat. Arm)

APR 2019 Chapter 25 Furnishings Page 25.29

25-79 Skid-Mounted Mirrors
A. Removal
1. Remove bolt and lock washer securing 97819 mirror to G138 strap & remove mirror.
2. As required, remove screws securing G138 support to skid tube & remove support.
3. Configure helicopter for flight with skid-mounted mirrors removed per Part D as
required.
B. Installation
1. If removed, install screws securing G138 support to skid tube. Verify security.
2. Install bolt and (new) lock washer securing 97819 mirror to G138 strap. Special
torque bolt to 150 in.-lb and torque stripe per Figure 5-1.
3. Configure helicopter for flight with skid-mounted mirrors installed per Part D as
required.
C. Scheduled Inspections
Every 100 hour/annual inspection: Inspect straps for security and any evidence of
cracking or corrosion. Inspect mirrors for cracks, cleanliness, and clarity.
D. Configurations for Flight
1. Configuration for flight with skid-mounted mirror(s) removed
a. Remove skid-mounted mirror(s), including G138 support(s) per Part A.
b. Reinstall screws in skid tube(s) to prevent debris and moisture from entering
tube(s).
c. Revise Weight and Balance Record in R66 Pilot’s Operating Handbook (POH)
Section 6 to incorporate the following data:
Right Skid-Mounted Mirror Subtract:
Weight Long. Arm Long. Moment Lat. Arm Lat. Moment
0.80 lb 32.00 in. 25.60 in.-lb 41.00 in. 32.80 in.-lb

Left Skid-Mounted Mirror Subtract:

Weight Long. Arm Long. Moment Lat. Arm Lat. Moment
0.80 lb 32.00 in. 25.60 in.-lb –41.00 in. –32.80 in.-lb

Page 25.30 Chapter 25 Furnishings APR 2019

25-79 Skid-Mounted Mirrors (continued)
D. Configurations for Flight (continued)
2. Configuration for Flight with Skid-Mounted Mirror(s) Installed
a. Remove screws from skid tube(s) and install skid-mounted mirror(s) per Part B.
b. Revise Weight and Balance Record in R66 Pilot’s Operating Handbook (POH)
Section 6 to incorporate the following data:
Right Skid-Mounted Mirror Add:
Weight Long. Arm Long. Moment Lat. Arm Lat. Moment
0.80 lb 32.00 in. 25.60 in.-lb 41.00 in. 32.80 in.-lb

Left Skid-Mounted Mirror Add:

Weight Long. Arm Long. Moment Lat. Arm Lat. Moment
0.80 lb 32.00 in. 25.60 in.-lb –41.00 in. –32.80 in.-lb

25-80 Cabin Interior Hardpoint Installation

A. Removal
Peel back headliner and remove hardware securing G949-2 ring to F087-1 frame;
remove ring.
B. Installation
Peel back headliner and install hardware securing G949-2 ring to F087-1 frame.
Standard torque fasteners per § 20-32 and torque stripe per Figure 5-1. Position
seam of grommet at top of hole, in-line with middle fastener.

25-81 Arm Rest

NOTE
Flight with G135-7 support assembly & 2454K71KNOB removed
is permissible. No change to helicopter weight and balance.

A. Removal
Remove 2454K71KNOB knob. Remove hardware securing G135-7 support assembly
to G135-8 cover assembly and remove support.
B. Installation
Position G135-7 support assembly on G135-8 cover assembly and install hardware;
verify security. Install 2454K71KNOB knob. Verify proper operation; position
support as desired and tighten knob.

APR 2019 Chapter 25 Furnishings Page 25.31

Intentionally Blank

Page 25.32 Chapter 25 Furnishings APR 2019

CHAPTER 28

FUEL SYSTEM
Section Title Page

28-00 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28.1

28-10 Bladder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28.3
28-11 Rollover Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28.5
28-12 Sump Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28.6
28-20 Fuel Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28.7
28-21 Fuel Quantity Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28.7
28-22 Low-Fuel Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28.10
28-23 Fuel Flow Meter Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28.11A
28-30 Fuel Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28.13
28-31 Fuel Valve Control Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28.13
28-40 Fuel Flow Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28.14
28-50 Aux Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28.17
28-51 Tank Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28.18
28-52 Support Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28.20
28-53 Bladder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28.21
28-54 Fuel Quantity Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28.25
28-55 Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28.25

JUL 2020 Chapter 28 Fuel System Page 28.i

Intentionally Blank

Page 28.ii Chapter 28 Fuel System JUL 2020

CHAPTER 28

FUEL SYSTEM

28-00 Description
A single bladder-type crash-resistant fuel cell supplies fuel via gravity flow to the engine.
The fuel cell incorporates left and right vent fittings, a filler port, a fuel gage sender, a low-
fuel switch assembly, a sump drain, and a finger strainer at the fuel outlet. The low-fuel
switch assembly activates the LOW FUEL segment on the annunciator panel, indicating
approximately five gallons of usable fuel remaining. The vent fittings each have a rollover
valve to prevent fuel leakage in any attitude.
The fuel cell is secured inside an aluminum structure. The filler cap is located under a cowl
door. The left and right side vent fittings are interconnected and vent through two risers
within the mast fairing. A fuel valve is located on the forward side of the firewall and is
controlled by a push-pull cable control at the base of the pilot’s collective stick.
The engine incorporates a fuel pump assembly with an inlet filter. A differential pressure
switch illuminates the FUEL FILTER warning light if the filter becomes contaminated.
A single drain allows fuel sampling from the low point in the fuel cell. The drain tube is
accessible via a left side cowl door. The drain is opened by extending the plastic tube clear
of the aircraft and pushing up on the drain.
Refer to § 28-50 for optional aux fuel tank installation system description.

APR 2019 Chapter 28 Fuel System Page 28.1

FIGURE 28-1 MAIN FUEL SYSTEM

Page 28.2 Chapter 28 Fuel System APR 2019

28-10 Bladder Assembly

CAUTION
G028-1 bladder assembly temperature should be above 65°F
before removing, installing, or flexing bladder.

A. Removal
1. Defuel helicopter per § 12-42.
2. Remove tailcone cowling assembly per § 53-23.
3. Remove fuel quantity sender per § 28-21.
4. Refer to Figure 28-1. Remove D277-8 clamps or cut and discard safety wire
securing A729 tube to left rollover valve and pull tube off of valve. Remove
screws securing F250-1 cover assembly to G028-1 bladder assembly and F028-1
support assembly and remove cover. Remove and discard o-ring.
5. Remove D277-8 clamp or cut and discard safety wire securing A729 tube to right
rollover valve and pull tube off of valve. Remove screws and washers securing
valve to bladder and support. Cut and discard ty-rap securing 35486 hanger tab
to G915-5 tab.
6. Remove low-fuel switch assembly per § 28-22. Tape bladder openings.
7. Disconnect D205-21 (fuel outlet) hose assembly from B254-3 strainer and cap
fittings. Remove screws and washers securing strainer to bladder and support.
Remove strainer and tape bladder opening.
8. Remove sump valve per § 28-12.
9. Remove hardware securing G004-4 (right side, aft fuselage) skin to cabin and
remove skin. Detach bladder hook tape from support loop tape, and remove bladder
through right side opening.

APR 2017 Chapter 28 Fuel System Page 28.3

28-10 Bladder Assembly (continued)
B. Installation
1. Refer to Figure 28-1. Dust exterior of G028-1 bladder assembly and F028-1
support assembly floor with talcum powder to facilitate bladder slippage along
metal surface. Do not allow powder to enter bladder.
2. Note locations of hook and loop tape on bladder lower surface and support floor.
Orient bladder, fold into thirds, place in center of support, and unfold into position.
3. Apply light coat A257-9 anti-seize to screw threads and install screws and washers
securing right rollover valve to bladder and support; verify security. Secure A729
tube to valve using D277-8 clamp; verify security.
4. Install (new) MS3367-7-9 ty-rap securing 35486 hanger tab to G915-5 tab. Cinch
ty-rap until snug without over-tightening, and trim tip flush with head.

NOTE
Verify bladder is free of wrinkles across lower surface and
properly located before attaching hook and loop tape. Bladder
may be pressurized with air to 1 psi max to assist installation.
CAUTION
Avoid contaminating bladder assembly interior. Cover arms with
sleeves and use lint-free gloves when working inside bladder.

5. Remove tape from bladder assembly openings. Insert a clean, smooth, blunt
wooden dowel through bladder’s fuel port opening and press on bladder lower
surface to attach hook and loop tape. Verify security.
6. Install low-fuel switch assembly per § 28-22.
7. Apply light coat A257-9 anti-seize to screw threads and install screws and washers
securing bladder outlet to support. Lubricate new MS29512-06 packing using
A257-6 grease and install on B254-3 strainer. Install strainer in bladder and special
torque strainer per § 20-33.
8. Remove caps and connect D205-21 hose assembly to strainer. Using backup
wrench, special torque hose nut per § 20-33, and torque stripe per Figure 5-1.
9. Install sump valve per § 28-12.
10. Lubricate (new) MS29513-270 packing using A257-6 grease and install packing in
recess at bladder’s fuel port opening. Apply light coat A257-9 anti-seize to screw
threads and install screws securing F250-1 cover assembly to bladder and support;
verify security. Secure A729 tube to left rollover valve using D277-8 clamps;
verify security.
11. Install fuel quantity sender per § 28-21.

Page 28.4 Chapter 28 Fuel System APR 2017

28-10 Bladder Assembly (continued)
B. Installation (continued)
12. Service helicopter with minimum two gallons fuel per § 12-41. Verify no leaks,
especially at bladder outlets. Install G004-4 (right side, aft fuselage) skin and
install hardware securing skin to cabin; verify security.
13. Perform fuel flow check per § 28-40.
14. Install tailcone cowling assembly per § 53-23.

28-11 Rollover Valves

WARNING
Orientation of rollover valve balls is critical to valve operation.
The gold ball on top (earlier ball on top was blue) floats and
seals the vent in the event of inadvertent over-filling or in-flight
sloshing. The red ball on bottom presses the top ball against
the vent seat if the aircraft is inverted.

A. Packing Replacement and Valve Inspection

1. Remove tailcone cowling assembly per § 53-23, as required.
2. Refer to Figure 28-1. Remove D277-8 clamp(s) or cut and discard safety wire
securing A729 tube to rollover valve and pull tube off of valve.
3. Remove G254-2 fitting or G254-6 retainer. Remove and discard MS29512-10
packing (G254-2 fitting only) and A215-015 o-ring.
4. Carefully remove B208-5 and B208-6 balls using a suction cup attached to a
syringe. Inspect condition of balls, valve body, and fitting or retainer. Clean
parts and verify no nicks, scratches, gouges, dents, cracks, or corrosion.
5. Carefully install B208-6 ball (red, solid) on bottom and B208-5 ball (gold or blue,
hollow) on top in valve body using a suction cup attached to a syringe.
6. Install new A215-015 o-ring in groove inside fitting or retainer. Lubricate new
MS29512-10 packing using A257-6 grease and install over G254-2 fitting
threads.
7. Install fitting or retainer and special torque per § 20-33.
8. Secure A729 tube to valve using D277-8 clamp; verify security.
9. Install tailcone cowling assembly per § 53-23, as required.

JUL 2020 Chapter 28 Fuel System Page 28.5

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

B. Installation
1. Actuate and lock A761-2 or 1250H (sump) valve to expose stem; install (new)
o-ring in stem seat.
2. Refer to Figure 28-1. Lightly coat valve threads using B270-6 sealant. Remove
tape and install valve in bladder outlet. Special torque A761-2 valve per § 20-33,
or standard torque 1250H valve per § 20-32, and torque stripe per Figure 5-1.
3. Secure A729 to valve stem. Note: safety wire is not required.
4. Service helicopter with minimum two gallons fuel per § 12-41. Verify no leaks.

Page 28.6 Chapter 28 Fuel System JUL 2020

28-20 Fuel Quantity

28-21 Fuel Quantity Sender

CAUTION
Avoid contaminating bladder interior. Cover arms with sleeves
and use lint-free gloves when working inside bladder.

A. Removal
1. Turn battery switch off and pull out (2 amp) GAGES circuit breaker at panel.
2. a. Main tank: Refer to Figure 28-1. Remove screws securing G271-1 guard to
F250 cover assembly and remove guard.
b. Aux tank: Pull out (5 amp) AUX FUEL PUMP circuit breaker at panel. Remove
screws securing G271-1 guard to G759 cover assembly and remove guard.

CAUTION
Rotation of fuel sender center stud or base nut is not permitted.

3. a. Main tank: Using a backup wrench, remove hardware securing F049-04

harness assembly to F550-1 fuel quantity sender.
b. Aux tank: Disconnect G768 harness assembly from airframe harness and
G759 cover assembly at connectors.
4. Remove bolts securing fuel sender to cover assembly. Carefully pull fuel sender
lever through opening. Tape bladder opening.
B. Installation
1. Perform fuel sender check per Part C.
2. Turn battery switch off and pull out (2 amp) GAGES circuit breaker at panel.
3. a. Main tank: Refer to Figure 28-1. Remove tape and carefully lower F550-1
fuel quantity sender lever through F250-1 cover assembly opening.
b. Aux tank: Pull out (5 amp) AUX FUEL PUMP circuit breaker at panel. Remove
tape and carefully lower F550-2 (large tank) or F550-3 (small tank) fuel
quantity sender lever through G759 cover assembly opening.
4. Install bolts securing fuel sender to cover assembly. Special torque bolts in criss-
cross pattern per § 20-33 and torque stripe per Figure 5-1.

JUL 2020 Chapter 28 Fuel System Page 28.7

FIGURE 28-2 FUEL SENDER CHECK

Page 28.8 Chapter 28 Fuel System JUL 2020

28-21 Fuel Quantity Sender (continued)
B. Installation (continued)

CAUTION
Rotation of fuel sender center stud or base nut is not permitted.

5. a. Main tank: Using a backup wrench, install hardware securing F049-04 harness
assembly to fuel sender. Special torque nuts per § 20-33, standard torque
palnuts per § 20-32, and torque stripe per Figure 5-1.
b. Aux tank: Connect G768 harness assembly to G759 cover assembly and
airframe harness at connectors. Verify security.
6. Apply light coat A257-9 anti-seize to threads and install screws securing G271-1
guard to cover assembly. Verify security.
7. Perform fuel indication check per Part D.
C. Fuel Sender Check
1. Remove fuel sender per Part A.
2. Simulate mounting position of appropriate F550 fuel quantity sender per Figure
28-2. Position float arm as shown and measure the resistance with a multimeter.
Verify resistance is within tolerance at each noted height.
3. If resistance is out of tolerance at any height, bend float arm up for a fuel sender
with excessive resistance, or bend float arm down for a fuel sender with too little
resistance. Repeat steps until fuel sender resistance is within tolerance.
4. Install fuel sender per Part B.

JUL 2020 Chapter 28 Fuel System Page 28.9

FIGURE 28-3 FUEL INDICATION CHECK

28-21 Fuel Quantity Sender (continued)

D. Fuel Indication Check
1. a. Main bladder fuel indication check: Defuel main bladder per § 12-42.
b. Aux tank fuel indication check: Verify main bladder has no more than 65
gallons fuel; defuel main bladder per § 12-42, as required.
2. Pull fuel valve into off position.
3. a. Main bladder fuel indication check: Fuel main bladder with 19.4 gallons ± 0.5
gallon per § 12-41.
b. Aux tank fuel indication check: Fuel aux tank with 10.1 gallons ± 0.5 gallon
(large tank) or 5.9 gallons ± 0.5 gallon (small tank) per § 12-41.
4. Refer to Figure 28-3. Push in (2 amp) GAGES circuit breaker at panel and turn
battery switch on. (Press QUANTITY button on aux fuel control panel for aux
tank quantity, displayed on fuel quantity gage.) Verify gage reads one-half needle
width to one & one-half needle widths below one-quarter mark. If fuel gage
indication is correct, proceed to step 6.
5. If fuel gage indication is incorrect, remove fuel quantity sender per Part A. Slightly
bend sender lever up for a gage that reads too high, or down for a gage that reads
too low. Install fuel quantity sender per Part B.
6. Turn battery switch off and push fuel valve into on position.

Page 28.9A Chapter 28 Fuel System JUL 2020

Intentionally Blank

JUL 2020 Chapter 28 Fuel System Page 28.9B

28-22 Low-Fuel Switch Assembly

CAUTION
Avoid contaminating bladder interior. Cover arms with sleeves
and use lint-free gloves when working inside bladder.

A. Schematic
Refer to Figure 98-1 or 98-2 for (single) low fuel warning installation wiring schematic.
Refer to Figure 98-33 for (dual) low fuel warning installation wiring schematic.
B. Removal
1. Defuel helicopter per § 12-42.
2. Open baggage compartment door. Remove G248 (battery compartment) cover.
3. Refer to Figure 28-1. Remove D277-6 clamp or cut and discard safety wire
securing A729 tube to G930-1 drain assembly. Remove screws securing G930-
4 retainer and drain assembly to G250-1 sump tray.
4. Remove fuel cap. Carefully capture A521-2 (single) or A521-4 (dual) switch
assembly body with clean mechanical fingers (avoid capturing float).
5. Inside baggage compartment, remove nut, washer assembly, and spacer securing
switch assembly to tray. Disconnect F049 harness assembly from switch
assembly at connectors; extract switch assembly pins from housing.
6. Carefully pull switch assembly through (fuel cap) opening, avoiding fuel sender.
Install fuel cap and tape bladder opening.
C. Installation
1. Lubricate (new) MS29512-05 packing with A257-6 grease and install packing
over switch assembly threads.
2. Refer to Figure 28-1. Remove fuel cap. Tape A521-2 (single) or A521-4 (dual)
switch assembly wiring to 4-ft length of lockwire; insert other end of wire through
fuel cap opening and through switch assembly opening. Carefully grip switch
assembly body with mechanical fingers and lower switch assembly to bottom
of bladder. Inside baggage compartment, remove tape, guide wiring through
opening, and install spacer, washer assembly, and nut securing switch assembly
to G250-1 sump tray. Special torque nut per § 20-33 and torque stripe per Figure
5-1. Remove tape and lockwire. Release and remove mechanical fingers, and
install fuel cap.
3. Assemble switch assembly pins in housing per Figure 98-1; connect F049 harness
assembly to switch assembly at connectors. Fit wiring through gap in G930-1
drain assembly seal; install G930-4 retainer and screws securing retainer and
drain assembly to tray. Verify security. Seal gap in drain assembly seal where
wires pass thru using B270-5 sealant.

Page 28.10 Chapter 28 Fuel System JUL 2020

28-22 Low-Fuel Switch Assembly (continued)
C. Installation (continued)
4. Secure A729 tube to drain assembly using D277-6 clamp; verify security.
5. Perform operation check per Part D.
D. Operation Check
1. Service helicopter with 7 gallons fuel per § 12-41.
2. If not previously accomplished, remove G248 (battery compartment) cover.
Verify no leaks around switch assembly. Open sump drain access door and verify
no leaks from (low-fuel switch) drain tube.
3. Turn battery switch on.
4. Remove fuel cap. Insert a clean, non-sparking rod through (fuel cap) opening
and gently depress A521 switch assembly’s float (lower float, if dual switch is
installed); verify LOW FUEL annunciator segment illuminates.
5. Dual switch only: Remove rod. Service helicopter with additional 5 gallons fuel
(12 gallons total) per § 12-41. Insert clean, non-sparking rod through opening
and gently depress switch assembly’s upper float; verify <12 GAL FUEL light
illuminates.
6. Remove rod and install fuel cap.
7. Turn battery switch off.
8. Secure access doors and install battery compartment cover; verify security.
E. Scheduled Maintenance
Every 12 Months: Perform operation check per Part D.

JUL 2020 Chapter 28 Fuel System Page 28.11

28-23 Fuel Flow Meter Installation
A. Description
The fuel flow meter installation consists of a fuel flow transducer installed in the
engine fuel line, and a fuel flow signal adapter installed behind the left rear seatback
on the cabin bulkhead. The output signal from the adapter provides fuel information
including flow rate, calculated fuel remaining, and fuel range rings on either Garmin
GTN-series or Avidyne IFD-series moving-map navigation displays.
The fuel flow meter transducer is installed between the engine fuel control unit
(FCU) and an engine fuel check valve. A short, rigid fuel line is installed between the
transducer and the FCU. A longer, rigid fuel line (delivered with the helicopter), may
be installed to put the engine in its original configuration.
Fuel gages and low fuel warning light(s) are independent of the fuel flow meter
installation and are the primary indicators of fuel quantity. Fuel flow meter data is
for electronic display purposes only.
B. Schematic
Refer to Figure 98-33 for fuel flow meter installation electrical schematic.
C. Removal
Transducer
1. Remove engine cowling assembly per § 53-21.
2. Turn battery & avionics switches off and pull out GPS (5 amp) circuit breaker
on panel. Pull fuel shut off valve off.
3. Disconnect airframe harness electrical connector from 660534HR-01 transducer
assembly.
4. Refer to Rolls-Royce OMM Task 73-00-00-000-801 and observe precautions.
Place a drip pan under the engine to catch fuel leakage.
5. Remove hardware securing G155-1 (aft) and G155-2 (forward) brackets to
engine horizontal shield assembly. Remove hardware securing forward bracket
to transducer and remove bracket.
6. Loosen nuts securing fuel tube and transducer sub-assembly to fuel control unit
and check valve using back-up wrench. Remove transducer sub-assembly and
engine nut, washers, and G155-1 aft bracket; discard AS4824N0 seals. Cap and
plug all open fittings.
7. Further disassemble parts from transducer as required; discard AS4824N08 seals.
8. As required, install the fuel check valve per Rolls-Royce OMM Task 73-11-15-
400-801. Install fuel control-to-check valve fuel tube per OMM Task 73-00-00-
420-005; install new AS4824N04 seals.

Page 28.11A Chapter 28 Fuel System JUL 2020

28-23 Fuel Flow Meter Installation (continued)
C. Removal (continued)
Adapter
1. Remove aft left back rest assembly per § 25-22.
2. Turn battery & avionics switches off and pull out GPS (5 amp) circuit breaker
on panel.
3. Disconnect airframe harness electrical connector from AIS-380 adapter.
4. Remove hardware securing adapter to cabin bulkhead and remove adapter.
D. Installation
Transducer
1. Configure AIS-380 adapter if a replacement adapter or 660534HR-01 transducer
assembly was installed per Part E.
2. Turn battery & avionics switches off and pull out GPS (5 amp) circuit breaker
on panel.
3. Refer to Rolls-Royce OMM Task 73-00-00-400-801 and observe precautions.
Place a drip pan under the engine to catch fuel leakage.
4. As required, remove fuel control-to-check valve fuel tube per Rolls-Royce OMM
Task 73-00-00-990-805; discard AS4824N04 seals. Refer to Rolls-Royce
OMM Task 73-11-15-000-801; remove hardware securing fuel check valve to
horizontal fireshield.
5. Remove caps and plugs from fittings. Assemble engine washers, G155-1 (aft)
bracket, engine nut, new (2) AS4824N04 seals, SS6565-8-4 (reducer) fitting,
new (2) AS4824N08 seals, 660534HR-01 transducer assembly, and 564601
tube assembly between fuel check valve and fuel control unit. Install hardware
securing G155-2 (forward) bracket to transducer and tighten screws; install
hardware securing G155 brackets to horizontal fireshield finger tight. Verify
proper alignment with aft bracket; relocate engine-supplied washers as required.
6. Special torque engine-supplied nut to fuel check valve per § 20-33; special
torque SS6565-8-4 fitting to fuel check valve per § 20-33; special torque
SS6565-8-4 fitting to transducer per § 20-33; special torque 564601 tube
assembly to transducer per § 20-33; special torque 564601 tube assembly to
fuel control unit per § 20-33. Tighten hardware securing G155 brackets to
horizontal fireshield. Verify security.
7. Connect airframe harness electrical connector to transducer assembly; verify
security.
8. Push in GPS circuit breaker (5 amp) on panel. Turn battery & avionics switches
on.

JUL 2020 Chapter 28 Fuel System Page 28.11B

28-23 Fuel Flow Meter Installation (continued)
D. Installation (continued)
Transducer (continued)
9. Perform appropriate functional checks per Garmin GTN-series or Avidyne IFD-
series moving-map navigation display Pilot’s Guide.
10. Install engine cowling assembly per § 53-21.
Adapter
1. Configure AIS-380 adapter if a replacement adapter or 660534HR-01 transducer
assembly was installed per Part E.
2. Turn battery & avionics switches off and pull out GPS (5 amp) circuit breaker
on panel.
3. Install hardware securing adapter to cabin bulkhead; verify security.
4. Connect airframe harness electrical connector to adapter; verify security.
5. Push in GPS circuit breaker (5 amp) on panel. Turn battery & avionics switches
on.
6. Perform appropriate functional checks per Garmin GTN-series or Avidyne IFD-
series moving-map navigation display Pilot’s Guide.
7. Install aft left back rest assembly per § 25-22.
E. Configuration
Configure AIS-380 fuel flow adapter per Shadin Avionics M833811-01 Installation
Manual Section 5.
Make the following selections for R66 installation:

Field Selection
Serial Port Autopopulated (may change depending on connection
point to PC)
ARINC Leave at defaults
Fuel Flow Parameters Enabled
Engine Type Single Engine
Engine 1 K Factor See transducer*
Engine 2 K Factor See transducer*
Fuel Density (lbs/Gal) 6.71
Serial Output Format SHADIN_Z
* The K Factor is 1000 times the number printed on the transducer. For example,
a transducer with a K Factor of 9.63 is configured as 9630.

Page 28.11C Chapter 28 Fuel System JUL 2020

28-23 Fuel Flow Meter Installation (continued)
F. Scheduled Maintenance
Every 12 Months:
Transducer
Visually inspect fuel control unit-to-transducer fuel tube connections, transducer,
and reducer connections to transducer and check valve for evidence of leakage.
Visually inspect components for any obvious damage; verify proper installation
and security. Verify no damaged connectors. Verify wiring neatness, proper
routing and installation, and security.
Adapter
Visually inspect adapter for any obvious damage; verify proper installation and
security. Inspect wiring for loose, chafed, frayed, or broken wires. Verify no damaged
connectors. Verify wiring neatness, proper routing and installation, and security.
G. Special Maintenance
Transducer and Adapter
Refer to configuration procedure per Part E. Determine K-factor printed on the
transducer; verify adapter is configured properly. Perform 100-Hour/Annual
inspection per Part F.

JUL 2020 Chapter 28 Fuel System Page 28.11D

FIGURE 28-4 FUEL VALVE

Page 28.12 Chapter 28 Fuel System JUL 2020

28-30 Fuel Valve
A. Removal
1. Defuel helicopter per § 12-42.
2. Refer to Figures 28-1 and 28-4. Open sump drain access door. Remove palnut
and loosen nut securing A462-4 fitting and A522-11 (fuel valve) control inner wire
to F670-1 fuel valve arm.
3. Disconnect D205-21 and B283-12 hose assemblies from fuel valve and cap fittings.
4. Remove screws and washers securing fuel valve to F233-1 firewall and remove
fuel valve through sump drain access door.
B. Installation
1. Refer to Figures 28-1 and 28-4. Install screws and washers securing F670-1 fuel
valve to F233-1 firewall. Verify security.
2. Remove caps and connect D205-21 and B283-12 hose assemblies to fuel valve.
Special torque hose nuts per § 20-33 and torque stripe per Figure 5-1.
3. Perform fuel valve control rigging per § 28-31.
4. Perform fuel flow check per § 28-40.

28-31 Fuel Valve Control Rigging

1. Refer to Figures 28-1 and 28-4. Open sump drain access door. Remove palnut and
loosen nut securing A462-4 fitting and A522-11 (fuel valve) control inner wire to
F670-1 fuel valve arm.
2. Open baggage compartment door. As required, loosen hardware securing AN742-3
clamps and control housing to G915-3 bracket. Position end of control housing flush
to 0.25 inch at or beyond edge of G244-1 panel and install fasteners. Verify security.
3. Refer to detail in Figure 76-3. Push fuel valve into on position then pull up slightly to
create 0.03-0.10 clearance under control knob. Position fuel valve arm in full open
detent. Verify sufficient inner wire beyond outboard edge of fitting and special torque
fitting nut per § 20-33.
4. Pull fuel valve into off position and verify valve arm fully contacts OFF detent. Push
fuel valve into on position and verify valve arm fully contacts ON detent, meeting
clearance requirement. Reposition fitting per previous steps, as required.
5. Install fitting palnut, standard torque per § 20-32, and torque stripe per Figure 5-1.
Trim control wire 0.10-0.30 inch beyond aft edge of fitting.
6. Close sump drain access door. Close and latch baggage compartment door.

APR 2017 Chapter 28 Fuel System Page 28.13

28-40 Fuel Flow Check
1. Open mast fairing per § 53-22. Remove engine cowling per § 53-21.
2. Refer to Figure 28-1. Attach a temporary hose to one of the vent weldment openings.
With the fuel cap installed, blow into the hose (do not use compressed air) and verify
air blows out the other vent opening. If air does not blow out the other vent, remove
obstruction(s) in vent line(s) or in fuel bladder and repeat check.
3. Defuel helicopter per § 12-42, then service helicopter with 19.4 gallons of fuel per §
12-41.
4. Weigh a suitable, empty container having a volume of at least one gallon. Record
weight of empty container in table below.
5. Pull fuel valve into off position and disconnect B283-12 hose assembly from the engine
fuel inlet fitting.
6. Using a second, suitable container, push fuel valve into on position and drain fuel into
second container for a few seconds to purge system of air. Then fill the weighed
container for 60 seconds. Weigh and record weight of empty container & 60 seconds
of fuel flow in table below.
7. Perform the following calculation:

Combined weight of empty container & 60 seconds fuel flow: lb

Subtract Weight of empty container: — lb
Equals Weight of 60 seconds fuel: = lb

8. Minimum fuel flow (at 19.4 gallons of fuel) is 4.75 lb/min (60 seconds). If fuel flow
is less than 4.75 lb/min, remove obstruction(s) in vent line(s), fuel bladder, fuel hoses,
fuel valve, or fuel strainer (inside bladder at outlet), and repeat check until fuel flow is
satisfactory.
9. Close mast fairing per § 53-22. Install engine cowling per § 53-21.

Page 28.14 Chapter 28 Fuel System APR 2017

Intentionally Blank

JUL 2020 Chapter 28 Fuel System Page 28.15

FIGURE 28-5 AUX FUEL SYSTEM (LARGE TANK SHOWN)

Page 28.16 Chapter 28 Fuel System JUL 2020

28-50 Aux Fuel System
A. Description
The auxiliary fuel system consists of a removable fuel tank located in the forward
section of the baggage compartment, hoses connecting the auxiliary tank to the main
fuel tank, and a small control panel on the instrument console.
The auxiliary fuel tank includes a crash-resistant bladder in an aluminum and fiberglass
enclosure, an internal fuel transfer pump, a quantity sender, a filler port, and a sump
drain. The filler port and sump drain are accessed by opening the baggage door. The
tank mounts on a separate fiberglass tray which is also removable.
The pump transfers fuel to the main tank at approximately 40 gallons per hour (150
liters per hour). Venting is provided through a second hose connected to the main
tank. If the main tank is full, any excess fuel transferred by the pump returns to the
auxiliary tank through the vent hose.
A fuel flow sensor is located at the fitting where transferred auxiliary fuel enters the
main tank (hose connection near the main tank filler port). The sensor illuminates the
NO FLOW light on the control panel when the pump switch is on but the fuel transfer
rate is less than ten gallons per hour.
The AUX FUEL control panel on the console includes a pump switch, a NO FLOW
annunciator light, and a QUANTITY button. The pump switch engages the transfer
pump. When the pump switch is on, the NO FLOW light indicates fuel is not transferring
from auxiliary tank to the main tank, either because the auxiliary tank is empty or the
pump has failed. It is normal for the light to illuminate for approximately five seconds
when the pump is first switched on while the system is priming.
A time-delay circuit automatically switches the pump off if the NO FLOW light is
illuminated for more than 15 seconds. The light will remain on even after the time
delay has removed power from the pump. Turning the pump switch off will extinguish
the light.
While the QUANTITY button is depressed, the fuel quantity gage indicates fuel quantity
in the auxiliary tank instead of the main tank. The NO FLOW light also comes on while
the QUANTITY button is depressed to provide a test of the circuit and to confirm that
the auxiliary tank quantity is being displayed on the fuel gage.
The auxiliary fuel tank has two drains through the belly of the helicopter. Any fuel
spilled at the filler port is collected by the surrounding scupper and drains through a
hose into the outboard belly drain location. The tank support tray has a drain at the
inboard drain location. Fuel leaking from the inboard drain indicates a possible leak in
the fuel bladder.
A sump drain hose stowed vertically along the right side of the tank allows preflight
fuel sampling from the low point of the tank. To sample fuel, extend hose away
from the helicopter and push in on the valve. The valve may be locked open to allow
draining of the tank.

JUL 2020 Chapter 28 Fuel System Page 28.17

28-50 Aux Fuel System (continued)
A. Description (continued)
Operationally, the fuel transfer pump may be switched on any time at the pilot’s
discretion. If the main tank is full, any excess fuel transferred from the auxiliary tank
will return through the vent/return hose. Note that fuel in the auxiliary tank is not
considered usable for flight planning purposes because the fuel transfer system has no
redundancy in case of pump failure.
The auxiliary fuel tank may be removed to provide additional baggage space. The
separate support tray may also be removed. A small container which may be clipped
to the outboard side of the tank is provided for stowing installation hardware.

28-51 Aux Fuel System – Tank Assembly

NOTE
Flight is permissible without G010 aux tank assembly installed
when (2) AN806-6D plugs installed on D205-36 hose assemblies
and hoses are stowed in G769-1 bracket assembly (see above
instructions).

6. As required, revise Weight and Balance Record in R66 Pilot’s Operating Handbook
(POH) Section 6 to reflect aux tank assembly removal using the following data:
Subtract:
Item Weight Long. Arm Long. Moment Lat. Arm Lat. Moment
Large Aux Tank Assy –30.0 lb 101.0 in. –3030.0 in.-lb 1.5 in. –45.0 in.-lb
Small Aux Tank Assy –23.0 lb 96.8 in. –2226.4 in.-lb 3.5 in. –80.5 in.-lb

Page 28.18 Chapter 28 Fuel System JUL 2020

28-51 Aux Fuel System – Tank Assembly (continued)
B. Installation
1. Turn battery switch off and pull out (5 amp) AUX FUEL PUMP circuit breaker at
panel. Open main baggage compartment door.
2. Position G010 aux tank assembly on G755 support assembly (tank pin will align
with relief in support); route drain tube into floor weldment. Install B526-6 screws
securing aux tank to G259-1 bulkhead and G251-1 panel. Verify security.
3. Remove AN820-6 or AN929-6 caps from aux tank fittings in G759-1 cover
assembly, and AN806-6D plugs from D205-36 (vent/return) and D205-36 (pump)
hose assemblies. Stow caps and plugs in MT183-1 kit’s jar assembly.
4. Connect hose assemblies to aux tank fittings. Using a back-up wrench on fittings,
special torque hose nuts per § 20-33, & torque stripe per Figure 5-1. Verify
security.
5. Connect G768-4 harness assembly to airframe harness at connectors. Verify
security.
6. As required, revise Weight and Balance Record in R66 Pilot’s Operating Handbook
(POH) Section 6 to reflect aux tank assembly installation using the following data:
Add:
Item Weight Long. Arm Long. Moment Lat. Arm Lat. Moment
Large Aux Tank Assy 30.0 lb 101.0 in. 3030.0 in.-lb 1.5 in. 45.0 in.-lb
Small Aux Tank Assy 23.0 lb 96.8 in. 2226.4 in.-lb 3.5 in. 80.5 in.-lb

7. Fuel as required per § 12-41.

8. Turn battery switch on and push in (5 amp) AUX FUEL PUMP circuit breaker at
panel. Turn pump switch on and inspect vent/return, pump, and sump drain hose
assemblies where they connect to tank. Verify no fuel leaks.
9. Turn pump and battery switches off. Close and secure main baggage compartment
door.

JUL 2020 Chapter 28 Fuel System Page 28.19

28-52 Aux Fuel System – Support Assembly
A. Removal
1. Remove aux fuel tank per § 28-51.
2. Remove B526-6 screws securing G755 support assembly to bulkhead and remove
B536-8 screws securing support assembly to floor. Carefully remove support.

3. As required, revise Weight and Balance Record in R66 Pilot’s Operating Handbook
(POH) Section 6 to reflect support assembly removal using the following data:
Subtract:
Item Weight Long. Arm Long. Moment Lat. Arm Lat. Moment
Large Tank Support Assy –3.0 lb 101.0 in. –303.0 in.-lb –1.2 in. 3.6 in.-lb
Small Tank Support Assy –2.0 lb 96.8 in. –193.6 in.-lb –0.4 in. 0.8 in.-lb

B. Installation
1. Verify baggage compartment floor where G755 support assembly is to be installed
is free of debris. Position support assembly on floor.
2. Install B526-6 screws securing support assembly to bulkhead and install B536-8
screws securing support assembly to floor. Verify security.
3. As required, revise Weight and Balance Record in R66 Pilot’s Operating Handbook
(POH) Section 6 to reflect support assembly installation using the following data:
Add:
Item Weight Long. Arm Long. Moment Lat. Arm Lat. Moment
Large Tank Support Assy 3.0 lb 101.0 in. 303.0 in.-lb –1.2 in. –3.6 in.-lb
Small Tank Support Assy 2.0 lb 96.8 in. 193.6 in.-lb –0.4 in. –0.8 in.-lb

4. Install aux fuel tank per § 28-51 or refer to NOTE in Part A.

Page 28.20 Chapter 28 Fuel System JUL 2020

28-53 Aux Fuel System – Bladder

CAUTION
Avoid contaminating bladder interior. Cover arms with sleeves
and use lint-free gloves when working inside bladder.

A. Removal
1. Remove aux fuel tank per § 28-51.
2. Cut ty-rap securing D205 (drain) hose assembly to G762-11 scupper. Using
a back-up wrench, disconnect hose from drain fitting, release hose at tab, and
remove hose. Cap and plug fittings. Remove screws securing G756 bladder and
scupper to G754 enclosure assembly.
3. Remove fuel quantity sender per § 28-21.
4. Remove screws securing G759-1 cover assembly and bladder to enclosure. Lift
cover and inside bladder, release clamp securing drain tube to fitting. Inside
bladder, remove screws securing G764-1 drain weldment and G765-1 pump
assembly to bladder. Remove weldment, pump, and tubes with connected cover
assembly.
5. Remove screws securing G758-1 cover to enclosure assembly. Remove G762-
12 hinge. Guide cover clear of strap and remove cover.
6. Detach bladder hook tape from enclosure loop tape and remove bladder. Tape
bladder openings.

B. Installation
1. Fold forward, aft, and left sides of G756 bladder inward; align bladder’s G759-4
ring assembly with G754 enclosure assembly’s servicing panel to clear strap, and
press bottom of bladder to enclosure’s tray. Unfold bladder, and align bladder
and enclosure hook and loop tape.

CAUTION
Verify bladder is free of wrinkles across lower surface and
properly located before attaching hook and loop tape. Bladder
may be pressurized with air to 1 psi max to assist installation.

2. Remove tape protecting bladder openings. Insert a clean, smooth, blunt wooden
dowel through bladder service opening and press on bladder lower surface to
attach hook and loop tape. Verify security.
3. Guide G758-1 cover clear of strap and install screws securing cover to enclosure.
Install G762-12 hinge. Verify security.

JUL 2020 Chapter 28 Fuel System Page 28.21

28-53 Aux Fuel System – Bladder (continued)
B. Installation (continued)
4. Position G765-1 pump assembly, G764-1 drain weldment, and tubes (with
connected G759-1 cover assembly) inside bladder and install screws. Verify
security.
5. Inside bladder, install clamp securing drain tube to fitting. Verify security.
6. Install screws securing bladder and G762-11 scupper to enclosure at drain. Verify
security.
7. Connect D205 (drain) hose assembly to drain fitting, aligning hose 8.5° ± 5.0°
from parallel with edge of enclosure’s G757-1 tray. Using a back-up wrench,
special torque hose nut per § 20-33, and torque stripe per Figure 5-1. Secure
hose near drain valve at tab. Install MS336-7-9 ty-rap securing scupper to hose.
Cinch ty-rap until snug without overtightening, and trim tip flush with head.
8. Apply light coat A257-9 anti-seize to screw threads and install screws securing
G759-1 cover and bladder to enclosure. Verify security.
9. Install fuel quantity sender per § 28-21.
10. Install aux fuel tank per § 28-51.

Page 28.22 Chapter 28 Fuel System JUL 2020

Intentionally Blank

APR 2019 Chapter 28 Fuel System Page 28.23

FIGURE 28-6 AUX FUEL SYSTEM
ELECTRICAL SCHEMATIC

Page 28.24 Chapter 28 Fuel System APR 2019

28-54 Aux Fuel System – Fuel Quantity Sender

Refer to § 28-21 for fuel quantity sender maintenance instructions.

28-55 Aux Fuel System – Pump Assembly

CAUTION
Avoid contaminating bladder interior. Cover arms with sleeves
and use lint-free gloves when working inside bladder.

A. Removal
1. Defuel aux fuel tank per § 12-42.
2. Turn battery switch off and pull out (5 amp) AUX FUEL PUMP circuit breaker at
panel. Open main baggage compartment door.
3. Disconnect G768-4 harness assembly from airframe harness at connectors.
4. Using a back-up wrench, disconnect D205-36 (vent/return) and D205-36 (pump)
hose assemblies from aux tank fittings in G759-1 cover assembly. Temporarily
cap and plug fittings (AN820-6 and AN929-6 caps, and AN806-6D plugs are
included in MT183-1 kit).
5. Refer to Figure 28-7. Remove screws securing G759-1 cover assembly and
G756 bladder to G754 enclosure assembly. Lift cover and inside bladder, release
clamp securing A729-73 tube to drain fitting. Inside bladder, remove screws
securing G764-1 drain weldment and G765-1 pump assembly to bladder. Remove
weldment, pump, and tubes with connected cover assembly. Tape opening to
prevent contamination of bladder interior.
6. Unwind B161-108 spirap from A729-24 tube and pump wiring. Remove D277‑8
clamp and tube from pump. Remove hardware securing pump connector to cover.

JUL 2020 Chapter 28 Fuel System Page 28.25

FIGURE 28-7 FUEL PUMP

Page 28.26 Chapter 28 Fuel System JUL 2020

28-55 Aux Fuel System – Pump Assembly (continued)
B. Installation
1. Turn battery switch off and pull out (5 amp) AUX FUEL PUMP circuit breaker on
circuit breaker panel. Open main baggage compartment door.
2. Remove tape from opening of G756 bladder. Verify bladder is free of wrinkles
across lower surface of tank and is properly located.
3. Refer to Figure 28-7. Position G764-1 drain weldment with attached tubes
(without pump) in bladder and temporarily secure with screws. Verify with
flashlight and mirror bottom end of A729-72 tube contacts bladder as shown.
Adjust tube and repeat step as required. Remove weldment with attached tubes.
4. Position A729-74 tube on G765-1 pump assembly as shown; install D277-8
clamp so prongs point opposite of wiring. Verify security. Run pump wiring
along tube and secure with B161-108 spirap as shown; ensure there is 1.00–
3.00 inches between spirap and clamp.
5. Place drain weldment with attached tubes on pump assembly and position
weldment and pump inside bladder; verify strainer is positioned as shown and
install mounting screws. Verify security.
6. Connect A729-73 tube to drain fitting and install D277-8 clamp; verify security.
Connect A729-74 tube to G759-1 cover assembly, install D277-8 clamp, and
ensure there is 1.00–3.00 inches between spirap and clamp; verify security.
Install hardware securing pump connector to cover; verify security.
7. Install screws securing cover and bladder to G754 enclosure assembly; verify
security.
8. Remove AN820-6 or AN929-6 caps from aux tank fittings in G759-1 cover
assembly, and AN806-6D plugs from D205-36 (vent/return) and D205-36 (pump)
hose assemblies. Stow caps and plugs in MT183-1 kit’s jar assembly.
9. Connect hose assemblies to aux tank fittings. Using a back-up wrench on fittings,
special torque hose nuts per § 20-33, and torque stripe per Figure 5-1. Verify
security.
10. Connect G768-4 harness assembly to G768-1 harness assembly at connectors.
Verify security.
11. Perform fuel quantity indication check per § 28-21.
12. Using ground power or during flight check, switch on aux pump and verify no
flow light extinguishes in less than 15 seconds. Continue timing from when
pump was switched on and verify light re-illuminates (aux fuel is transferred to
main tank) in less than 16 minutes. Verify aux fuel quantity indication is empty
after light re-illuminates.

JUL 2020 Chapter 28 Fuel System Page 28.27

Intentionally Blank

Page 28.28 Chapter 28 Fuel System JUL 2020

CHAPTER 29

HYDRAULICS
Section Title Page

29-00 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.1

29-10 Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.1
29-20 Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.5
29-30 Hydraulic Servos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.6

MAY 2015 Chapter 29 Hydraulics Page 29.i

Intentionally Blank

Page 29.ii Chapter 29 Hydraulics MAY 2015

CHAPTER 29

HYDRAULICS

29-00 Description

WARNING

Except as instructed in this manual, service on the hydraulic

system is limited to component removal and replacement.
CAUTION

Cleanliness of hydraulic fluid is vital to proper system

operation. Use only clean fluid from sealed containers and
avoid contamination from dirty funnels, tubing, etc. Use LPS
PreSolve to clean hydraulic parts. Do not use alcohol.

Hydraulically boosted main rotor flight controls eliminate cyclic and collective feedback forces.
The hydraulic system consists of a pump, three servos, a reservoir, and interconnecting lines.
Normal operating pressure is 450 to 500 psi. The pump is mounted on and driven by the
main rotor gearbox. A servo is connected to each of the three push-pull tubes that support
the main rotor swashplate. The reservoir is mounted to the aft end of the main rotor gearbox
and includes a filter, pressure relief valve, and pilot-controlled pressure shut-off valve.

A sight glass for pre-flight fluid level checks is incorporated in the reservoir and accessible
via a left side cowl door. A vented filler cap is located on top of the reservoir.

The pressure shut-off valve is solenoid-actuated and controlled by the hydraulic switch on
the pilot's cyclic. The switch should be left on during helicopter shutdown and start up
except during the hydraulic system check.

Electrical power is required to turn off hydraulics. Pulling HYD circuit breaker will NOT turn
off hydraulics but will disable hydraulic switch.
29-10 Hydraulic Pump

A. Removal

1. Remove tailcone cowling per § 53-23.

2. For helicopters with air conditioning:

a. Loosen hardware securing G777-1 compressor assembly to G781-1 arm weldment.

CAUTION

Do not use refrigerant hose assemblies or fittings to rotate

compressor. Do not rotate compressor further than necessary,
to avoid damaging system wiring and refrigerant hoses or fittings.

b. Rotate compressor down and inboard as required to disengage B173-5 v-belt from
pulleys.

MAY 2015 Chapter 29 Hydraulics Page 29.1

FIGURE 29-1 HYDRAULIC FLIGHT CONTROL SYSTEM

Page 29.2 Chapter 29 Hydraulics MAY 2015

29-10 Hydraulic Pump (continued)
A. Removal (continued)
2. c. Remove hardware securing G779-1 pulley to F908-1 yoke assembly and slide
pulley aft (do not scuff paint on tail rotor drive fan shaft).
3. Remove hydraulic reservoir filler-vent and temporarily install an air-tight plug.
4. Refer to Figure 12-4. Remove F902 suction line assembly and protect exposed line
and fitting openings.
5. Remove F902 pressure line assembly and protect exposed line and fitting openings.
6. Remove aft jam nut from both MR rpm senders and remove both senders from
bracket attached to hydraulic pump. Temporarily secure senders away from drive
train to prevent damage.
7. Remove four self-locking nuts and washers securing pump to gearbox and remove
pump and o-ring. Discard o-ring. Protect pump opening on gearbox.
B. Installation
1. Prelubricate new o-ring with gearbox oil and install on pump mounting flange.
With pump bracket pointing down, install pump on gearbox and secure. Special
torque nuts per § 20-33.
2. Install both MR rpm senders in pump bracket. Adjust clearance between both senders
and both yoke magnets to 0.040/0.020 inch and hand-tighten sender jam nuts.
3. Refer to Figure 12-4. Install F902 pressure line assembly & special torque per § 20-33.
4. Install F902 suction line assembly and special torque per § 20-33.
5. Remove temporary air-tight plug from reservoir and adjust fluid level as required.
Install filler-vent and special torque per § 20-33.
6. Torque stripe jam nuts and B-nuts.
7. Bleed hydraulic system per § 12-34.
8. Install a 110-4 Telatemp on aft surface of pump.
9. For helicopters with air conditioning:
a. Position G779-1 pulley on F908-1 yoke assembly. Install hardware, standard
torque nuts per § 20-32, and torque stripe per Figure 5-1.
b. Route B173-5 v-belt onto pulleys. Rotate compressor up and outboard to
tension belt, then tighten hardware securing compressor to weldment. Adjust
belt until 4.5-5.5 lb of force applied mid-span deflect belt 0.16-inch. Standard
torque bolts per § 20-32 and torque stripe per Figure 5-1.
10. Install tailcone cowling per § 53-23.

JUL 2020 Chapter 29 Hydraulics Page 29.3

FIGURE 29-2 HYDRAULIC SYSTEM SCHEMATIC

FIGURE 29-3 HYDRAULIC SERVO RIGGING

Page 29.4 Chapter 29 Hydraulics JUL 2020

29-20 Hydraulic Reservoir

A. Removal

1. Temporarily install a "DO NOT MOVE FLIGHT CONTROLS" sign in cockpit.

2. Remove tailcone cowling per § 53-23.

3. Place a one-liter container beneath suction tee fitting on reservoir. Remove cap from
tee fitting and allow reservoir fluid to drain into container. Reinstall cap and special
torque per § 20-33.

4. Remove suction and pressure lines, and disconnect and cap servo supply and return
hoses, from reservoir. Protect line and fitting openings.

5. Disconnect pump bypass solenoid and sight gage LED electrical connectors.

6. Remove three screws securing reservoir to gearbox and remove reservoir.

7. Note alignment of tee fittings and sight gage LED. Transfer LED and line and hose
fittings from removed reservoir to replacement reservoir.

B. Installation

1. Note alignment of tee fittings and sight gage LED on removed reservoir. Transfer LED
and line and hose fittings from removed reservoir to replacement reservoir. Special
torque fittings per § 20-33.

2. Install reservoir on gearbox and secure with three screws.

3. Install pressure and suction lines, repositioning tee fittings as required, and special
torque per § 20-33.

4. Connect servo supply and return hoses to reservoir. Position hose elbows to minimize
preload and special torque per § 20-33.

5. Connect pump bypass solenoid and sight gage LED electrical connectors and ty-rap
wires as required.

6. Fill reservoir with A257-15 hydraulic fluid and special torque filler vent per § 20-33.

7. Bleed hydraulic system per § 12-34.

8. Install tailcone cowling per § 53-23.

MAY 2015 Chapter 29 Hydraulics Page 29.5

29-30 Hydraulic Servos
A. Servo Removal

CAUTION
Do not pressurize hydraulic system while any hydraulic system
component is disconnected or removed.
1. Remove mast fairing per § 53-22. Remove tailcone cowling per § 53-23.
2. Refer to Figures 29-1 and 29-3. Perform the following measurements on all D212
hydraulic servo assemblies to be removed:
a. Measure and record dimension between D200-1 clevis hole center & top of servo
piston.
b. Apply cyclic and collective frictions. With collective full down and hydraulics
unpressurized, position cyclic stick so piston in servo to be removed is in its lowest
position. Measure and record dimension between top of servo piston and top of
cylinder assembly.
3. Remove hardware securing servo clevis to F121-3 push-pull tube’s lower rod end.
4. a. Forward Servo: Remove hardware securing servo to F121-5 push-pull tube’s upper
rod end. Remove hardware joining D200-2 scissors.
b. Aft Servo: Remove hardware securing C343-8 tube’s lower rod end to F339-1
jackshaft weldment.
5. Disconnect D205 hose assemblies from servo unions and tees. Cap and plug fittings.
6. Remove hardware securing servo to G201-1 frame weldment and remove servo.
7. Aft Servo: Measure and record center-to-center dimension between aft servo’s lower
rod end and C343-8 tube’s lower rod end. Loosen palnut and nut securing C343-8
tube to aft servo’s lower rod end and remove tube.

CAUTION
Do not remove tri-wing fastener; aft servo’s lower rod end must
remain attached to servo.
CAUTION
Dimension between clevis hole center and top of servo piston
must be 1.40 ± 0.03 inches; dimension between top of servo
piston and top of cylinder assembly must be 0.28 ± 0.03 inch;
dimension between C343-8 tube’s rod ends must be 4.00 ±
0.03 inches. If dimension(s) are not within required range,
perform main rotor rigging per § 18-40 after servo installation.
8. Remove clevis, scissor, D200-3 washer, unions, and tee fittings from servo, as
applicable.
9. Actuate servo piston by hand and drain as much hydraulic fluid from servo as possible.
Plug servo ports.

Page 29.6 Chapter 29 Hydraulics MAY 2015

29-30 Hydraulic Servos (continued)
B. Servo Installation

CAUTION
Do not pressurize hydraulic system while any hydraulic system
component is disconnected or removed.
CAUTION
Refer to Part A. Dimension between clevis hole center and top
of servo piston must be 1.40 ± 0.03 inches; dimension between
top of servo piston and top of cylinder assembly must be 0.28
± 0.03 inch; dimension between C343-8 tube’s rod ends must
be 4.00 ± 0.03 inches. If dimension(s) recorded during servo
removal were not within required range, or if dimension(s) are
unknown, adjust to correct dimensions in Part B steps 1 and 2,
proceed with servo installation thru step 10, then perform main
rotor rigging per § 18-40.

1. Refer to Figures 29-1 and 29-3. Lightly coat D200-1 clevis threads with B270‑21
protectant. Assemble clevis, palnut, nut, D200-3 washer (forward servo), and
D200-2 scissor (forward servo), and install assembly in D212 hydraulic servo
assembly piston. Adjust dimension between clevis hole center & top of servo
piston to dimension recorded during servo removal, then tighten jam nut and palnut
finger tight.
2. Aft Servo: Lightly coat servo’s lower rod end threads with B270-21 protectant
and install C343-8 tube. Adjust tube on servo‘s rod end, and tube’s rod end, to
the center-to-center dimension (between rod ends) recorded during servo removal,
and with rod ends 90° to each other. Tighten jam nuts and palnuts finger tight.

CAUTION
Do not remove tri-wing fastener; aft servo’s lower rod end must
remain attached to servo.

3. Install hardware securing servo to G201-1 frame weldment. Standard torque

fasteners per § 20-32 and torque stripe per Figure 5-1.
4. Forward Servos: Install hardware joining scissors (scissor overlap direction not
critical); special torque nut to 25 in.-lb, special torque palnut to 5–10 in.-lb, and
torque stripe per Figure 5-1.
5. Using backup wrench, align clevis parallel with helicopter’s longitudinal axis,
standard torque jam nut and palnut per § 20-32, and torque stripe per Figure 5-1.
6. Install hardware securing servo clevis to F121-3 push-pull tube’s lower rod end.
Standard torque fastener per § 20-32 and torque stripe per Figure 5-1.

JUL 2020 Chapter 29 Hydraulics Page 29.7

29-30 Hydraulic Servos (continued)
B. Servo Installation (continued)
7. a. Forward Servo: Install hardware securing servo to F121-5 push-pull tube’s upper
rod end. Standard torque fastener per § 20-32 and torque stripe per Figure 5-1.
b. Aft Servo: Install hardware securing C343-8 tube’s lower rod end to F339-1
jackshaft weldment. Standard torque fastener per § 20-32 and torque stripe per
Figure 5-1. Using backup wrench, standard torque jam nuts and palnuts, and
torque stripe per Figure 5-1.
8. Refer to Figure 5-2. Verify proper rod end centering on all push-pull tubes attached
to servos.
9. Remove caps and plugs. Lubricate new packings using A257-15 hydraulic fluid and
install packings on servo unions and tees. Install fittings with associated hardware in
servo ports and connect D205 hose assemblies to fittings. Align fittings to minimize
hose preload and ensure hose clearance with surrounding structure; special torque
fittings per § 20-33 and torque stripe per Figure 5-1. Special torque hose B-nuts per
§ 20-33 and torque stripe per Figure 5-1.
10. Bleed hydraulic system per § 12-34.
11. Perform the following measurements on all servos just installed:
a. Measure and record dimension between clevis hole center & top of servo piston.
b. Apply cyclic and collective frictions. With collective full down and hydraulics
unpressurized, position cyclic stick so piston in servo just installed is in its lowest
position. Measure and record dimension between top of servo piston and top of
cylinder assembly.

CAUTION
Dimension between clevis hole center and top of servo piston
must be 1.40 ± 0.03 inches; dimension between top of servo
piston and top of cylinder assembly must be 0.28 ± 0.03 inch;
dimension between C343-8 tube’s rod ends must be 4.00 ±
0.03 inches. If dimension(s) recorded are not within required
range, adjust to correct dimensions in Part B steps 1 and 2,
proceed with servo installation thru step 10, then perform main
rotor rigging per § 18-40.

12. Install tailcone cowling per § 53-23. Install mast fairing per § 53-22.

Page 29.8 Chapter 29 Hydraulics JUL 2020

29-30 Hydraulic Servos (continued)
C. Inspection
1. Disconnect servo from upper push-pull tube per § 29-30 Part A steps 1 thru 3.
2. Remove clevis, scissor, and D200-3 washer from servo, as applicable.
3. Visually inspect threaded bore in piston with borescope. Replace servo if corrosion
is detected.
4. Assemble servo and connect to upper push-pull tube per § 29-30 Part B steps 1,
4, 5, 6, 8, 11, and 12.

JUL 2020 Chapter 29 Hydraulics Page 29.9

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Page 29.10 Chapter 29 Hydraulics JUL 2020

CHAPTER 32

LANDING GEAR

Section Title Page

32-00 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32.1
32-10 Landing Gear Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32.1
32-20 Cross Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32.5
32-30 Skid Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32.7
32-31 Skid Shoes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32.8
32-32 Skid Extension Replacement . . . . . . . . . . . . . . . . . . . . 32.8
32-33 Ground Handling Wheel Support Replacement . . . . . . . . 32.8
32-40 Fairing Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32.9
32-50 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32.9
32-60 Pop-Out Floats Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32.11
32-61 Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 32.11
32-62 Lever Rigging and Shear-Rivet Replacement . . . . . . . . . 32.17
32-63 Float Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32.19
32-64 System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 32.22

SEP 2012 R66 Maintenance Manual Chapter 32 Landing Gear Page 32.i
Intentionally Blank

Page 32.ii Chapter 32 Landing Gear R66 Maintenance Manual SEP 2012
CHAPTER 32

LANDING GEAR

32-00 Description

A spring and yield skid type landing gear is used. Most hard landings will be absorbed
elastically. However, in an extremely hard landing, the struts will hinge up and outward as
the center crosstube yields (takes permanent set) to absorb the impact. Slight yielding of
the aft crosstube is acceptable. For tail skid height limitation, see § 32-20. For hard landing
inspection, see § 5-65.

Hardened steel wear shoes are mounted on the bottom of the skids. Inspect skid tubes and
skid shoes per § 32-30, particularly if autorotation landings with ground contact have been
performed.

Pop-out float landing gear is available as optional equipment. See § 32-60 for pop-out float
installation description.

32-10 Landing Gear Assembly

A. Removal

1. Open cabin aft doors and baggage compartment door. Remove engine cowling per §
53-21.

2. Refer to § 6-70; remove G308-2 and two F475-6 cross tube covers. Remove fairing
assemblies per § 32-40.

3. Refer to Figure 32-1. If installed, remove hardware securing A936-3 (ground) wire
assembly to aft, right landing gear attachment.

4. Using putty knife or plastic scraper, cut sealant securing four cross tube rain caps to
landing gear assembly and remove caps. Remove sealant residue from caps, cross
tubes, and strut assemblies. Clean surfaces with solvent.

5. Hoist helicopter per § 7-20. Raise skids above ground approximately one foot.

CAUTION

Support landing gear assembly as mounting bolts are removed.

Do not damage forward cross tube hinged inspection cover.

6. Remove hardware securing forward, right strut assembly & forward cross tube to
fuselage support. Mounting bolt access hole is located on aft, right seat box forward
wall.

7. Remove hardware securing aft, right strut assembly & aft cross tube to fuselage
support. Mounting bolt access hole is located on baggage compartment aft wall.
8. Rotate forward, left shackle to align mounting bolt with access hole on aft, left seat
box forward wall. Remove hardware securing landing gear to shackle.

MAY 2015 Chapter 32 Landing Gear Page 32.1

FIGURE 32-1 LANDING GEAR ATTACHMENT

Page 32.2 Chapter 32 Landing Gear MAY 2015

32-10 Landing Gear Assembly (continued)
A. Removal (continued)
9. If air conditioning is installed, remove hardware securing G787-3 and G787-4
brackets to condenser support and remove brackets.
10. Remove nut, washer, and spacer from aft, left mounting bolt (bolt stays in place).
Carefully lower forward cross tube below belly, then move assembly aft, off of aft
left bolt.
B. Installation

WARNING
Landing gear mounting bolts are critical fasteners. See § 20-30
for torque requirements.
CAUTION
Support landing gear assembly as mounting bolts are installed.
Do not damage forward cross tube hinged inspection cover.

1. Hoist helicopter per § 7-20 to required height.

2. Refer to Figure 32-1. Align mounting bolt (in place) with aft, left landing gear
attachment. Install hardware, special torque fastener per § 20-33, & torque stripe
per Figure 5-1. If air conditioning is installed, install hardware securing G787-3 and
G787-4 brackets to condenser support. Verify security.
3. Insert hardware thru access hole on aft, left seat box forward wall, and thru shackle.
Align mounting bolt with forward, left landing gear attachment. Install hardware,
special torque bolt per § 20-33, & torque stripe per Figure 5-1.
4. Insert hardware thru right side access hole on baggage compartment aft wall and aft,
right landing gear attachment. Install hardware, special torque bolt per § 20-33, &
torque stripe per Figure 5-1.
5. Insert hardware thru access hole on aft, right seat box forward wall and forward, right
landing gear attachment. Install hardware, special torque bolt per § 20-33, & torque
stripe per Figure 5-1.
6. Lower helicopter per § 7-20. Close cabin aft doors and baggage compartment door.
7. If installed, verify surface under terminal is clean and dry and install hardware securing
A936-3 (ground) wire assembly to aft, right landing gear attachment. Standard torque
screw per § 20-32 and torque stripe per Figure 5-1.
8. Verify rain caps and bonding surfaces are clean and dry. Bond caps to landing gear
cross tubes (painted side against cross tube, window up) using B270-1 sealant.
Remove excess adhesive and allow to cure.

APR 2017 Chapter 32 Landing Gear Page 32.3

32-10 Landing Gear Assembly (continued)
B. Installation
9. Refinish landing gear as required per Chapter 20.
10. When surfaces are dry, install engine cowling per § 53-21. Refer to § 6-70; install
G308-2 and two F475-6 cross tube covers. Install fairing assemblies per § 32-40.
11. Perform electrical bond check per the following:
a. Remove aux fuel tank per § 28-51, if installed.
b. Disconnect battery negative (ground) cable, then positive cable from battery.
c. Attach positive (red) and negative (black) leads to digital milliohm meter (Model
310, BK Precision or similar).
d. Attach negative (black) leads to battery ground strap; attach positive (red) leads
to the following ground locations and check readings:
i. Tailcone forward bay (strobe light ground stud)
ii. Horizontal stabilizer (tail light ground stud)
iii. Main gearbox (chip detector housing or MR temperature switch screw)
iv. Left and right skid tube (ground handling support)
v. Avionics ground (C448 terminal assembly)
vi. Upper console ground (G050/G060)
vii. Battery charge negative post
e. Verify resistance at each location is maximum 1 ohm; if more than 1 ohm, check
installation points and repeat steps as required.

Page 32.3A Chapter 32 Landing Gear APR 2017

Intentionally Blank

APR 2017 Chapter 32 Landing Gear Page 32.3B

FIGURE 32-2 CROSS TUBE REMOVAL

Page 32.4 Chapter 32 Landing Gear APR 2017

32-20 Cross Tubes

A. Inspection

For helicopters with F014-1 (standard) landing gear or F014-4 (pop-out float) landing gear,
replace aft cross tube if tail skid height is less than 38 inches from ground when aircraft is
minimally loaded on level pavement.

For helicopters with F014-5 (extended) landing gear, replace aft cross tube if tail skid height
is less than 30 inches from ground when aircraft is minimally loaded on level pavement.

For hard landing inspection, see Section 5-65.

B. Removal

1. Remove landing gear per Section 32-10.

2. Refer to Figure 32-2. Remove hardware securing one skid tube (left or right) to same
side strut assemblies.

3. Remove hardware securing cross tube (to be replaced) to strut assemblies. Using brass
drift, tap on strut assembly collars to separate struts from cross tube. Do not tap on
jack tabs.

C. Installation

Refer to R66 Illustrated Parts Catalog (IPC) Figure 32-1.

NOTE

When installing A936-3 (ground) wire assembly, verify finish is

removed from surface under wire terminal.

1. Refer to Figure 32-2. Lightly coat mating surfaces of cross tube with zinc-chromate or
epoxy primer using approved materials per Section 20-70. While primer is wet, install
cross tube into strut assemblies and align fastener holes.

2. Install hardware securing cross tube to strut assemblies, standard torque screws per
Section 20-32, and torque stripe per Figure 5-1.

3. Install hardware securing left or right skid tube to strut assemblies, standard torque
bolts per Section 20-32, and torque stripe per Figure 5-1.

4. Install landing gear per Section 32-10.

SEP 2012 R66 Maintenance Manual Chapter 32 Landing Gear Page 32.5
FIGURE 32-3 SKID TUBES AND FAIRINGS
(Strut and skid tube angles exaggerated for clarity)

Page 32.6 Chapter 32 Landing Gear R66 Maintenance Manual SEP 2012
32-30 Skid Tubes

Refer to R66 Illustrated Parts Catalog (IPC) Figure 32-1.

CAUTION
Minimize personnel movement around raised helicopter. Use
caution when working under raised skid tubes.

A. Inspection

1. Install ground handling wheels per Section 9-11.

2. Pull down on tail rotor gearbox and place blocks under skid tubes, forward of forward
strut assemblies. Skids should be approximately parallel with the ground.

3. Measure damage on left or right skid tube. Replace skid tube if damage exceeds the
following limits:

a. 0.030 inch maximum depth longitudinal scratch (no length limit).

b. 0.030 inch maximum depth and 0.50 inch maximum length circumference scratch.
c. 0.500 inch maximum width flat spot.
4. Measure the thickness of skid tube's skid shoes (five per skid). Replace a skid shoe
per Section 32-31 if damage exceeds 0.050 inch minimum thickness. Repeat steps on
opposite skid tube.

B. Removal

1. Jack or hoist helicopter per Sections 7-10 or 7-20. Raise skids above ground approximately
4 inches.

2. Refer to Figure 32-3. Remove hardware securing left or right skid tube to same side
strut assemblies.

C. Installation

1. Jack or hoist helicopter per Sections 7-10 or 7-20 to required height.

2. Refer to Figure 32-3. Install hardware securing skid tube to strut assemblies. Standard
torque bolts per Section 20-32 and torque stripe per Figure 5-1.

3. Lower helicopter per Sections 7-10 or 7-20.

SEP 2012 R66 Maintenance Manual Chapter 32 Landing Gear Page 32.7
32-31 Skid Shoes

Refer to R66 Illustrated Parts Catalog (IPC) Figure 32-1.

A. Inspection

Inspect skid tubes and skid shoes per Section 32-30.

B. Replacement

1. Refer to Figure 32-3. Remove and discard hardware securing skid shoe to skid tube.
Discard a shoe damaged beyond limits in Section 32-30.

2. Install new A142-1 screws to secure skid shoe to skid tube. Standard torque screws
per Section 20-32.

32-32 Skid Extension Replacement

Refer to R66 Illustrated Parts Catalog (IPC) Figure 32-1.

1. Remove skid tube per Section 32-30.

2. Refer to Figure 32-3. Remove and discard hardware securing aft skid shoe to skid tube.
Remove skid extension.

3. Clean interior of skid tube as practical. Install new skid extension and align fastener
holes.

4. Install new A142-1 screws to secure aft skid shoe to skid tube. Standard torque screws
per Section 20-32.

5. Install skid tube per Section 32-30.

6. Fill gap in side of skid extension using B270-1 sealant. Mix sealant according to
manufacturer's instructions.

32-33 Ground Handling Wheel Support Replacement

Refer to R66 Illustrated Parts Catalog (IPC) 32-1.

1. Refer to Figure 32-3. Remove hardware securing support weldment to skid tube and
remove support.

2. Install hardware securing new support weldment to skid tube. Verify correct support
orientation. Special torque hardware per Section 20-33 and torque stripe per Figure 5-1.

Page 32.8 Chapter 32 Landing Gear R66 Maintenance Manual SEP 2012
32-40 Fairing Assemblies
A. Removal
1. Refer to Figure 32-3. Remove screws securing fairing assembly together at trailing
edge.
2. Remove screws securing fairing assembly to strut assembly. Unscrew clamp
through fairing inboard access hole and remove fairing.
B. Installation
1. Refer to Figure 32-3. Verify fairing assembly clip nuts are installed. Verify clamp
threads through fairing clips, with hex facing inboard access hole.
2. Position fairing assembly on strut assembly and install screws securing fairing to
strut.
3. Tighten clamp, and special torque hex through fairing assembly inboard access
hole per § 20-33.
4. Install screws securing fairing assembly together at trailing edge.
5. Verify 0.20–0.30 inch clearance between fairing assembly edge and fuselage.
Remove and trim fairing as required; reinstall per preceding steps.

32-50 Maintenance
1. Refer to Figure 32-3. Verify drain holes in bottom of skid tubes are free of obstructions
(two per skid, between two forward skid shoes and aft of skid shoe at forward strut
assembly).
2. Refinish landing gear to prevent corrosion per Chapter 20.
3. Inspect skid tubes and skid shoes per § 32-30, especially following touch-down
autorotations or running take-offs or landings.
4. Verify skid tube and strut assembly rain caps are properly sealed. Replace or re-seal rain
caps per the following:
a. Using putty knife or plastic scraper, cut sealant securing rain cap to landing gear
assembly and remove cap. Remove sealant residue from caps, cross tubes, and/or
strut assemblies. Clean surfaces with solvent.
b. Verify rain caps and bonding surfaces are clean and dry. Bond caps to landing
gear assembly using B270-1 sealant. Mix sealant according to manufacturer's
instructions.

APR 2019 Chapter 32 Landing Gear Page 32.9

FIGURE 32-4 POP-OUT FLOATS INSTALLATION

Page 32.10 Chapter 32 Landing Gear APR 2019

32-60 Pop-Out Floats Installation

Pop-out floats are optional equipment for R66 helicopters. The pop-out float installation
includes inflatable floats stowed in protective covers secured to the skid tubes, a pressure
cylinder located in the compartment beneath the right aft seat, an inflation manifold, an inflation
lever located on the pilot’s collective stick, and a modified aux stabilizer.

The valve located on top of the pressure cylinder has a pressure gage, a thermal relief valve
which releases pressure if exposed to excessive heat (281º F), a metal sealing disk, and a
spring-loaded pin.

The red inflation lever on the pilot’s collective stick is equipped with a spring-loaded safety to
prevent inadvertent float inflation. To inflate the floats, the safety is pushed in and rotated
from LOCKED to READY position, then the inflation lever is squeezed with enough force to
shear the aluminum rivet. The spring-loaded pin in the pressure cylinder valve punctures the
metal sealing disk, and 4945 psig (nominal, at 20º C) of helium is released into the inflation
manifold to inflate both floats.

The manifold consists of hoses, fittings, and a check valve at each of the six float chambers
(per float). Each float chamber has a topping valve for manual inflation, and a pressure relief
valve to vent excess internal pressure.

A modified aux stabilizer improves controllability at high airspeeds with floats inflated.

32-61 Cylinder Assembly

Refer to R66 Illustrated Parts Catalog (IPC) Figure 32-7.

NOTE
Cylinders are discharged during float inflation check every 3
years. Cylinder hydrostatic test is required every 5 years.
Cylinder life-limit is 15 years from date of manufacture. To
ensure cylinder limitations are not overflown, returning to
service cylinders with more than 2 years since hydrostatic test
or 12 years since date of manufacture is not recommended.
WARNING
D679 Cylinder contents are under extreme pressure. Install
MT545-1 pin assembly in D757-1 valve assembly during
maintenance to prevent cylinder discharge.

SEP 2012 R66 Maintenance Manual Chapter 32 Landing Gear Page 32.11
FIGURE 32-5 POP-OUT FLOATS CYLINDER ASSEMBLY

Page 32.12 Chapter 32 Landing Gear R66 Maintenance Manual SEP 2012
32-61 Cylinder Assembly (continued)

A. Removal

1. Refer to Figure 32-5. Hinge right aft seat assembly forward. Install MT545-1 pin
assembly in D757-1 valve assembly.

2. Disconnect D674-9 hose assembly from valve fitting. Install MT546-1 diffuser on
valve fitting and special torque diffuser to 120 in.-lb. Cap hose to prevent foreign
object contamination.

3. Remove hardware securing D761-2 cover to valve and D761-1 support. Remove
cover.

4. Remove hardware securing D761-1 support to valve. Do not kink cable.

5. Cut and discard MS3367-4-9 ty-rap secured to D760-1 trigger. Disengage D676-2
cable assembly ball from trigger, but do not kink cable.

6. Remove screws securing D669-3 strap to D669-6 cradle assembly and remove strap.
Carefully remove cylinder.

B. Depressurization

CAUTION

Use appropriate eye and hearing protection. Do not service

cylinder assembly while cylinder is installed in helicopter.

1. Remove cylinder per Section 32-61 Part A. Verify MT545-1 pin assembly and
MT546-1 diffuser are properly installed.

2. Refer to Figure 32-5. Remove D760-7 cap (etched with “FILL PORT”) from valve
assembly. A loud pop may be heard when cap’s seal is broken.

3. In a well-ventilated area, slowly screw MT546-4 bleed fitting assembly into fill-port
until the noise of escaping gas is heard. Screw fitting in or out to adjust flow rate.
Finish bleeding cylinder with bleed fitting fully in. When noise ceases, verify cylinder
pressure gage indicates zero. Remove bleed fitting.

4. Install cap in valve assembly and special torque cap to 40 in.-lb.

5. Evaluate cylinder life and hydrostatic test status.

SEP 2012 R66 Maintenance Manual Chapter 32 Landing Gear Page 32.13
32-61 Cylinder Assembly (continued)

C. Filling

CAUTION

Use appropriate eye and hearing protection. Do not service

cylinder assembly while cylinder is installed in helicopter.
WARNING

ONLY cylinders labeled “DOT-E 10915-4945” may be refilled.

Cylinders labeled “DOT-E 10915-4500” must be returned to
RHC for exchange/upgrade.
WARNING

Verify D757-1 (gray) valve assembly is engraved with “D758-4”

or has a data plate indicating B900-8 modification.

Filling equipment (pumps, hoses, fittings, etc.) must be rated for 6000 psi minimum
working pressure and be in good condition.

Cylinder temperature and pressure must be kept within safe limits. Monitor pressure gage
and use thermocouple or other appropriate temperature probe to monitor temperature
on face of thermal relief fitting during fill. Do not allow temperature to exceed 50ºC
(122ºF) or pressure to exceed 5500 psig. If limits are approached, stop fill and allow
cylinder to cool and pressure to drop before continuing. Placing cylinder in a water bath
and using slow to moderate fill rates is recommended. If using water bath, keep water
level below valve assembly to avoid water contamination of valve.

1. Evaluate cylinder life and hydrostatic test status.

2. Refer to Figure 32-5. Install MT545-1 pin assembly in D757-1 valve assembly.
Install MT546-1 diffuser on valve fitting and special torque diffuser to 120 in.-lb.

3. Remove D760-7 cap (etched with “FILL PORT”) from valve assembly. A loud pop
may be heard when cap’s seal is broken.

4. Install MT546-2 adapter assembly into fill port and special torque adapter to 40 in.-
lb. Attach fill hose to adapter.

5. Fill with 99.98% minimum purity (industrial grade) helium per chart below:

Ambient Temperature (ºC) Pressure (psig)

-20 4268
-10 4437
0 4606
10 4776
20 4945
30 5114
40 5283

Page 32.14 Chapter 32 Landing Gear R66 Maintenance Manual SEP 2012
32-61 Cylinder Assembly (continued)

C. Filling (continued)

6. Allow cylinder and valve to cool to ambient temperature. Top off with helium to
compensate for any pressure loss due to cooling.

7. Remove fill hose and MT546-2 adapter assembly.

8. Remove & discard old o-ring from cap. Lightly coat new MS28778-2 o-ring with
A257-19 lubricant and install o-ring on fill-port cap at base of threads. Install cap in
valve assembly and special torque cap to 40 in.-lb.

D. Installation

WARNING

Verify D757-1 (gray) valve assembly is engraved with “D758-4”

or has a data plate indicating B900-8 modification.

1. Fill cylinder per Section 32-61 Part C, if not previously accomplished.

2. Refer to Figure 32-5. Install MT545-1 pin assembly in D757-1 valve assembly.
3. Hinge right aft seat assembly forward. Verify A701-5 (anti-chafe) tape protects
cylinder where cylinder base contacts cabin structure in three locations. Carefully
position cylinder in D669-6 cradle assembly.
4. Engage D676-2 cable assembly ball in D760-1 trigger; do not kink cable. Install
MS3367-4-9 ty-rap as shown. Cinch ty-rap until snug without over-tightening, and
trim tip flush with head. Install hardware securing D761-1 support to valve.
5. Verify cable housing protrudes through clamps on support flush-to-0.200 inch
maximum. Adjust as necessary.
6. Rotate cylinder as required to minimize cable bending and to ensure clearance with
cabin structure.
7. Verify D682-6 decal is in specified location. If decal location is incorrect, remove
old decal and install new decal on cylinder. Install screws securing D669-3 strap
to cradle assembly.
8. Install hardware securing D761-2 cover to valve and D761-1 support.
9. Remove MT546-1 diffuser, if installed. Connect D674-9 hose assembly to valve
fitting. Orient hose as required to maintain miminum 0.25 inch clearance to cylinder
and adjacent vertical panel. Special torque B-nut per Section 20-33 and torque
stripe per Figure 5-1.
10. Rig inflation lever and replace shear-rivet per Section 32-62.

SEP 2012 R66 Maintenance Manual Chapter 32 Landing Gear Page 32.15
FIGURE 32-6 POP-OUT FLOATS LEVER RIGGING AND SHEAR-RIVET REPLACEMENT

Page 32.16 Chapter 32 Landing Gear R66 Maintenance Manual SEP 2012
32-62 Lever Rigging and Shear-Rivet Replacement

Refer to R66 Illustrated Parts Catalog (IPC) Figure 32-9.

WARNING
D679 Cylinder contents are under extreme pressure. Install
MT545-1 pin assembly in D757-1 valve assembly during
maintenance to prevent cylinder discharge.
WARNING

Install MS20470A2-6-5 (or MS20470A2-6.5) annealed rivet in

lever assembly or rivet may be too hard to shear.

1. Install cylinder per Section 32-61 Part D, if not previously accomplished. Install MT545-1
pin assembly in D757-1 valve assembly.

2. Refer to Figure 32-6. With no shear-rivet installed, raise collective full up, push in and
rotate D680-1 lever assembly safety to READY position, squeeze lever to remove cable
slack, and verify 1.25 - 1.30 in. between tip of lever and collective stick as shown. As
required, reposition D676-2 cable assembly housing at lever to obtain dimension.

3. Push in and rotate lever safety to LOCKED position. Simultaneously squeeze lever and
verify no preload in cable thru full collective travel.

4. Refer to Figure 32-6. Insert MS20470A2-6-5 (or MS20470A2-6.5) rivet in lever as

shown. Using locking pliers or similar, flatten shop-head end of rivet to 0.080-0.100 in.

5. Verify lever safety is in LOCKED position. Remove MT545-1 pin assembly from D757-1
valve assembly.

SEP 2012 R66 Maintenance Manual Chapter 32 Landing Gear Page 32.17
FIGURE 32-7 POP-OUT FLOATS FLOAT INSTALLATION

Page 32.18 Chapter 32 Landing Gear R66 Maintenance Manual SEP 2012
32-63 Float Installation

Refer to R66 Illustrated Parts Catalog (IPC) Figure 32-11 and 32-17.

WARNING
D679 Cylinder contents are under extreme pressure. Install
MT545-1 pin assembly in D757-1 valve assembly during
maintenance to prevent cylinder discharge.

A. Removal

NOTE
Floats are subject to damage during removal. Remove floats if
necessary for repairs.

1. Refer to Figure 32-5. Hinge right aft seat assembly forward. Install MT545-1 pin
assembly in D757-1 valve assembly.

2. Disconnect D674-12 hose assembly from T-fitting near float. Cap fittings to prevent
foreign object contamination.

3. Refer to Figure 32-7. Detach float cover hook and loop tape inboard of skid and
loosen lacing.

4. Remove hardware securing float to skid tube, and skid extension.

5. Use care when removing C944 retainer strips from girts, and when separating girts
from skid tube and skid extension. Repeat steps for opposite float.

B. Installation

1. Refer to Figure 32-7. Verify (outboard) bolt heads securing struts to skids are
covered with B270-1 sealant. Apply additional sealant as required.
2. Position deflated float over skid tube and skid extension. Align holes in C944 retainer
strips, float covers, float girts, and skid and install hardware. Special torque nuts per
Section 20-33.

3. Inflate float with filtered, oil-free, dry air to 3.0 psig at topping valves.

4. Remove caps and connect D674-12 hose assembly to T-fitting near float. Special
torque hose B-nut per Section 20-33, apply B270-22 protectant to exposed aluminum
surfaces on hose B-nut and T-fitting, and torque stripe per Figure 5-1. Repeat steps
for opposite float.
5. Pack floats per Section 32-63 Part C.

SEP 2012 R66 Maintenance Manual Chapter 32 Landing Gear Page 32.19
FIGURE 32-8 POP-OUT FLOATS FLOAT PACKING

Page 32.20 Chapter 32 Landing Gear R66 Maintenance Manual SEP 2012
32-63 Float Installation (continued)
C. Packing
1. Install floats per § 32-63 Part B.
2. Spread deflated float outboard of skid tube. Vacuum as much air as possible
from each float chamber through topping valves. Smooth out wrinkles.
3. Lightly dust float and inside float cover with talcum powder.
4. Refer to Figure 32-7 and Figure 32-8 Detail A. At girt forward edges, fold float
perpendicular to skid tube; tuck material under and aft of float as shown.
5. Refer to Figure 32-8 Detail B. At girt aft edges, fold float perpendicular to skid
tube; lay material over and forward of float as shown.
6. Refer to Figure 32-8 Detail C. Loosen lacing cords securing float cover to inboard
girt. Detach, align, and secure inboard hook and loop fasteners.

NOTE
If possible, roll float into cover with the assistance of six or
seven people.

7. Refer to Figure 32-8 Detail D. Align hoses and valve cover flaps. Roll float from
outboard edge toward skid tube, as tightly as possible. Hold float on top of skid.
8. Apply A257-7 lubricant to mating surfaces of float cover and (outboard) girt
snaps. Button snaps, and secure hook and loop fasteners.
9. Refer to Figure 32-8 Detail E. Verify lacing cords are installed in cover grommets
in crossover (“ladder” lacing) method shown. Tighten cords starting at the aft
skid extension working forward: at each segment, pull cords tight or until material
edges join, but do not overtighten near valves. Tie cord ends in double square
knots (4 alternating overhand knots).
10. Refer to Figure 32-8 Detail F. Tuck-in cord ends and secure hook and loop
fasteners. Secure hook and loop fasteners at end caps.
11. Verify all fasteners are properly secured. Verify floats are rolled tight, with no
lumps or loose areas.

APR 2019 Chapter 32 Landing Gear Page 32.21

32-64 System Maintenance
A. Leak Check

WARNING
D679 Cylinder contents are under extreme pressure. Install
MT545-1 pin assembly in D757-1 valve assembly during
maintenance to prevent cylinder discharge.

1. Disconnect D674-9 hose assembly from presssure cylinder valve. Install

protective cap on cylinder valve fitting. Cover D674-9 hose fitting to prevent
contamination, but do not install an air-tight seal (D674-9 hose fitting must be
allowed to leak to verify check valve function at each float chamber).
2. Unfasten hook-and-loop fasteners along inboard sections of float cover to expose
lacing. Loosen, but do not remove, lacing.
3. Unfasten outboard sections of float cover and unroll float to expose valves.
4. Inflate floats with filtered, oil-free, dry air to 2.0 psig via topping valves.
5. Allow float air temperature to stabilize for 5 minutes minimum then record OAT
and pressure in each float chamber.
6. One to two hours after initial pressure check, again record OAT and pressure in
each float chamber. Allowable chamber pressure drop from initial measurement
is 0.2 psig adjusted for any temperature change. Pressure will change by 0.06
psig per degree C temperature change. For example, float chamber pressure will
decrease 0.6 psig if temperature drops 10 degrees C.
7. If leaks are detected, repair float with supplied repair kit and repeat steps 4, 5, &
6.
8. Connect D674-9 hose assembly to cylinder valve and torque per § 20-33.
9. Pack float per § 32-63 Part C.

NOTE
Annually apply A257-7 dry-film lubricant (see § 20-78) to float
cover snap mating surfaces.

Page 32.22 Chapter 32 Landing Gear APR 2019

32-64 System Maintenance (continued)

B. Inflation Check

WARNING
D679 Cylinder contents are under extreme pressure. Install
MT545-1 pin assembly in D757-1 valve assembly during
maintenance to prevent cylinder discharge.

1. Unsnap outboard edge of both float covers.

2. Remove locking pin from valve, move inflation lever safety to READY position, and
verify area around floats is clear.

3. Squeeze inflation lever to inflate floats. Approximately 20 pounds force will be

required due to the shear-rivet. Time for floats to attain full shape without wrinkles
should be three seconds or less.

CAUTION
Floats inflate rapidly and with a loud noise. Keep area clear
during inflation and inform all nearby personnel. Remove or
close all doors prior to inflation. Open doors interfere with float
inflation and may be damaged.

4. Allow float temperatures to stabilize for at least five minutes then record OAT and
pressure in each float chamber. Minimum allowable pressures are:

Minimum Pressure Minimum Pressure Minimum Pressure

OAT (degrees C) (psig) in Forward (psig) in Middle (psig) in Aft Two
Two Chambers Chamber Chambers

5-9 1.30 1.00 0.60

10-14 1.60 1.30 0.90

15-19 1.90 1.60 1.20

20-24 2.20 1.90 1.50

25-29 2.50 2.20 1.80

30-34 2.80 2.50 2.10

35-39 3.10 2.80 2.40

SEP 2012 R66 Maintenance Manual Chapter 32 Landing Gear Page 32.23
32-64 System Maintenance (continued)

B. Inflation Check (continued)

5. Disconnect D674-1 hose assembly from pressure cylinder valve immediately after
initial pressure check. Install protective cap on cylinder valve fitting. Cover D674-1
hose fitting to prevent contamination, but do not install an air tight seal (D674-1 hose
must be allowed to leak to verify check valve function at each float chamber).
6. Verify no rips or chafing on floats or covers.
7. One to two hours after initial pressure check, again record OAT and pressure in
each float chamber. Allowable chamber pressure drop from initial measurement is
0.20 psi adjusted for any temperature change. For example, float chamber pressure
will decrease 0.6 psig if temperature drops 10 degrees C.
8. If leaks are detected, repair float with supplied repair kit then perform leak check per
Section 32-64 Part A on repaired float chamber.
9. Connect D674-1 hose assembly to valve fitting. Orient line as required to maintain
minimum 0.25 inch clearance to cylinder and C390-5 panel. Torque B-nut per
Section 20-33 and torque stripe.
10. Pack floats per Section 32-63 Part C.

NOTE
Annually apply A257-7 dry-film lubricant (see Section 20-78) to
float cover snap mating surfaces.

11. Remove cylinder assembly and depressurize cylinder per Section 32-61 Parts A &
B. Return cylinder to RHC for overhaul-exchange.
12. Install serviceable cylinder assembly per Section 32-61 Part D.

Page 32.24 Chapter 32 Landing Gear R66 Maintenance Manual SEP 2012
CHAPTER 33

LIGHTS
Section Title Page

33-00 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.1

33-10 Exterior Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.1
33-11 Strobe Light(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.1
33-12 Navigation Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.2
33-13 Landing Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.3
33-20 Interior Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.3
33-21 Panel Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.3

MAY 2015 Chapter 33 Lights Page 33.i

Intentionally Blank

Page 33.ii Chapter 33 Lights MAY 2015

CHAPTER 33

LIGHTS

33-00 Description

A red anti-collision light is installed on the tailcone and is controlled by the strobe switch.
Position lights are installed on each side of the cabin and in the tail and are controlled by the
nav lights switch. A light at the top of the windshield and post lights illuminate the instrument
panel. Panel 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 with high and low settings. The map light may be used for emergency
lighting of the instrument panel. An additional cabin light with an adjacent switch is located
just aft of the map light. The map and cabin lights are not connected to the dimmer circuit.

Two long-life, high intensity discharge (HID) landing lights are installed in the nose. One
wide-angle and one narrow-beam light are used to increase lighted area. One landing light
switch controls both lights and is located on the cyclic center post.

NOTE

Continuous operation of landing and position lights in flight is

recommended to promote collision avoidance.

An optional flashing light may be mounted on the tailcone in addition to the standard anti-
collision light. On earlier aircraft, the optional light is controlled by an additional position on
the strobe switch. On later aircraft, the optional light is controlled by a separate switch.

33-10 Exterior Lights

33-11 Strobe Light(s)

A. Removal

1. Turn battery switch off. Pull out STROBE circuit breaker (5 amp, or 7½ amp if
forward strobe is installed) at panel.

2. Remove hardware securing A708 strobe light assembly's retainer, lens, and gasket
to light assembly.

3. Remove hardware securing light assembly to tailcone mount.

4. Remove hardware securing ground wire, if ground is installed at mount. Disconnect

light assembly harness from airframe harness and remove light assembly.

MAY 2015 Chapter 33 Lights Page 33.1

33-11 Strobe Light(s) (continued)

B. Installation

1. Turn battery switch off. Pull out STROBE circuit breaker (5 amp, or 7½ amp if
forward strobe is installed) at panel.

2. Install hardware securing A708 strobe light assembly's ground wire to tailcone
mount, if ground is installed at mount. Connect light assembly's harness to airframe
harness at connectors.

3. Install hardware securing light assembly to tailcone mount (white forward strobe:
two missing columns of LEDs facing forward). Verify security.

4. Install hardware securing light assembly's gasket, lens, and retainer to light
assembly. Verify security.

5. Push in STROBE circuit breaker (5 amp, or 7½ amp if forward strobe is installed)

at panel. Turn battery switch and strobe switch(es) on and verify function. Turn
battery switch off.

33-12 Navigation Lights

A. Removal

1. Turn battery switch off. Pull out LTS circuit breaker (5 amp) at panel.

2. a. Position Lights: Remove screw securing retainer, lens, 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
connector.

b. Tail Light: Remove screws securing retainer, lens, gasket, and light assembly to
stabilizer mount. Pull out light assembly and disconnect light assembly harness
from airframe harness at connector.

B. Installation

1. Turn battery switch off. Pull out LTS circuit breaker (5 amp) at panel.

2. a. Position Lights: Connect light assembly harness to airframe harness at connector.

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 screw
securing retainer, lens, and gasket to light assembly. Verify security.

b. Tail Light: Connect light assembly harness to airframe harness at connector.

Install screws securing retainer, lens, gasket, and light assembly to stabilizer
mount. Verify security.

3. Push in LTS circuit breaker (5 amp) at panel. Turn battery switch and LTS switch
on and verify function. Turn battery switch and LTS switch off.

Page 33.2 Chapter 33 Lights MAY 2015

33-13 Landing Lights

A. Removal

1. Turn battery switch off. Pull out LAND LT circuit breaker (7½ amp) at panel.

2. Remove screws securing C526-1 retainer to chin and remove retainer.

3. Disconnect landing light cable from lamp and remove lamp.

B. Installation

1. Turn battery switch off. Pull out LAND LT circuit breaker (7½ amp) at panel.

NOTE

B557-1 (spot) landing light is installed in LH location and B557-

2 (flood) taxi light is installed in RH location.

2. Connect landing light cable to landing light.

3. Install screws securing C526-1 retainer to chin.

4. Push in LAND LT circuit breaker (7½ amp) at panel. Turn battery switch and
landing light switch on (cyclic center post) and verify function. Turn battery switch
and landing light switch off.

33-20 Interior Lights

33-21 Panel Light

A. LED Assembly Replacement

1. Turn battery switch off. Pull out LTS circuit breaker (5 amp) at panel.

2. Remove hardware securing G196 light assembly to windshield stiffener. Remove

two cap screws securing cover and LED assembly to housing. Disconnect LED
assembly wires from airframe harness and remove LED assembly.

3. Connect F090-2289 (white) airframe harness wire to new LED assembly red wire,
and F090-2290 airframe harness wire to LED assembly black wire. Install cover
(chamfer facing away from housing) and install two cap screws. Install hardware
securing G196 light assembly to windshield stiffener. Verify security.

4. Push in LTS circuit breaker (5 amp) at panel. Turn battery switch and LTS switch
on and verify function. Verify dimming knob adjusts brightness. Turn battery
switch and LTS switch off.

MAY 2015 Chapter 33 Lights Page 33.3

Intentionally Blank

Page 33.4 Chapter 33 Lights MAY 2015

CHAPTER 52

DOORS AND WINDOWS

Section Title Page

52-00 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52.1

52-10 Door Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52.1
52-11 Door Lock Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52.4
52-12 Weather Seal (Door Assembly) Replacement . . . . . . . . . . . . . . . . . . . . 52.4
52-13 Gas Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52.7
52-20 Door Vent Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52.7
52-21 Weather Seal (Door Vent) Replacement . . . . . . . . . . . . . . . . . . . . . . . . 52.7
52-22 Door Vent Hinge Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52.8
52-23 Pivot Friction Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52.8
52-30 Windshield Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52.11
52-31 Standard (Acrylic) Windshield Installation . . . . . . . . . . . . . . . . . . . . . . . . 52.11
52-32 Impact-Resistant (Polycarbonate) Windshield Installation . . . . . . . . . . . . 52.14

JUL 2020 Chapter 52 Doors and Windows Page 52.i

Intentionally Blank

Page 52.ii Chapter 52 Doors and Windows JUL 2020

CHAPTER 52

DOORS AND WINDOWS

52-00 Description
The R66 has four passenger doors and one main baggage compartment door. All four
cabin doors may be removed and installed by maintenance personnel or pilots.
Passenger doors are constructed of fiberglass and thermoplastics. Passenger doors, locks,
weather seal, gas springs, and door vents and hinges may be replaced, and vent pivot
friction may be adjusted.
Two windshield halves are retained in aluminum frames and an aluminum tubular bow
oriented vertically along the helicopter’s centerline. A standard (acrylic) windshield
installation and an impact-resistant (polycarbonate) windshield installation are available.
Refer to § 52-30 for detailed description.

52-10 Door Assembly

A. Cleaning
Refer to § 20-10 Part B for cleaning windows.
B. Removal
1. Refer to Figures 52-1 and 52-2. To disconnect door from gas spring mechanism:
a. Forward Doors: Pull D573-4 rod up and off of arm assembly ball joint.
b. Aft Doors: Insert flat-tip screwdriver and pry up spring clip locking C394-1
gas spring to channel ball joint. Pull gas spring up and off of ball joint.
2. Remove rings from door hinge pins, lift pins up from door frame hinge assemblies,
and remove door.
3. Adjust weight and balance per R66 Pilot’s Operating Handbook Section 6.
C. Installation

WARNING
Failure to install a ring in each door's two hinge pins may allow
door to depart aircraft in flight.

1. Refer to Figures 52-1 and 52-2. Align and insert door hinge pins in door frame
hinge assemblies.
2. Align forward door D573-4 rod with arm assembly ball joint, or aft door C394-1
gas spring with channel ball joint, and push down to lock.
3. Install rings in door hinge pins.
4. Adjust weight and balance per R66 Pilot’s Operating Handbook Section 6.

JUL 2020 Chapter 52 Doors and Windows Page 52.1

FIGURE 52-1 DOOR ASSEMBLY

Page 52.2 Chapter 52 Doors and Windows JUL 2020

52-10 Door Assembly (continued)
D. Replacement

CAUTION
Use proper respiratory protection when handling fiberglass.
CAUTION
Protect door windows and paint from scratches or scuff marks
when door maintenance is performed on workbench.

1. Refer to Figure 52-1. As required, lay masking tape on surfaces of door frame,
new door hinges, and new door, to mark with soft pencil.
2. Press new door forward and top edge weather seals against door frame recess (rain
gutter interferes with top edge until trimmed).
3. Using soft pencil, trace door forward edge onto masked frame, then transfer
approximate edge distance to door. From inside cabin, estimate approximate
material to be removed from door top edge, then transfer approximate edge distance
to door. Remove door.
4. Using 60-grit grinder, trim forward and top door edges. Perform steps 1 thru 3
until weather seals sit approximately even against door frame recess.
5. Using soft pencil and a straight edge, draw cross hairs through (centers of) door
upper hinge assembly pre-drilled holes. Hold fitted door against frame, insert new
(door-mounted) hinge assembly in frame-mounted hinge assembly, and transfer
cross hairs onto hinge. Remove hinge and door.
6. Drill two 0.170-inch diameter holes at cross hair intersections in hinge assembly
and deburr. Remove tape, clean up debris, and prepare hinge assembly and door
clamping surfaces using approved solvents per § 20-70.
7. Install upper hinge assembly on door and special torque screws per § 20-33.
8. Repeat steps 5 thru 7 for lower door-mounted hinge assembly.
9. Install door. Using 60-grit grinder, trim edges as required for final fitting. Verify
doors open and close smoothly and latch correctly. Remove door and bevel edges
using 60-grit sandpaper.
10. Prepare surfaces with solvent and touch-up door using approved materials per §
20-70. Install new door per § 52-10.

JUL 2020 Chapter 52 Doors and Windows Page 52.3

52-11 Door Lock Replacement

CAUTION
Protect door windows and paint from scratches or scuff marks
when door maintenance is performed on workbench.

1. Remove door per § 52-10.

2. Refer to Figure 52-1. Remove hole plug opposite key slot on door interior.
3. Remove screw, bent cam, and 90° rotation washer. Remove nut and A538-1 washer.
Press and catch cylinder lock and ring through door.
4. Install new cylinder lock and ring in door. Install lock so key is vertical with teeth
down in locked position. Apply thin coat B270-10 adhesive on screw threads, install
hardware, and tighten screw.
5. Bond hole plug in place using B270-9 adhesive.

52-12 Weather Seal (Door Assembly) Replacement

1. Remove damaged weather seal using plastic wedge or putty knife. Remove hardened
adhesive using approved solvent per § 20-70, or 60-grit sandpaper, as required.
2. Refer to Figure 52-1. Measure and trim continuous length of A226-2 seal to fit
perimeter of door except forward side, as shown. Neatly bond seal to stiffener using
B270-18 adhesive. Wipe away excess adhesive prior to curing.
3. Measure and trim length of A226-6 seal to fit forward side of door. Remove self-
adhesive preserving strip and neatly bond seal to stiffener.

Page 52.4 Chapter 52 Doors and Windows JUL 2020

Intentionally Blank

25 OCT 2010 R66 Maintenance Manual Chapter 52 Doors and Windows Page 52.5
FIGURE 52-2 GAS SPRINGS AND DOOR VENTS

Page 52.6 Chapter 52 Doors and Windows R66 Maintenance Manual 25 OCT 2010
52-13 Gas Springs
Refer to R66 Illustrated Parts Catalog (IPC) Figures 52-5 and 52-11.
A. Removal
1. a. Forward Doors: Insert flat-tip screwdriver and pry down on caps to unlock D575-
1 gas spring from ball joints. Push gas spring down and off of ball joints.
b. Aft Doors: Insert flat-tip screwdriver and pry up spring clips to unlock C394-1
gas spring from ball joints. Pull gas spring up and off of ball joints.
B. Installation
1. a. Forward Doors: Unlock D575-1 gas spring caps. Snap gas spring onto ball joints
and lock caps.
b. Aft Doors: Insert flat-tip screwdriver and pry up C394-1 gas spring spring clips.
Snap gas spring onto ball joints and release clips.
52-20 Door Vent Replacement
Refer to R66 Illustrated Parts Catalog (IPC) Figures 52-1 and 52-7.

CAUTION
Use proper respiratory protection when handling fiberglass.
1. Refer to Figure 52-2. Drill out rivets securing hinge and pivot arm assembly angle to door
vent. Rotate knob to unlock and remove door vent.
2. Using 60-grit grinder, trim new vent door forward edge as required to match door recess
and smooth corners. Bevel edges using 60-grit sandpaper.
3. Hold fitted door vent in recess and match drill hinge four 0.098-inch diameter holes. Smooth
hole edges; clean up debris. Prepare surfaces for clamping using approved solvents per
Section 20-70. Install rivets securing door to hinge.
4. Extend pivot arm to approximately 1.85 inch between center of pins. Match drill pivot
arm assembly angle two 0.098-inch diameter holes. Smooth hole edges; clean up debris.
Prepare surfaces for clamping using approved solvents per Section 20-70. Install rivets
securing door to arm assembly angle. Verify vent door opens and closes smoothly and
latches correctly.
52-21 Weather Seal (Door Vent) Replacement
Refer to R66 Illustrated Parts Catalog (IPC) Figures 52-1 and 52-7.
1. Remove damaged weather seal using plastic wedge or putty knife. Remove hardened
adhesive using approved solvent per Section 20-70, or 60-grit sandpaper, as required.
2. Refer to Figure 52-2. Measure and trim continuous length of A226-7 seal to fit perimeter
of vent door except forward side, as shown. Remove self-adhesive preserving strip and
neatly bond seal to stiffener.
3. Measure and trim length of A226-3 seal to fit ledge of barrier. Remove self-adhesive
preserving strip and neatly bond seal to stiffener.

25 OCT 2010 R66 Maintenance Manual Chapter 52 Doors and Windows Page 52.7
52-22 Door Vent Hinge Replacement

Refer to R66 Illustrated Parts Catalog (IPC) Figures 52-1 and 52-7.

CAUTION

Protect door windows and paint from scratches or scuff marks

when door maintenance performed on workbench.

1. Remove door per Section 52-10.

2. Refer to Figure 52-2. Drill out rivets securing hinge to door assembly and door vent.
Remove hinge.

3. Smooth hole edges; clean up debris. Prepare surfaces for clamping using approved
solvents per Section 20-70.

4. Refer to Section 52-20. Verify proper vent door fit; install rivets securing hinge to door
assembly and door vent. Prepare surfaces and touch-up rivet heads and hinge using
approved materials per Section 20-70.

52-23 Pivot Friction Adjustment

To increase pivot arm assembly friction, tighten nut securing pivot knob to arms. Do not
overtighten screw. No thread exposure required beyond nut.

Page 52.8 Chapter 52 Doors and Windows R66 Maintenance Manual 25 OCT 2010
Intentionally Blank

JUL 2020 Chapter 52 Doors and Windows Page 52.9

FIGURE 52-3 WINDSHIELD INSPECTION (ACRYLIC WINDSHIELD SHOWN)

Page 52.10 Chapter 52 Doors and Windows JUL 2020

52-30 Windshield Installation

52-31 Standard (Acrylic) Windshield Installation

A. Description
Acrylic windshields are sandwiched between thin aluminum retainers that are
screwed to the door and windshield frames. An adhesive/sealant is applied between
the retainers and the windshields for security and weatherproofing.
B. Cleaning
Refer to § 20-10 Part B for cleaning windshield.
C. Inspection
Inspect both windshields for cracks and crazing adjacent to retainers per Figure
52‑3. If cracks exceed these limits, replace damaged windshield per § 52-31 Part F.
Minor defects or imperfections that do not impair pilot visibility or indicate impending
structural failure are acceptable.
D. Removal
1. Remove forward door assembly per § 52-10 Part B. Remove hardware securing
C228-4 (upper) hinge assembly to door frame and remove hinge.

NOTE
If windshield is to be reinstalled, prior to removal, tape protective
paper or film to the inside and outside of the windshield to
prevent damage.

2. Remove hardware securing C238-27 or C238-28 (side) retainer to door frame

and remove retainer.
3. Install upper hinge assembly, and install door assemblies for cabin structure
support with windshield removed.
4. Support windshield. With a second person inside cabin to remove nuts, latch
forward doors. Remove hardware securing F238-4 (upper) retainer, B409-
5 gusset, D805-2 restraint, C366-5 bracket, C366-8 retainer, F367 (lower)
retainers, B295-1 clip with trim string, F367-12 stiffener, and F367-10 (center)
retainer to cabin and remove parts. Remove windshield.
5. Remove sealant from cabin and parts.
6. If windshield is to be reinstalled, remove sealant from windshield.
7. Repeat steps to remove opposite-side windshield, as required.

JUL 2020 Chapter 52 Doors and Windows Page 52.11

52-31 Standard (Acrylic) Windshield Installation (continued)
E. Installation

NOTE
Prior to installation, if not previously accomplished, tape
protective paper or film to the inside and outside of the
windshield to prevent damage.

1. Verify sealant has been removed from cabin, parts, and windshield.
2. Position windshield on helicopter and cleco retainers to frames.
3. Attach 1/2”-wide masking tape to windshield along edge of retainers to catch
sealant squeeze-out during retainer installation.
4. Remove C238-27 or C238-28 (side) retainer and install C228-4 (upper) door
hinge assembly. Install forward door assemblies for cabin structure support
during windshield installation.
5. Remove F367-10 (center) retainer. Run a bead of B270-26 sealant along entire
edge of tape line. Install hardware securing center retainer, F367-12 stiffener,
and B295-1 clip with trim string to cabin. Special torque screws per § 20-33.
Remove tape and wipe off excess sealant with cheesecloth wet with lacolene.
6. Remove F367 (lower) retainers. Run a bead of B270-26 sealant along entire edge
of tape line. With a second person inside cabin to tighten nuts, latch forward
doors. Install hardware securing lower retainers, C366-8 retainer, and C366-5
bracket to cabin. Remove tape and wipe off excess sealant with cheesecloth wet
with lacolene.
7. Remove F238-4 (upper) retainer. Run a bead of B270-26 sealant along entire
edge of tape line. With a second person inside cabin to tighten nuts, latch forward
doors. Install hardware securing upper retainer and B409-5 gusset to cabin.
Remove tape and wipe off excess sealant with cheesecloth wet with lacolene.
8. Remove door and hinge assembly. Run a bead of B270-26 sealant along entire edge
of tape line. Install hardware securing side retainer and D805-2 restraint to cabin.
Remove tape and wipe off excess sealant with cheesecloth wet with lacolene.
9. Reinstall hinge assembly, and install door assembly per § 52-10 Part C.
10. Ensure all fasteners are tight. Wipe off excess sealant with cheesecloth wet with
lacolene.
11. Allow sealant to dry according to manufacturer’s instruction.
12. Remove protective paper or film from inside and outside of the windshield.
13. Repeat steps to install opposite-side windshield, as required.

Page 52.12 Chapter 52 Doors and Windows JUL 2020

52-31 Standard (Acrylic) Windshield Installation (continued)
F. Replacement

NOTE
Prior to installation, if not previously accomplished, tape
protective paper or film to the inside and outside of the
windshield to prevent damage.

1. Verify sealant has been removed from cabin and parts.

2. Cleco retainers to frames, checking for proper alignment. Remove retainers,
except C238-27 or C238-28 (side) retainer.
3. Install C228-4 (upper) door hinge assembly, and install forward door assemblies
for cabin structure support during windshield installation.
4. Lay out masking tape on frames to identify location for windshield edge (estimate
edge where side retainer is clecoed to frame). Hold oversized windshield in place
by hand and verify it overlaps masking tape on all frames and retainer. When
satisfied with alignment, lay out masking tape on windshield for trimming.

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

5. A band saw with a blade containing at least 24 teeth per inch is recommended
for initial trimming. Tape cardboard to band saw table to prevent scratching
of windshield. Trim windshield carefully to prevent binding of saw blade and
cracking windshield. Finish initial cut using an orbital sander, as required.
6. Hold windshield in place and check for fit. Re-trim as necessary.
7. After windshield is fitted, use sanding block with 100-grit paper to smooth edges.
Finish edge and bevel corners using a triangular machinist’s scraping tool. Verify
all edges are clean and free of notches.
8. Remove trimming debris from windshield and cabin.
9. Install windshield per § 52-31 Part E.

JUL 2020 Chapter 52 Doors and Windows Page 52.13

52-32 Impact-Resistant (Polycarbonate) Windshield Installation
A. Description
The polycarbonate windshield installation is similar to the acrylic windshield installation,
but the windshields fasten to the door and windshield frames via small stainless steel
straps. If a wire strike provisions kit is installed, a different stainless steel strap
configuration secures the polycarbonate windshields to a strengthened bow.
While polycarbonate has superior strength and flexibility properties when compared
with acrylic, it is also more susceptible to ultraviolet (UV) degradation, and has a low
scratch resistance. A hardcoat is applied during manufacturing to protect against
UV damage and scratching, however, further effort must be made by the operator to
to maximize windshield service life. Follow instructions closely to avoid scratching
windshield during cleaning (refer to § 20-10 Part B). Exposure to incompatible
cleaning agents or solvents can result in embrittlement or crazing. Use a cabin cover
when parking helicopter outdoors, or store helicopter in hanger when possible.
B. Cleaning
Refer to § 20-10 Part B for cleaning windshield.
C. Inspection
Inspect both windshields for cracks and crazing adjacent to retainers per Figure 52‑3.
Also inspect areas adjacent to fasteners and stainless steel straps for cracks and
crazing. If cracks exceed these limits, replace damaged windshield per § 52-31 Part F.
Inspect windshields for any significant discoloration or cloudiness. Minor defects or
imperfections that do not impair pilot visibility or indicate impending structural failure
are acceptable.
D. Removal
1. Perform § 52-31 Part D steps 1 thru 3.
2. Support windshield. With a second person inside cabin to remove nuts and
washers, latch forward doors. Remove hardware securing G367 ties and straps
to windshield near center bow (all other hardware installed in windshield may
remain in place during windshield removal).
3. Remove hardware securing F238-4 (upper) retainer, B409-5 gusset, D805-2
restraint, C366-5 bracket, C366-8 retainer, F367 (lower) retainers, B295-1 clip
with trim string, F367-12 stiffener (or G933-2 bow assembly), and F367-10
retainer (or G935-2 retainer) to cabin and remove parts. Remove windshield.
4. Remove sealant from cabin and parts.
5. If windshield is to be reinstalled, remove sealant from windshield but leave
hardware and G367 ties, straps, pads, and tabs installed. If replacing windshield,
remove hardware and G367 ties, straps, pads, and tabs, as required.
6. Repeat steps to remove opposite-side windshield, as required.

Page 52.14 Chapter 52 Doors and Windows JUL 2020

52-32 Impact-Resistant (Polycarbonate) Windshield Installation (continued)
E. Installation

NOTE
Prior to installation, if not previously accomplished, tape
protective paper or film to the inside and outside of the
windshield to prevent damage.
NOTE
Inspect condition of G367 ties, straps, pads, and tabs to be
installed. Verify no obvious damage, deformation, or stretching.
If windshield is being replaced due to bird strike or other impact
which could deform ties, straps, pads, or tabs, replacement of
these items is recommended.
NOTE
Refer to R66 Illustrated Parts Catalog Chapter 52. Note location
of G367 ties, straps, pads, and tabs on work table or by marking
on tape at fasteners to facilitate installation.

1. Verify sealant has been removed from cabin, parts, and windshield.
2. Position windshield on helicopter and cleco G367 ties, straps, tabs, and retainers
to frames. Also, cleco G367 ties, straps, and tabs to windshield at center bow,
if drilled.
3. Install C228-4 (upper) door hinge assembly. Install forward door assemblies for
cabin structure support during windshield installation.
4. If windshield is drilled and has hardware, G367 ties, straps, pads, and tabs installed:
a. With a second person inside cabin to tighten nuts, latch forward doors.
Remove clecoes and install hardware securing G367 ties and straps to
windshield at center bow; special torque screws per § 20-33.
b. Attach 1/2”-wide masking tape to windshield along edge of retainers to
catch sealant squeeze-out during retainer installation.
c. Remove F367-10 (center) retainer (or G935-2 retainer). Run a bead of
B270‑26 sealant along entire edge of tape line. Install hardware securing
center retainer, F367-12 stiffener (or G933-2 bow assembly), and B295-1
clip with trim string to cabin; special torque screws per § 20-33. Remove
tape and wipe off excess sealant with cheesecloth wet with lacolene.
d. Perform § 52-31 Part E steps 6 thru 13.

JUL 2020 Chapter 52 Doors and Windows Page 52.15

52-32 Impact-Resistant (Polycarbonate) Windshield Installation (continued)
E. Installation (continued)
5. Align G367 ties and straps perpendicular to retainers within 2°. Install F367‑12
stiffener (or G933-2 bow assembly) and special torque screws per § 20-33.
Match drill #40 pilot holes through windshield and install clecos.
6. At center bow:
a. Remove F367‑12 stiffener (or G933-2 bow assembly) and F367-10 (center)
retainer (or G935-2 retainer). Remove G367 ties and straps and expand
pilot holes to 0.169–0.175 inch diameter holes thru windshield. Finish holes
with reamer; deburr back side of holes using plastic razor. Clean up debris.
b. Apply B270-26 sealant to G367 tabs and pads and position on windshield. Run
a bead of B270-26 sealant along entire edge of windshield. Install hardware
securing center retainer, F367-12 stiffener (or G933-2 bow assembly), and
B295-1 clip with trim string to cabin. Special torque screws per § 20-33.
c. With a second person inside cabin to tighten nuts, latch forward doors and install
hardware securing G367 ties and straps to windshield; special torque screws
per § 20-33. Wipe off excess sealant with cheesecloth wet with lacolene.
7. At lower retainers:
a. Remove F367 (lower) retainers. Remove G367 straps and expand pilot
holes to 0.169–0.175 inch diameter holes thru windshield. Finish holes
with reamer; deburr back side of holes using plastic razor. Clean up debris.
b. Apply B270-26 sealant to G367-12 tabs and position on windshield. Run
a bead of B270-26 sealant along entire edge of windshield. With a second
person inside cabin to tighten nuts, latch forward doors, and install hardware
securing lower retainers, C366-8 retainer, and C366-5 bracket to cabin.
Install hardware securing G367 straps to windshield; special torque screws
per § 20-33. Wipe off excess sealant with cheesecloth wet with lacolene.
8. At upper retainer:
a. Remove F238-4 (upper) retainer. Remove G367 straps and expand pilot
holes to 0.169–0.175 inch diameter holes thru windshield. Finish holes
with reamer; deburr back side of holes using plastic razor. Clean up debris.
b. Run a bead of B270-26 sealant along entire edge of windshield. With a
second person inside cabin to tighten nuts, latch forward doors, and install
hardware securing upper retainer and B409-5 gusset to cabin. Install
hardware securing G367 straps and ties to windshield; special torque screws
per § 20-33. Wipe off excess sealant with cheesecloth wet with lacolene.

Page 52.16 Chapter 52 Doors and Windows JUL 2020

52-32 Impact-Resistant (Polycarbonate) Windshield Installation (continued)
E. Installation (continued)
9. At door frame:
a. Remove door and hinge assembly. Remove G367 straps and expand pilot
holes to 0.169–0.175 inch diameter holes thru windshield. Finish holes
with reamer; deburr back side of holes using plastic razor. Clean up debris.
b. Run a bead of B270-26 sealant along entire edge of windshield. Install hardware
securing side retainer and D805-2 restraint to cabin. Install hardware securing
G367 straps and ties to windshield; special torque screws per § 20-33. Wipe
off excess sealant with cheesecloth wet with lacolene.
10. Reinstall hinge assembly, and install door assembly per § 52-10 Part C.
11. Ensure all fasteners are tight. Wipe off excess sealant with cheesecloth wet with
lacolene.
12. Allow sealant to dry according to manufacturer’s instruction.
13. Remove protective paper or film from inside and outside of the windshield.
14. Repeat steps to install opposite-side windshield, as required.
F. Replacement
1. Perform § 52-31 Part F steps 1 thru 4.

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

2. A band saw with 20°–30° clearance angle, 0–5° rake angle, 600–1000 m/min
rotation speed, and 1.5–4 mm tooth spacing is recommended for initial trimming.
Tape cardboard to band saw table to prevent scratching of windshield. Trim
windshield carefully to prevent binding of saw blade and cracking windshield.
Finish initial cut using an orbital sander, as required.
3. Hold windshield in place and check for fit. Re-trim as necessary.
4. After windshield is fitted, use sanding block with 100-grit paper to smooth edges.
Verify all edges are clean and free of notches.
5. Remove trimming debris from windshield and cabin.
6. Install windshield per § 52-32 Part E.

JUL 2020 Chapter 52 Doors and Windows Page 52.17

Intentionally Blank

Page 52.18 Chapter 52 Doors and Windows JUL 2020

CHAPTER 53

FUSELAGE

Section Title Page

53-00 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53.1

53-10 Cabin Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53.1
53-11 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53.1
53-20 Fairings, Cowlings, and Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53.3
53-21 Engine Cowling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53.3
53-22 Mast Fairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53.3
53-23 Tailcone Cowling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53.4
53-24 Access and Inspection Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53.4
53-30 Frame Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53.5
53-31 Lower Frames . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53.5
53-32 Hydraulic Servo Support Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53.9
53-33 Upper Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53.10
53-40 Tailcone Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53.13
53-41 Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53.15
53-50 Empennage Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53.17
53-51 Vertical Stabilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53.18
53-52 Horizontal Stabilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53.19
53-53 Tail Rotor Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53.21
53-54 Tail Skid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53.22

APR 2017 Chapter 53 Fuselage Page 53.i

Intentionally Blank

Page 53.ii Chapter 53 Fuselage APR 2017

CHAPTER 53

FUSELAGE

53-00 Description

The R66 is a five-place, single main rotor, single engine helicopter constructed primarily of
metal and equipped with skid type landing gear.

The primary fuselage structure is welded steel tubing and riveted aluminum sheet. The tailcone
is a monocoque structure in which aluminum skins carry most primary loads. Fiberglass and
thermoplastics are used in secondary cabin structure and in various ducts and fairings.

Several cowl doors provide access to the drive system, engine, engine oil tank, fuel filler cap,
and fuel sump drain. A right-side door provides access to the main baggage compartment.
Removable panels and cowlings allow additional access to controls and other components for
maintenance.

The instrument console hinges up and aft for instrument and avionics access. The battery is
installed behind an access panel under the left front seat, or in the main baggage compartment,
depending on aircraft configuration.

The engine is located aft of the main baggage compartment. The engine compartment is
isolated from the rest of the airframe by stainless steel firewalls in front of and above the
engine.

53-10 Cabin Assembly

The cabin assembly is a non-field-replaceable assembly.

53-11 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 sheet.

3. To preserve crashworthiness, seat assembly maintenance is limited to replacement

only.

25 OCT 2010 R66 Maintenance Manual Chapter 53 Fuselage Page 53.1

FIGURE 53-1 FAIRING, COWLINGS, AND PANELS

Page 53.2 Chapter 53 Fuselage R66 Maintenance Manual 25 OCT 2010

53-20 Fairing, Cowlings, and Panels

CAUTION
Mast fairing, cowlings, and panels must be installed for flight.

53-21 Engine Cowling

A. Removal
1. Refer to Figure 53-1. Open G040-1 engine cowling assembly right and left doors.
2. Loosen clamp securing starter-generator hose to air inlet. Slide hose off of inlet.
3. Remove screws securing cowling to fuselage, unfasten cowling doors, and
remove cowling.
B. Installation
1. Refer to Figure 53-1. Position G040-1 engine cowling assembly on helicopter,
fasten cowling doors, and install screws securing cowling to fuselage.
2. Slide starter-generator hose onto air inlet and tighten clamp. Close right and left
doors.
3. Ensure G039 ring is centered on exhaust weldment within 0.1 inch. Remove and
reinstall/replace ring as required.

53-22 Mast Fairing

A. Opening and Closing
1. Refer to Figure 53-1. Remove right-side screws securing F261-1 mast fairing
assembly at aft, vertical seam.
2. Remove right-side screws securing fairing to ribs. Keep fairing from springing
open and minimize strain on nutplates by holding fairing closed until all right-side
screws are removed. Slowly open fairing.
3. Hold fairing closed. Install right-side screws securing fairing to ribs, and screws
securing fairing at aft, vertical seam.
B. Removal
1. Open mast fairing assembly per § 53-22 Part A.
2. Disconnect (pitot system) 15-4-N-O union near G201-1 (servo support) frame
assembly. Cap fitting and plug line.
3. Remove remaining screws securing fairing to ribs and remove fairing.

APR 2019 Chapter 53 Fuselage Page 53.3

53-22 Mast Fairing (continued)
C. Installation
1. Refer to Figure 53-1. Install left-side screws securing F261-1 mast fairing
assembly to ribs.
2. Remove cap and plug and connect (pitot system) 15-4-N-O union near G201-1
(servo support) frame assembly.
3. Hold fairing closed. Install right-side screws securing fairing to ribs, and screws
securing fairing at aft, vertical seam.
4. Perform pitot line leak test per § 95-10.

53-23 Tailcone Cowling

A. Removal and Installation
1. Refer to Figure 53-1. Thru left access door, disconnect ELT antenna lead from
antenna mounted to F706-1 tailcone cowling assembly, as required.
2. Remove screws securing cowling to fuselage and remove cowling.
3. Reinstall cowling and install screws securing cowling to fuselage.
4. Connect ELT antenna lead to cowling thru left access door, as required.

53-24 Access and Inspection Panels

Refer to § 6-70 for access and inspection panel location and illustration.

Page 53.4 Chapter 53 Fuselage APR 2019

53-30 Frame Assemblies

NOTE
See § 54-40 for F237-1 tailcone attachment frame weldment
replacement.
WARNING
R66 welded steel tube frames are stress relieved. Field weld
repairs are not allowed; send frames to RHC for repair.

53-31 Lower Frames

A. Removal
1. Remove engine per § 71-10.
2. Refer to Figure 53-2.
a. F046-1 (LH) only: Remove hardware securing power turbine governor
control cable clamps, F723-3 line assembly clamp, and firewall clamp to
F046-1 lower frame.
b. F046-2 (RH) only: Remove hardware securing battery cable harness clamp,
external power block, and firewall clamp to F046-2 lower frame.
3. Remove hardware securing clamps to firewall securing F049-03 harness assembly,
as required. Cut and discard ty-raps as required, mark wires, and disconnect
wires at plastic connectors to liberate frame.
4. Using plastic scraper, remove sealant around frame weldment(s) at firewalls.
5. Support tailcone (until frames are reinstalled).
a. F046-1 (LH) only: Remove hardware securing frame to F574-5 block (access
bolt thru G246-1 brace, inside baggage compartment). Remove hardware
securing shackle and frame to F574-8 block (threaded).
b. F046-2 (RH) only: Remove hardware securing frame to F574-1 support
assembly (access bolts from inside baggage compartment).
6. Remove hardware securing F174-1 support weldment rod end(s) to F046 lower
frame(s).
7. Remove two bolts and associate hardware securing F020-1 frame weldment,
firewall, and F046 lower frame.
8. Remove hardware securing F046 lower frame to F574-10 block assembly
(threaded). Remove lower frame.

JUL 2020 Chapter 53 Fuselage Page 53.5

FIGURE 53-2 LOWER FRAMES

Page 53.6 Chapter 53 Fuselage JUL 2020

53-31 Lower Frames (continued)
B. Installation
1. Refer to Figure 53-2.
a. F046-1 (LH) only: Install hardware securing shackle and frame to F574-8
block (threaded). Special torque bolt per § 20-33, and torque stripe per
Figure 5-1. Install hardware securing frame to F574-5 block (insert bolt thru
G246-1 brace, inside baggage compartment). Standard torque bolt per §
20-32, and torque stripe per Figure 5-1.
b. F046-2 (RH) only: Install hardware, and G914-5 tab, securing frame to
F574-1 support assembly (access bolts from inside baggage compartment).
Remove finish from surface under braided wire terminal, if installed. Standard
torque bolts per § 20-32, and torque stripe per Figure 5-1.
2. Install hardware securing F046 lower frame to F574-10 block assembly (threaded).
Install hardware securing F020-1 frame weldment, firewall, and F046 lower
frame. Standard torque bolts per § 20-32, and torque stripe per Figure 5-1.
3. Verify rod end engagement in F174-1 support weldment is approximately
symmetrical with minimal preload. Adjust rod end extension on both sides as
required per § 5-33, and Figures 5-1 & 5-2; ensure rod extension is no more
than 1.10 inches. Install hardware securing weldment to lower frames, standard
torque bolts per § 20-32, and torque stripe per Figure 5-1. Remove tailcone
support.
4. Seal around frame weldment(s) at firewalls using B270-1 sealant.
5. Connect F049-03 harness assembly wires at plastic connectors, install hardware
securing clamps to firewall, and install ty-raps as required. Cinch ty-raps until
snug without over-tightening, and trim tips flush with heads.
6. a. F046-1 (LH) only: Install hardware securing power turbine governor control
cable clamps, F723-3 line assembly clamp, and firewall clamp to F046-1 lower
frame. Standard torque hardware per § 20-32, and torque stripe per Figure
5-1.
b. F046-2 (RH) only: Install hardware securing battery cable harness clamp,
external power block, and stiffener clamp to F046-2 lower frame. Standard
torque hardware per § 20-32, and torque stripe per Figure 5-1.
7. Install engine per § 71-10.

JUL 2020 Chapter 53 Fuselage Page 53.7

FIGURE 53-3 HYDRAULIC SERVO SUPPORT FRAME

Page 53.8 Chapter 53 Fuselage JUL 2020

53-32 Hydraulic Servo Support Frame

Refer to R66 Illustrated Parts Catalog (IPC) Figure 67-19.

A. Removal

1. Remove main rotor gearbox per Section 63-20.

2. Remove main rotor hub per Section 62-20.

3. Remove mast fairing per Section 53-22.

4. Remove swashplate assembly per Section 67-40.

5. Refer to Figure 53-3. Tag F121-3 push-pull tube assemblies with corresponding
D212 servo assembly, and tag servos with location on G201-1 servo support frame.
Remove hardware securing push-pull tubes to servos.

6. Remove hardware securing F339-1 jackshaft weldment to frame.

7. Remove hardware securing servos to frame forward plates and aft bracket. Support
forward servos, and aft servo and jackshaft, during hardware removal.

8. Remove gearbox mounting bolts, mounts, and hardware. Lift frame off of gearbox,
over mast assembly.

B. Installation

1. Refer to Figure 53-3. Lower G201-1 servo support frame over mast assembly, onto
main rotor gearbox. Install gearbox mounting bolts, mounts, and hardware. Install
nuts finger tight.

2. Remove tags and install hardware securing D212 servo assemblies to frame forward
plates and aft bracket. Standard torque bolts per Section 20-32, and torque stripe
per Figure 5-1.

3. Install hardware securing F339-1 jackshaft weldment to frame. Standard torque

bolts per Section 20-32, and torque stripe per Figure 5-1.

4. Install F121-3 push-pull tube assemblies as removed. Standard torque bolts per
Section 20-32, and torque stripe per Figure 5-1.

5. Install swashplate assembly per Section 67-40.

6. Install mast fairing per Section 53-22.

7. Install main rotor hub per Section 62-20.

8. Install main rotor gearbox per Section 63-20.

25 OCT 2010 R66 Maintenance Manual Chapter 53 Fuselage Page 53.9

53-33 Upper Frame

Refer to R66 Illustrated Parts Catalog (IPC) Figure 53-11 and 53-11B.

A. Removal

1. Remove main rotor blades per Section 62-10.

2. Remove tailcone assembly per Section 53-40.
3. Remove tail rotor drive shaft weldment per Section 65-10.
4. Remove hardware securing F236-1 scroll assembly to F306-1 box assembly. Remove
hardware securing box to firewall.
5. Remove hardware securing F252-1 strut to F020-1 upper frame and remove strut.
6. Remove air filter and cage assembly per Section 71-22. Disconnect air bypass
switch assembly wiring at connector and remove hardware securing G258-4 strap
to fuel bladder support assembly.
7. Remove engine shaft weldment per Section 63-10.
8. Remove engine per Section 71-10.
9. Remove main rotor gearbox per Section 63-20, steps 2 thru 12.
10. Cut and discard ty-raps securing wires and antenna cables to frame, as required.
11. Disconnect D205-19 hose assembly and F724-1 line assembly from F823-1 thermostat
assembly. Plug hose and line and cap fittings. Remove hardware securing F651-1
oil filter assembly to frame.
12. Remove hardware securing F231-8 braces to fuel bladder support, and to frame.
13. Remove hardware securing rotor brake cable assembly to frame. Remove hardware
securing B157-1 (pulley) mount to frame.
14. Remove ELT transmitter per Section 25-61, if installed. Remove hardware securing
clamps to upper frame and remove clamps.
15. Remove palnut, nut, and spacer securing F316-1 bellcrank assembly to upper frame,
and slide C494-2 shaft inboard until it clears frame. Remove fastener securing
A331-4 bellcrank assembly to upper frame and swing bellcrank clear of frame.
16. Remove fasteners securing upper frame to horizontal firewall.
17. Using plastic scraper, remove sealant around frame weldment edges at firewalls,
cabin bulkhead, and fuel bladder support.
18. Remove mounting hardware securing upper frame to firewalls, bulkhead, and support
and remove frame.

Page 53.10 Chapter 53 Fuselage R66 Maintenance Manual 25 OCT 2010

53-33 Upper Frame (continued)

B. Installation

1. Position F020-1 upper frame inside helicopter. Install mounting hardware securing
upper frame to firewalls, cabin bulkhead, and fuel bladder support assembly.
Standard torque bolts per § 20-32, and torque stripe per Figure 5-1. Seal around
frame weldment edges at firewalls, bulkhead, and support using B270-1 sealant.

2. Install fasteners securing upper frame to horizontal firewall. Standard torque

hardware per § 20-32, and torque stripe per Figure 5-1.

3. Install hardware securing A331-4 bellcrank assembly to upper frame. Standard

torque bolt per § 20-32, and torque stripe per Figure 5-1. Slide C494-2 shaft
outboard thru F316-1 bellcrank assembly and upper frame and install spacer, nut,
and palnut. Special torque nut per § 20-33, and torque stripe per Figure 5-1.

4. Install ELT transmitter per § 25-61, if installed. Install clamps and hardware
securing clamps to upper frame.

5. Install B157-1 (pulley) mount and hardware securing mount to frame. Install
hardware securing rotor brake cable assembly to frame.

6. Install F231-8 braces and hardware securing braces to fuel bladder support, and to
frame.

7. Install hardware securing F651-1 oil filter assembly to frame. Standard torque
hardware per § 20-32, and torque stripe per Figure 5-1. Remove caps and plugs and
connect D205-19 hose assembly and F724-1 line assembly to F823-1 thermostat
assembly. Standard torque hose assembly nuts per § 20-32, special torque line
assembly nuts per § 20-33, & torque stripe per Figure 5-1.

8. Install MS3367-4-9 or -5-9 ty-raps as required to secure wire harness & cables
to frame. Cinch ty-raps until snug without over-tightening, & trim tips flush with
heads.

9. Install main rotor gearbox per § 63-20, but do not install F252-1 strut until step 13.

10. Install engine per § 71-10.

11. Install engine shaft weldment per § 63-10.

12. Install air filter and cage assembly per § 71-22. Install hardware securing G258-
4 strap to fuel bladder support and connect air bypass switch assembly wiring at
connector.

13. Install hardware securing F252-1 strut to F020-1 upper frame. Standard torque
bolts per § 20-32, and torque stripe per Figure 5-1.

14. Install F306-1 box assembly and hardware securing box to firewall. Install F236-1
scroll assembly and hardware securing scroll to box.

15. Install tail rotor drive shaft weldment per § 65-10.

16. Install tailcone assembly per § 53-40.

MAY 2015 Chapter 53 Fuselage Page 53.11

FIGURE 53-4 TAILCONE ASSEMBLY

Page 53.12 Chapter 53 Fuselage MAY 2015

53-40 Tailcone Assembly
Refer to R66 Illustrated Parts Catalog (IPC) Figure 53-15.
A. Removal
1. Remove tailcone cowling assembly per § 53-23. Remove engine cowling assembly
per § 53-21.

2. Refer to Figure 53-4. Cut and discard ty-raps as required and disconnect tailcone
wiring at connectors. Disconnect two antenna cables inside tailcone forward bay, and
cables at forward bulkhead, as required.

3. Remove hardware securing D224 tail rotor drive shaft yoke to C947-3 (intermediate)
plate assembly, noting hardware removed.

4. Remove hardware securing C121-17 push-pull tube to A331-4 bellcrank assembly.

5. Remove hardware securing C023 tailcone assembly to frames and remove tailcone.

6. Cut and discard ty-raps as required and remove F237-1 tailcone attachment frame, as
required.
B. Installation

1. Refer to Figure 53-4. Install F237-1 tailcone attachment frame, if not previously
accomplished. Verify correct damper assembly orientation per Figure 65-3.

2. Position C023 tailcone assembly on F020-1 upper frame assembly; do not pinch wiring
between tailcone bulkhead and frames. Install hardware securing tailcone to frames,
standard torque bolts per Section 20-32, and torque stripe per Figure 5-1.

3. Install hardware securing D224 tail rotor drive shaft yoke to C947-3 (intermediate)
plate assembly. Shim tail rotor driveline per § 65-30. Standard torque bolts per § 20-
32, and torque stripe per Figure 5-1.

4. Install hardware securing C121-17 push-pull tube to A331-4 bellcrank assembly.

Standard torque bolt per § 20-32, and torque stripe per Figure 5-1.

5. Perform tail rotor drive shaft runout per § 65-21.

6. Connect tailcone wiring at connectors, connect two antenna cables inside tailcone
forward bay, and connect antenna cables at forward bulkhead, as required. Individually
test and verify correct function of tail position light, strobe, and TR chip light circuits.

7. Install MS3367-4-9 or -5-9 ty-raps as required to secure wire harness and cables
to frame. Cinch ty-raps until snug without over-tightening, and trim tips flush with
heads.

8. Install tailcone cowling assembly per § 53-23. Install engine cowling assembly per §
53-21.

MAY 2015 Chapter 53 Fuselage Page 53.13

FIGURE 53-5 TAILCONE INSPECTION AND REPAIR

Page 53.14 Chapter 53 Fuselage MAY 2015

53-41 Inspection and Repair

This procedure outlines the inspection criteria and repair limits for the tailcone assembly.
Repairs are limited to blending out scratches and refinishing skins. Contact RHC Technical
Support if allowable damage is exceeded.

A. Scratches

1. Refer to Figure 53-5. Verify damage does not exceed the following limits:

a. 0.005 inch maximum scratch depth more than 15° from tailcone centerline.
b. 0.010 inch maximum scratch depth less than 15° from tailcone centerline.

2. If damage exceeds limits, return tailcone assembly to RHC for repair. If damage is
within limits, blend out scratches with a 0.10 inch minimum blend radius. Refinish
skins using approved materials per Section 20-70.

B. Dents

1. Refer to Figure 53-5. Smooth, round bottom dents with 0.125 inch minimum radius
without sharp nicks or cracks are acceptable when damage does not exceed the
following limits:

a. 0.030 inch maximum dent depth.

b. 1.250 inch maximum dent diameter.
c. One dent permitted per tailcone station (inch).
d. 4.000 inch minimum distance between dented tailcone stations.

2. If damage exceeds limits, replace tailcone or return to RHC for repair.

25 OCT 2010 R66 Maintenance Manual Chapter 53 Fuselage Page 53.15

FIGURE 53-6 EMPENNAGE - TAILCONE CASTING

Page 53.16 Chapter 53 Fuselage R66 Maintenance Manual 25 OCT 2010

53-50 Empennage Assembly
A. Removal
1. Remove tail rotor guard assembly per § 53-53.
2. Remove hardware securing forward MS21919WDG3 clamp to upper horizontal
stabilizer. Cut and discard ty-raps securing position light and gearbox chip detector
wires and connectors together. Disconnect position light at connectors.
3. Refer to Figure 53-6. Support C004-2 empennage assembly, remove two bolts and
associate hardware securing assembly to tailcone casting, and remove assembly.
B. Installation
1. Refer to Figure 53-6. Position C004-2 empennage assembly on tailcone casting.
Install two bolts and associate hardware securing assembly to casting; select bolt
length to meet torque requirements per § 20-30. Standard torque bolts per §20-
32, and torque stripe per Figure 5-1.
2. Connect position light wire connectors. Secure wires and install hardware securing
forward MS21919WDG3 clamp to upper horizontal stabilizer. Install MS3367-4-9
or -5-9 ty-raps as required to secure wires and connectors together. Cinch ty-raps
until snug without over-tightening, and trim tips flush with heads.
3. Test and verify correct function of position and TR chip light circuits.
4. Install tail rotor guard assembly per § 53-53.
C. Repair
A single dent on the C044-1 stabilizer leading edge outboard of the vertical stabilizers
is permitted provided:
1. Dent is no more than 0.050 inch deep.
2. Dent must have a smooth bottom, with minimum 0.125-inch radius, and no
sharp nicks or cracks.
3. Dent must be less than 1.25 inches spanwise.
4. It is permissible to remove above dent via metalworking.
Depending on the damage, U.S. FAA AC (Advisory Circular) 43.13-1B may be used
to repair some horizontal stabilizer minor skin damage; refer to the AC’s Title Page
for limitations. Damage to spars, and either forward or middle attachment for vertical
stabilizers, is not field repairable.
To inspect spars, remove NAS1919B04S01 rivets securing D292-3 outboard rib. Only
the inboard D292-2 nose rib or D292-3 outboard tip rib may be field replaced; all other
parts require use of the factory jig.

JUL 2020 Chapter 53 Fuselage Page 53.17

53-51 Vertical Stabilizer
A. Upper Vertical Stabilizer Removal
1. Refer to Figure 53-6. Remove fastener securing vertical stabilizer C554 clips to
upper horizontal stabilizer trailing edge.
2. Support C042-1 upper vertical stabilizer. Remove four bolts (threaded) and
spacers securing C042-1 stabilizer to upper horizontal stabilizer, and remove
C042-1 stabilizer.
3. If replacing stabilizer, C554-1 clip may be reused. Drill out two rivets securing
clip to stabilizer.
B. Upper Vertical Stabilizer Installation
1. Refer to Figure 53-6. Position C042-1 stabilizer on empennage. Verify 0.030-
0.120 inch gap between C042-1 stabilizer skin edges and upper horizontal
stabilizer skins. File vertical stabilizer skin edge(s) as required.
2. Install four bolts (threaded) and spacers securing C042-1 stabilizer to upper horizontal
stabilizer. Special torque bolts per § 20-33 and torque stripe per Figure 5-1.
3. Install fastener securing C554 clips to upper horizontal stabilizer trailing edge.
(If reusing C554-1 clip, install clip and fastener, and match drill clip to vertical
stabilizer with #30 drill. Deburr holes and install rivets.) Torque stripe fastener
per Figure 5-1.
C. Lower Vertical Stabilizer Removal
1. Remove tail rotor guard assembly per § 53-53.
2. Remove aux stabilizer assembly per § 53-52, and tail skid per § 53-54, as required.
3. Refer to Figure 53-6. Remove fastener securing C554 clips to upper horizontal
stabilizer trailing edge.
4. Support C043-1 lower vertical stabilizer. Remove four bolts (threaded) and
spacers securing C043-1 stabilizer to upper horizontal stabilizer, and remove
C043-1 stabilizer.
5. If replacing stabilizer, C554-2 clip may be reused. Drill out two rivets securing
clip to stabilizer.
D. Lower Vertical Stabilizer Installation
1. Refer to Figure 53-6. Position C043-1 stabilizer on empennage. Verify 0.030-
0.120 inch gap between C043-1 stabilizer skin edges and upper horizontal
stabilizer skins. File vertical stabilizer skin edge(s) as required.
2. Install four bolts (threaded) and spacers securing C043-1 stabilizer to upper horizontal
stabilizer. Special torque bolts per § 20-33 and torque stripe per Figure 5-1.
3. Install fastener securing C554 clips to upper horizontal stabilizer trailing edge.
(If reusing C554-2 clip, install clip and fastener, and match drill clip to vertical
stabilizer with #30 drill. Deburr holes and install rivets.) Torque stripe fastener
per Figure 5-1.
4. Install aux stabilizer assembly per § 53-52, and tail skid per § 53-54, as required.
5. Install tail rotor guard assembly per § 53-53.
Page 53.18 Chapter 53 Fuselage JUL 2020
53-52 Horizontal Stabilizer

Refer to R66 Illustrated Parts Catalog (IPC) Figure 53-29.

A. Upper Horizontal Stabilizer Assembly Removal

1. Remove upper vertical stabilizer assembly and lower vertical stabilizer assembly per
§ 53-51.

2. Remove hardware securing forward clamp to upper horizontal stabilizer assembly.

Cut and discard ty-raps securing position light and gearbox chip detector wires and
connectors together. Disconnect position light at connectors.

3. Support upper horizontal stabilizer, remove two bolts and associate hardware
securing stabilizer to tailcone casting, and remove assembly.

B. Upper Horizontal Stabilizer Assembly Installation

1. Position upper horizontal stabilizer assembly on tailcone casting. Install two bolts
and associate hardware securing stabilizer to casting; select bolt length to meet
torque requirements per § 20-30. Standard torque hardware per § 20-32, and
torque stripe per Figure 5-1.

2. Install upper vertical stabilizer assembly and lower vertical stabilizer assembly per
§ 53-51.

3. If C044-1 stabilizer was replaced, match drill C554 clips 0.144-inch diameter hole
through trailing edge of horizontal stabilizer. Deburr hole and install fastener.

4. Connect position light at connectors. Install hardware securing forward clamp

to upper horizontal stabilizer. Install MS3367-4-9 or -5-9 ty-raps as required to
secure position light and gearbox chip detector wires and connectors together.
Cinch ty-raps until snug without over-tightening, and trim tips flush with heads.

5. Test and verify correct function of position and TR chip light circuits.

C. Lower Horizontal Stabilizer Assembly Removal

1. Remove tail skid per § 53-54.

2. Refer to Figure 53-7. Using plastic scraper, remove sealant around edges where
lower horizontal stabilizer assembly brackets attach to lower vertical stabilizer
assembly doublers. Remove lower horizontal stabilizer assembly.

D. Lower Horizontal Stabilizer Assembly Installation

1. Refer to Figure 53-7. Position lower horizontal stabilizer assembly on lower vertical
stabilizer assembly and install tail skid per § 53-54.

2. Seal lower horizontal stabilizer bracket edges to lower vertical stabilizer doublers
using B270-1 sealant.

MAY 2015 Chapter 53 Fuselage Page 53.19

FIGURE 53-7 EMPENNAGE - TAIL ROTOR GUARD

Page 53.20 Chapter 53 Fuselage MAY 2015

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

A. Removal

1. Refer to Figure 53-7. Loosen two (forward) fasteners securing D081-2 block and
D079-1 guard assembly to C043-1 lower vertical stabilizer.

2. Remove hardware securing guard to D082-1 tube assembly. Slide guard off of
tube, then forward through blocks. Remove D081-1 spacer from tube.

B. Installation

CAUTION
Do not install D079-1 revision U or prior tail rotor guard assembly
on R66 helicopters.

1. Refer to Figure 53-7. Loosen two (forward) fasteners securing D081-2 block to
C043-1 lower vertical stabilizer, if not previously accomplished. Insert D079-1
guard assembly aft through blocks.

2. Lightly coat retaining hardware and mating surfaces of D082-1 tube assembly and
D079-1 guard assembly with approved primer per § 20-70, prior to installation.

3. Install D081-1 spacer inside tube. While wet with primer, slide guard onto tube
and install hardware. Standard torque bolts per § 20-32, and torque stripe per
Figure 5-1. Seal around end of guard with primer after assembly.

4. Verify D081 blocks clamp guard sleeve. For proper guard-to-stabilizer clamping,
first standard torque (forward, top) NAS1351-4-53P screw and associate hardware
per § 20-32, then special torque (forward, bottom) NAS1352-3-14P screw and
associate hardware per § 20-33. Torque stripe fasteners per Figure 5-1.

MAY 2015 Chapter 53 Fuselage Page 53.21

53-54 Tail Skid
Refer to R66 Illustrated Parts Catalog (IPC) Figures 53-25.

A. Removal

1. Refer to Figure 53-7. Support D079-1 guard assembly. Remove hardware securing
D081-2 block to C043-1 lower vertical stabilizer and remove block.

2. Support C050-2 aux stabilizer assembly and C470-1 tail skid. Remove hardware
securing D081-4 block assembly to C043-1 stabilizer and remove block assembly.

3. Remove C470-1 tail skid, two C470-2 blocks, and remove C470-3 spacer from
skid. Support guard and C050-2 stabilizer while hardware is removed.

B. Installation

1. Refer to Figure 53-7. Install C470-3 spacer inside C470-1 tail skid. Install tail skid
and two C470-2 blocks inside C043-1 lower vertical stabilizer. Install D081-4 block
assembly, and install hardware securing block assembly to stabilizer. Standard
torque screw per § 20-32, and torque stripe per Figure 5-1.

2. Install D081-2 block, and hardware securing block to stabilizer. Verify D081 blocks
clamp guard sleeve. For proper guard-to-stabilizer clamping, first standard torque
(forward, top) NAS1351-4-53P screw and associate hardware per § 20-32, then
special torque (forward, bottom) NAS1352-3-14P screw and associate hardware
per § 20-33. Torque stripe fasteners per Figure 5-1.

Page 53.22 Chapter 53 Fuselage MAY 2015

CHAPTER 62

MAIN ROTOR
Section Title Page

62-00 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62.1

62-10 Main Rotor Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62.1
62-11 Blade Boots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62.6
62-20 Main Rotor Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62.7
62-21 Bearing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62.9
62-22 Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62.10A
62-30 Main Rotor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62.11
62-31 Journal and Shim Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62.11
62-32 Adjusting Hinge Friction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62.15
62-33 Drilling Nuts and Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62.17
62-34 Static Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62.17B
62-40 Inspection of Main Rotor Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62.18
62-41 Scratches and Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62.19
62-42 Dents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62.20
62-43 Spar Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62.21A
62-44 Root Fitting Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62.21B
62-45 Nicks and Notches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62.23
62-46 Voids and Debonds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62.25
62-50 Repair of Main Rotor Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62.27
62-51 Sealing, Filling, and Fairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62.27
62-52 Painting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62.28
62-60 Main Rotor Blade Tip Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62.29

JUL 2020 Chapter 62 Main Rotor Page 62.i

Intentionally Blank

Page 62.ii Chapter 62 Main Rotor JUL 2020

CHAPTER 62

MAIN ROTOR

62-00 Description

The main rotor has two all-metal blades and a forged-aluminum hub. Blades mount to the hub
by coning hinge; the hub mounts to the main rotor shaft by teeter hinge. Coning and teeter
hinges have self-lubricated bearings inside the hub.

The leading edge of the main rotor blade is a corrosion and erosion resistant stainless-steel
spar. Aluminum skins are bonded to the spar approximately one inch aft of the leading edge,
to the aluminum honeycomb core, and to the forged-aluminum root fitting.

Each blade has six pitch change bearings that attach to a forged, stainless-steel spindle. The
bearings and part of the spindle are submerged in oil inside the root fitting housing. The housing
is sealed with an elastic boot. The spindle tusk contacts an aluminum droop stop attached to
the main rotor shaft, to minimize teetering when blades are at rest or turning at low RPM.

62-10 Main Rotor Blades

WARNING

Due to potentially destructive results, use of blade tape (anti-

erosion tape) is prohibited.

A. Removal

Refer to Figure 62-1. Four people will be required to remove the blades. One person must
support the blade approximately 2/3 its length from the root while another supports the
root and removes or installs the attached bolt.

1. Mark one blade and its corresponding hinge nut & bolt, pitch link and rotor head location
with a colored marker, such as a grease pencil and, mark as “X”. Using a different color
marker, mark as “O”, on the other blade, nut, bolt, pitch link and rotor head location.

2. Disconnect pitch links from each main rotor blade.

FIGURE 62-1 SUPPORTING MAIN ROTOR BLADES DURING BLADE REMOVAL OR INSTALLATION

25 OCT 2010 R66 Maintenance Manual Chapter 62 Main Rotor Page 62.1
FIGURE 62-2 TEETER HINGE (HUB INSTALLATION)

FIGURE 62-3 CONING HINGE (BLADE INSTALLATION)

Page 62.2 Chapter 62 Main Rotor R66 Maintenance Manual 25 OCT 2010
62-10 Main Rotor Blades (continued)

A. Removal (continued)

3. Refer to Figure 62-3. Remove cotter pins and loosen nuts of blade coning hinge bolts
so they are just finger tight.

4. Remove nut, thrust washer, and shims (if used) from trailing-edge side of one blade hinge
bolt. Cone blade so spindle tusk no longer contacts droop stop. While supporting blade
at root, carefully rotate pitch horn down and remove hinge bolt and thrust washer.

NOTE

Installation hardware is matched individually to each blade

installation; carefully reinstall all attach hardware into rotor hub
exactly as removed.
CAUTION

Support remaining main rotor blade in a level position during

and after removal of opposite blade.

5. Store rotor blades on a cushioned surface to prevent damage to blade skins.

6. Repeat step 4 to remove remaining blade.

B. Installation

Refer to R66 Illustrated Parts Catalog (IPC) Figures 62-1, 62-3, and 62-5.

1. Verify correct teeter hinge friction per Section 62-32, step 4.

2. If previously installed information is unavailable, perform coning hinge journal and shim
calculation per Section 62-31.

3. Refer to Figure 62-3. With rotor hub level, insert journals into coning hinge bearings.
Install thrust washer on coning hinge bolt.

4. Position blade in hub until spindle hole aligns with journal bores, coning blade as required
to keep tusk away from droop stop. Rotate pitch horn down and install hinge bolt at
leading-edge side.

NOTE

To assist bolt installation, temporarily insert an old bolt from

trailing-edge side to align spindle with journals.

5. Install trailing-edge shims (if used) and thrust washer and, prior to installing nut, coat
bolt threads and nut face with A257-9 anti-seize compound.

NOTE

Do not allow anti-seize compound to contact journals or hub

bearing areas. These areas must be clean and dry.

25 OCT 2010 R66 Maintenance Manual Chapter 62 Main Rotor Page 62.3
FIGURE 62-4 MEASURING BOLT STRETCH
(Shown on teeter hinge bolt)

Page 62.4 Chapter 62 Main Rotor R66 Maintenance Manual 25 OCT 2010
62-10 Main Rotor Blades (continued)
B. Installation (continued)

CAUTION
To prevent damage, level and support installed blade until
opposite blade is installed.
6. With installed blade level and supported near tip, install opposite blade per steps 1 thru 5.
7. Tighten nut on hinge bolt until journals and thrust washer are firmly seated. Then
back nut off until both thrust washers can be freely rotated.
8. Install MT122-6 main rotor bolt stretch tool on hinge bolt per Figure 62-4. Zero dial
indicator by rotating dial face. Lock dial and remove tool.
9. Using wrenches with at least 600 ft-lb torque capacity, tighten nut until drilled hole in
nut and bolt align. Reinstall MT122-6 tool and measure bolt stretch; the stretch must
be between 0.020 - 0.022 inch (0.021 - 0.022 inch for new, undrilled bolt). Remove
tool. Install a new cotter pin with wet epoxy primer.

NOTE
If drilled holes in nut and bolt do not align, both nut and bolt
must be replaced. Stretch new bolts per § 20-33; drill new nuts
and bolts per § 62-33.
WARNING
The main rotor blade and hub attach bolts must be stretched
from 0.020 - 0.022 inch (0.021 - 0.022 inch for new, undrilled
bolt) to obtain proper clamping force. Under-stretching or over-
stretching can cause catastrophic failure of the bolts.
10. Connect pitch link to pitch horn. Standard torque per § 20-32, install palnut, and
torque stripe per Figure 5-1.
11. Repeat steps 1 thru 10 for remaining blade. If installed main rotor blade pitch bearing
housing has recently been serviced (including new or overhauled blades), perform
steps 12 thru 16.
12. Position cyclic and collective at approximately mid-travel positions to minimize wrinkles
in boots.
13. Insert two (2) MT549-1 spacers between hub and boot with gaps at top and bottom.
Spacers should fit in recess of boot. Hold spacers in place against boot and insert
MT549-2 plate from top between hub and spacers. Push plate down until it contacts
spindle.
14. Remove lower plug from pitch horn and allow oil to flow. Place a finger over hole as
soon as oil flow decreases to a drip to prevent air from being sucked inside blade.
15. Remove finger from hole and quickly install drain plug. Special torque per § 20-33 and
torque stripe per Figure 5-1.
16. Remove plate and spacers. Repeat on second blade.

MAY 2015 Chapter 62 Main Rotor Page 62.5

62-11 Blade Boots

Refer to R66 Illustrated Parts Catalog (IPC) Figure 62-1.

A. Removal

1. Remove main rotor blades per § 62-10.

2. Place a suitable drain container below main rotor blade spindle assembly. Remove
two B289-2 bolts and drain fluid.

3. Remove outer boot clamp and hold boot back to expose inner boot clamp. Remove
inner clamp and peel boot from spindle. Boot inner portion may be sealed to spindle
with B270-1 sealant.

4. As required, use a plastic scraper and vacuum cleaner to remove old B270-1 sealant
from spindle area to be covered by boot inner lip. Avoid contaminating spindle
bearings with old sealant.

WARNING

Use only plastic scrapers to remove old sealant; chemical

removal is prohibited.

B. Installation

NOTE

C156-1 (Black) blade boots are standard; C156-2 (grey) boots

are optional for use in sub-freezing temperatures.

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 C165-1 (inner) clamp assembly and tighten clamp to 2.850 ± 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
arm bolt hole with spindle bolt hole. Install C165-2 (outer) clamp assembly and
tighten clamp. Verify security.

4. Fill pitch bearing housing per § 12-51.

Page 62.6 Chapter 62 Main Rotor MAY 2015

62-20 Main Rotor Hub

Refer to R66 Illustrated Parts Catalog (IPC) Figure 62-3.

A. Removal

1. Remove main rotor blades per Section 62-10.

2. Refer to Figure 62-2. Mark rotor hub using a grease pencil or soft marker as follows:

a. Indicate nut side of teeter bolt.

b. Indicate chord arm side of drive shaft.

62-30 Main Rotor Assembly

62-31 Journal and Shim Calculations

Refer to Figures 62-2 and 62-3.

A. Teeter Hinge Calculation

1. Measure main rotor hub width across the teeter hinge bearing faces: inches
2. Subtract measured width of C251 driveshaft at teeter hinge bolt hole: – inches
Calculated empty space: = inches
3. Use one C106-5 journal and a selection of C117 shims to create a combined length of
approximately 1.835 inches. Use as many different size shims as possible. Place thrust
washer, shims, and journal under teeter bolt head; shims must be placed between thrust
washer and journal.
Subtract combined measured thickness of selected journal and shims: – inches
Difference: = inches
4. Subtract measured length of C106-5 journal to be used on nut-side: – inches
Difference: = inches

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 inch

Result: = inch
of C117 shims
6. Preceding Result is initial calculated C117 shim stack between nut-side journal and
thrust washer. Use as many different size shims as possible to facilitate head shifting
during balancing. Deviate from initial shim stack as required to meet teeter hinge
friction requirements (8-12 pounds is ideal).

25 OCT 2010 R66 Maintenance Manual Chapter 62 Main Rotor Page 62.11
62-31 Journal and Shim Calculations (continued)

B. Coning Hinge Calculation

1. Measure and record main rotor hub width across the coning hinge
bearing faces: inches
2. Subtract blade’s spindle width measured across faces at coning hinge
bolt bore: – inches
Calculated empty space: = inches

CAUTION

Initial coning hinge hardware stack-up must be adjusted to

0.007/0.011 inch greater than calculated empty space. A
smaller initial stack-up could damage thrust washers and hub
bearings during installation.

3. To accommodate dimensional change due to clamping force, add: + 0.007/0.011 inch

Sum: = inch

4. Subtract combined measured length of both C106-7 journals to be

installed: – inches
Result: = inch
of C117 shims
5. Preceding Result is initial calculated C117 shim stack required between trailing-edge
journal and thrust washer. Deviate from initial trailing edge shim stack-up as necessary
to meet coning hinge axial play per Figure 62-8 and maintain friction requirements 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. Increasing shim stack-up
or journal length decreases hinge friction.

C106 Journal Lengths

Part No. Length Location
C106-5 1.775 Teeter hinge (two per hinge)
C106-7 1.284 Coning hinge (two per hinge)

C117 Shim Sizes

Part No. Thickness Location (Between thrust washer and journal)
C117-8 0.012 Teeter hinge; Coning hinge trailing-edge side
C117-9 0.015 Teeter hinge; Coning hinge trailing-edge side
C117-10 0.020 Teeter hinge; Coning hinge trailing-edge side
C117-11 0.025 Teeter hinge; Coning hinge trailing-edge side

TABLE 62-1 HINGE FRICTION JOURNALS AND SHIMS

(Journal length and shim thickness values given in inches)

Page 62.12 Chapter 62 Main Rotor R66 Maintenance Manual 25 OCT 2010
Intentionally Blank

25 OCT 2010 R66 Maintenance Manual Chapter 62 Main Rotor Page 62.13
FIGURE 62-7 MEASURING TEETER HINGE FRICTION

Page 62.14 Chapter 62 Main Rotor R66 Maintenance Manual 25 OCT 2010
62-32 Adjusting Hinge Friction

A. Teeter Hinge Adjustment

NOTE
Teeter hinge friction must be checked and adjusted with main
rotor blades removed from main rotor hub. If required, remove
main rotor blades per Section 62-10.

Teeter hinge friction is adjusted by changing C117 shim stack in small increments.

NOTE
If shim stack is changed per following instructions, a new bolt and
nut must be installed per Section 62-10 Part B, steps 3 thru 5.

1. Refer to Figure 62-7. Install MT354 teeter moment tool into main rotor hub coning
hinge bearings. Using a spring scale, measure force required to teeter main rotor
hub; use sliding force reading, not breakaway reading. Force required to teeter main
rotor hub must be:

Minimum: No axial play

Maximum: 19 pounds

2. Refer to Figure 62-2. Remove cotter pin and teeter hinge nut. Remove thrust
washer and C117 shims under nut.

3. Refer to Table 62-1. Measure thickness of C117 shims under teeter hinge nut.
Change shims as necessary to adjust friction. Reducing shim stack-up by 0.003 -
0.005 inch will increase teeter friction. Increasing shim stack-up will reduce teeter
friction.

4. Reassemble teeter shims, thrust washer, and nut. Repeat step 1. Torque teeter
hinge bolt per Section 62-20 Part B steps 4 thru 6 and check teeter friction often
while stretching bolt. Do not exceed maximum teeter hinge friction. If required,
increase shim stack-up per preceding step so proper bolt stretch is reached prior to
maximum friction.

5. Cotter pin holes in nut and bolt will not align. Remove teeter hinge bolt by pressing
it out with an old bolt. Install a new bolt and nut per Section 62-10 Part B, steps
4 thru 6. Drill new bolt and nut per Section 62-33; coat new cotter pin with epoxy
primer and install wet.

6. If required, install main rotor blades per Section 62-10.

25 OCT 2010 R66 Maintenance Manual Chapter 62 Main Rotor Page 62.15
FIGURE 62-8 MEASURING THRUST WASHER AND HUB BEARING GAP

Page 62.16 Chapter 62 Main Rotor R66 Maintenance Manual 25 OCT 2010
62-32 Adjusting Hinge Friction (continued)
B. Coning Hinge Adjustment
Coning hinge friction is adjustable through use of various thickness C117 shims.
Shims are installed between the thrust washer and the trailing-edge journal.
1. Check blade hinge friction by lifting blades until spindle tusks clear droop stops.
Hold one blade level and cone opposite blade. Rotor hub should not teeter as
blade is coned. Repeat check on opposite blade.
2. Refer to Figure 62-8. Using a feeler gage, measure gap between thrust washer
and rotor hub bearing. Gap must be measured on both leading edge & trailing
edge sides of coning hinge and the total must not exceed 0.005 inch (0.003
inch if new hub bearings are installed).
3. Refer to Figure 62-3. Remove cotter pin, nut, and thrust washer from coning
hinge bolt.
4. Refer to Table 62-1. Remove shim(s) to be changed. Measure shim thickness
and select next size thicker or thinner as required. A thicker shim will decrease
blade’s coning hinge friction. A thinner shim will increase blade’s coning hinge
friction and decrease any gap between blade’s thrust washers and hub bearings.

NOTE
When a shim is replaced with a shim of a different size, it will
be necessary to install a new nut and bolt. Drilled holes in
original bolts will not align at required bolt stretch.

5. Replace coning hinge bolt with a new bolt.

6. Install shims, and new bolt and nut, per § 62-10 Part B, steps 4 thru 6.
7. Repeat steps 1 and 2. Drill new bolt and nut per § 62-33; coat new cotter pin
with epoxy primer and install wet. Repeat on opposite blade as required.

62-33 Drilling Nuts and Bolts

New bolts and nuts must be installed and bolts stretched to § 20-32 limits prior to drilling.
Nuts have three blind holes pre-drilled into every other nut flat to be used as drilling guides.
Using a six inch long 0.156-inch diameter Cobalt twist-drill, drill a hole through nut and
bolt using an accessible pre-drilled hole in nut. If a shorter length drill is used, protect
hub from damage due to chuck contact by wrapping chuck and/or covering hub edge with
several layers of tape. Prevent chips from contaminating other mechanisms.

NOTE
If none of the predrilled holes in nut are accessible for use as a
guide after stretching bolt, loosen nut and reposition bolt and
nut. Restretch bolt per § 20-32.

JUL 2020 Chapter 62 Main Rotor Page 62.17

FIGURE 62-8A MT524-2 MAIN ROTOR STATIC BALANCE FIXTURE ASSEMBLY

Page 62.17A Chapter 62 Main Rotor JUL 2020

62-34 Static Balance

CAUTION
Ensure surfaces contacting blade skins and trailing edges are
sufficiently cushioned to prevent blade damage.

1. Refer to Table 62-1. Assemble main rotor blade & spindle assembly to main rotor hub
by selecting a combination of C106-7 coning hinge journals and C117 coning hinge
shims to obtain total axial clearance between 0.002–0.006 inch.
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 62-8; verify total axial clearance at each hinge is between 0.002–0.006 inch.
3. Refer to Figure 62-8A. Install MT524-2 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 62-8B. Verify blade pitch angles are approximately equal with pitch
horns adjusted as shown. If blade pitch angles are not equal, then pitch horn(s) are
not correctly installed.
5. Place a spirit level chordwise (parallel with teeter and coning hinges) atop main rotor
hub. Level by adjusting NAS1351-3-10P screws.

FIGURE 62-8B EQUALIZING BLADE PITCH

JUL 2020 Chapter 62 Main Rotor Page 62.17B

62-34 Static Balance (continued)
6. Refer to Figure 62-8C. Insert depth micrometer (or calipers) thru (either) hole of
MT524-3 end plate until dowel contacts MT524-4 shaft and mark dowel at edge
of end plate; repeat on opposite side of hub. Determine side of hub with smaller
measured distance and mark top of hub with letter "N" 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 C298 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 62-8C MEASURING GAP BETWEEN THRUST WASHER AND HUB BEARING

Page 62.17C Chapter 62 Main Rotor JUL 2020

Intentionally Blank

JUL 2020 Chapter 62 Main Rotor Page 62.17D

FIGURE 62-9 MEASURING MAIN ROTOR BLADE DAMAGE

62-40 Inspection of Main Rotor Blades

NOTE
Main rotor blades are 14 CFR § 27.602 critical parts. Notify RHC
Technical Support when voids exceeding the limits specified in
the instructions below are found, providing blade serial number,
helicopter serial number, time in service for the rotor blade, and
location and size of the voids that exceed the limits.
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.

Page 62.18 Chapter 62 Main Rotor JUL 2020

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

62-41 Scratches and Corrosion

A. Skins and Doublers
1. Refer to § 62-50 for repair procedures. Polish out damage by hand with a 0.10
inch minimum blend radius.
2. Refer to § 62-40 for measuring damage and measuring material removed after
repair. Repair may not exceed the following limits:
a. 3.0 inch maximum diameter.
b. 3.0 inch minimum distance from another repaired area.
c. 0.012 inch maximum depth between RS 174.0 and RS 198.0.
d. 0.008 inch maximum depth between RS 18.7 and RS 174.0.
3. When recording repair(s), indicate upper or lower blade surface, diameter, depth,
and rotor station location (span and chord).

JUL 2020 Chapter 62 Main Rotor Page 62.19

FIGURE 62-11 DENTS ON SKINS AND DOUBLERS – DAMAGE LIMITS (TOP AND BOTTOM OF BLADE)

FIGURE 62-12 DENTS ON TRAILING EDGE BOND JOINTS – DAMAGE LIMITS (TOP AND BOTTOM OF BLADE)

62-42 Dents

Page 62.20 Chapter 62 Main Rotor JUL 2020

62-42 Dents (continued)

CAUTION
Do not repair any dent that has a sharp cut or break in the
skin. If necessary, locally penetrant inspect, keeping penetrant
materials away from bond joints.

A. Skins and Doublers

1. Refer to Figure 62-11. Smooth, round bottom dents with 0.060 inch minimum
radius that occur in honeycomb and unsupported areas of the blade as listed
below may be repaired when damage does not exceed the following limits:
a. 0.125 inch maximum depth dent between RS 162.90 and RS 196.50
b. 0.090 inch maximum depth dent between RS 124.00 and RS 162.90.
c. 0.030 inch maximum depth dent between RS 70.00 and RS 124.00.
d. Maximum area of any dent or dents is 12 square inches and maximum length
is 2.0 inches between RS 70.00 and RS 162.90.
e. Maximum area of any dent or dents is 24 square inches and maximum length
is 4.0 inches between RS 162.90 and RS 196.50.
f. Replace blade with any dent in 0.7 inch area immediately aft of skin-to-spar
bond line.
g. For dents in skins and/or doublers inboard of RS 70.00, contact RHC for
repair procedures.
2. Refer to Part C for leading edge cap damage. Refer to § 62-50 for repair procedures
for damage within limits.
B. Trailing Edge Bond Joints
1. Refer to Figure 62-12. Verify damage does not result in an edge void and does
not exceed the following limits:
a. 0.030 inch maximum damage between RS 70.00 and RS 124.00.
b. 0.060 inch maximum damage between RS 124.00 and 198.00.
c. Refer to Part A, step 1(d).
2. Refer to § 62-50 for repair procedures for damage within limits. Blend out dents
in trailing edge bond joints with a 0.10 inch blend radius.
C. Leading Edge Cap
1. Verify damage does not result in a crack or tear and dent depth does not exceed
0.020 inch.
2. Dents do not require blending or filling. Dents may be blended with a 0.10 blend
radius.

APR 2019 Chapter 62 Main Rotor Page 62.21

FIGURE 62-13 SPAR DAMAGE

FIGURE 62-14 ROOT FITTING DAMAGE

62-43 Spar Damage

1. Refer to Figure 62-13. Spar damage limits exclude leading edge cap. Verify damage
does not exceed the following limits:
a. 0.020 inch maximum depth between RS 70.00 and RS 198.00.
b. Replace blade if erosion has reduced thickness at spar leading edge to 0.040 inch.
c. Replace blade if erosion has cause ripples in or deformation to spar leading edge.
2. Refer to § 62-50 for repair procedures for damage within limits. Blend out spar
damage with a minimum 1.0 inch blend radius.

Page 62.21A Chapter 62 Main Rotor APR 2019

62-44 Root Fitting Damage
1. Refer to Figure 62-14. Verify damage does not exceed the following limits:
a. 0.040 inch maximum depth on outside diameter of flange.
b. 0.002 inch maximum depth on area 0.35 inch outboard of flange.
c. 0.060 inch maximum depth on other root fitting exposed areas.
2. Refer to § 62-50 for repair procedures for damage within limits. Blend out root fitting
damage with a minimum 1.0 inch blend radius.

APR 2019 Chapter 62 Main Rotor Page 62.21B

FIGURE 62-15 REPAIRS TO BLADE AND TRIM TAB TRAILING EDGES

FIGURE 62-16 MINIMUM CHORD AFTER BLADE AND TRIM TAB TRAILING EDGE REPAIRS

Page 62.22 Chapter 62 Main Rotor APR 2019

62-45 Nicks and Notches
A. Blade Trailing Edge (see also Blade Tip)
1. Refer to Figure 62-15 and § 62-50 for repair procedures for damage within limits.
Blend out nicks and notches in blade trailing edge for 1.0 inch minimum each side
of nick or notch (with a minimum 12 inch blend radius).
2. Refer to Figure 62-16. After repair, verify minimum chord is within the following
limits:
a. 12.10 inch minimum chord between RS 124.00 and RS 194.00.
b. 11.40 inch minimum chord between RS 19.55 and RS 122.00.
3. See § 62-42 for additional inspection criteria.
B. Blade Tip
1. Refer to Figure 62-17. Using a fine-toothed hand file, file in spanwise or
chordwise direction, within limits indicated. Remove file marks using 220 grit or
finer aluminum oxide abrasive paper.
2. File trailing edge to maintain square edge at skins, perpendicular to chord line, per
Figure 62-15. Seal exposed trailing edge bond joint.
3. Track and Balance Main Rotor per Chapter 18.
C. Trim Tab Trailing Edge
1. Verify damage does not exceed 0.050 inch chordwise or 0.30 inch spanwise.
2. Refer to Figure 62-15 and § 62-50 for repair procedures for damage within limits.
Blend out nicks & notches in trim tab trailing edges, 1.0 inch minimum each side
of nick or notch (with a minimum 12 inch blend radius) keeping edge parallel with
blade trailing edge.

APR 2019 Chapter 62 Main Rotor Page 62.23

FIGURE 62-17 BLADE TIP REPAIR LIMITS

FIGURE 62-18 TIP CAP, SPAR, AND TRAILING EDGES - VOID AND DEBOND LIMITS

Page 62.24 Chapter 62 Main Rotor APR 2019

62-46 Voids and Debonds

WARNING
Voids or debonds in rotor blades are not field repairable. Notify
RHC Technical Support when voids exceeding the limits specified
in the instructions below are found, providing blade serial number,
helicopter serial number, time in service for the rotor blade, and
location and size of the voids that exceed the limits.
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. Tip Caps, Spars, and Trailing Edges

1. Refer to Figure 62-18. Verify no continuous void larger than 0.10 square inch.
90% of the area must be securely bonded. Voids separated by 0.25 inch or less
spanwise are considered continuous.
B. Doublers
1. Refer to Figure 62-19. Voids or debonds in doublers are not field-repairable.
a. Critical Areas: Area less than 0.50 inch spanwise and less than 0.30 inch
chordwise from edge of doubler. Verify no individual void larger than 0.10
square inch except at the doubler finger tips. The finger tips may be debonded
from the outboard tip to 1.0 inch inboard. Voids that are separated by less
than 0.25 inch shall be considered continuous.
b. Non-Critical Areas: Area more than .50 inch spanwise or more than .30
inch chordwise from doubler edges. Verify void does not exceed 2.0 inches
chordwise by 7.0 inches spanwise maximum continuous void. Voids that
are separated by less than 0.25 inch shall be considered continuous. Total
area of any void may not exceed 6.0 square inches.
2. If voids or debonds are beyond limit, contact RHC Technical Support.
C. Honeycomb
1. Refer to Figure 62-20. Verify damage does not exceed the following limits:
a. 1.50 inch chordwise or 20.00 inch spanwise maximum continuous void
between RS 121.00 & inboard. Total area of any void may not exceed 15.0
square inches.
b. 2.50 inch chordwise or 20.00 inch spanwise maximum continuous void
between RS 121.00 & RS 196.50. Total area of any void may not exceed
15.0 square inches.

JUL 2020 Chapter 62 Main Rotor Page 62.25

FIGURE 62-19 DOUBLERS - VOID AND DEBOND LIMITS

FIGURE 62-20 HONEYCOMB - VOID AND DEBOND LIMITS

Page 62.26 Chapter 62 Main Rotor JUL 2020

62-50 Repair of Main Rotor Blades

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

1. Measure damage per § 62-40.

2. Polish out blade 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.
3. 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. Hand-sand or file in spanwise direction.
4. Remove only the material necessary to reach the bottom of the damage, and to blend
the reworked area to the radius or dimension required. Visually inspect and verify all
damage is removed.
5. Measure reworked area and verify material removed and/or new chord dimension is
permissible per § 62-40.
6. Seal and fill per § 62-51, as required. Paint per § 62-52, as required.
7. Track and balance main rotor per Chapter 18, as required.

62-51 Sealing, Filling, and Fairing

1. Clean area needing sealing, filling, and fairing with QSOL 220.
2. a. Apply B270-27 adhesive to seal all exposed bond joints except at tip of blade and
4–6 inches of outboard end of skin/spar joint; remove excess adhesive.
b. Apply B270-1 sealant to seal tip of blade and 4–6 inches of outboard end of skin/
spar joint; remove excess sealant. Cure for 2–3 hours at 125° ± 25° or air dry for
72 hours minimum.
3. Using 240 grit or finer wet-or-dry aluminum-oxide abrasive paper, hand-sand cured
adhesive in spanwise direction to a smooth, aerodynamic finish, congruent with the
blade airfoil. Do not remove metal.
4. Hand-sand surrounding painted surface until 25% primer remains. Keep bare metal to
a minimum.

JUL 2020 Chapter 62 Main Rotor Page 62.27

62-52 Painting

CAUTION
If force-drying paint, do not exceed 175°F surface temperature
on blade; monitor blade temperature by temporarily installing
P/N 110-2 Telatemp on blade skin.

1. Mask area to prevent overspray contamination.

2. Clean bare metal to be painted with a lint-free cloth dampened with enamel cleaner
(see Approved Materials, § 20-70).
3. Prime bare metal with at least two coats of 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 new coat.

NOTE
Best results are achieved if primer is allowed to air-dry for 12
hours prior to top coat application.

4. Refer to Figure 62-21. Apply dark gray, flat black, white, and/or yellow Dupont Imron
polyurethane enamel (or equivalent; see Approved Materials, § 20-70), 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).

5. Remove masking materials.

FIGURE 62-21 MAIN ROTOR BLADE PAINT SCHEME

Page 62.28 Chapter 62 Main Rotor JUL 2020

62-60 Main Rotor Blade Tip Maintenance
After removing rounded tip covers, use 10X magnification when visually inspecting blade
tip to verify no loose or blistered paint, white-powder corrosion products, or pitting of skins
aft of skin-to-spar bond lines (upper & lower). If bare metal (other than spar leading edge)
or corrosion is detected, proceed as follows:

WARNING
Review appropriate Safety Data Sheet (SDS) when working in
proximity to hazardous materials. Specific recommendations
for use of personal protective equipment are located in the SDS.
CAUTION
Do NOT use power tools or chemical paint strippers to remove
blade paint.

1. Remove any corrosion and loose paint on tip cap and outboard edges of blade skins
by hand-sanding vertical surface in a chordwise direction; use a hard, flat block with
220-grit aluminum-oxide abrasive paper, then finish sand with 320-grit aluminum-oxide
abrasive paper. Remove only material necessary to eliminate corrosion.

2. Remove any corrosion and loose paint from skins on upper or lower surface of blade,
aft of skin-to-spar bond joint, by hand-sanding in a spanwise direction using 220-grit
aluminum-oxide abrasive paper and minimum 0.1 inch blend radius; finish sand with
320-grit aluminum-oxide abrasive paper. Remove only material necessary to eliminate
corrosion.

JUL 2020 Chapter 62 Main Rotor Page 62.29

62-60 Main Rotor Blade Tip Maintenance (continued)
3. Clean bare metal area with lint-free cloth dampened with acetone and allow to dry.
4. Seal exposed bond joints, including bond joints on vertical surfaces, with smooth layer
of B270-1 sealant (poly-sulfide, refer to § 20-79) and allow to cure.
5. Prime remaining exposed metal with two coats of epoxy primer (chromated epoxy
preferred).
6. Apply yellow paint topcoat within 2 – 48 hours of primer application. For best
performance, allow paint to cure 48 hours before flight.
7. Install tip covers and special torque screws to 40 in.-lb wet with A257-9 anti-seize;
ensure cover edges are flush with blade profile.

Page 62.30 Chapter 62 Main Rotor JUL 2020

CHAPTER 63

MAIN ROTOR DRIVE SYSTEM

Section Title Page

63-00 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63.1

63-10 Engine Shaft Weldment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63.1
63-11 (Engine Driveline) Forward Flex Plate Shimming . . . . . . . . . . . . . . . . . . . . 63.2
63-12 Clutch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63.5
63-20 Main Rotor Gearbox Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63.6
63-21 Yoke and Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63.8
63-30 Rotor Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63.13
63-31 Pad Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63.14
63-40 Rotor RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63.14

APR 2017 Chapter 63 Main Rotor Drive System Page 63.i

Intentionally Blank

Page 63.ii Chapter 63 Main Rotor Drive System APR 2017

CHAPTER 63

MAIN ROTOR DRIVE SYSTEM

63-00 Description
The engine is mounted in a 37º nose-up attitude. A sprag-type overrunning clutch mates
directly to the splined engine power take-off (PTO) shaft. The clutch is connected to a shaft
with flexible couplings at both ends to transmit power to the main gearbox. A ring and pinion
spiral bevel gearset at the main gearbox input reduces speed to tail rotor driveline RPM. A
second ring and pinion stage reduces speed from tail rotor driveline RPM to main rotor RPM.
The main gearbox is pressure lubricated. The oil is pumped through an airframe-mounted
filter and cooled as required by a thermostatically-controlled oil cooler which receives its
airflow from the fanwheel. The main gearbox also drives the flight control hydraulic pump.

63-10 Engine Shaft Weldment

A. Removal
1. Remove tailcone cowling assembly per § 53-23. Remove engine cowling assembly
per § 53-21.
2. Remove filter and cage assemblies per § 71-22.
3. Refer to Figure 63-1. Remove hardware securing F453-1 box assembly to F234-1 firewall.
4. Remove hardware securing forward A947-2 flex plate assembly to F910-1 (main gearbox)
yoke and F642 (engine) shaft weldment forward flange, noting hardware removed.
Remove flex plate, and temporarily suppport forward portion of shaft weldment.
5. Remove hardware securing shaft weldment to aft A947-2 flex plate assembly. Remove
support, then remove shaft weldment through main gearbox compartment.
B. Installation

1. Refer to Figure 63-1. Position F642 engine shaft weldment in helicopter, and install
hardware securing shaft weldment to aft A947-2 plate assembly. Standard torque
nuts and palnuts per § 20-32, and torque stripe per Figure 5-1.
2. Shim engine driveline per § 63-11.
3. Install hardware securing F453-1 box assembly to F234-1 firewall.
4. Verify 0.2 inch minimum clearance between shaft weldment and firewall grommet;
verify equal gap concentrically between shaft and box assembly hole edges. Adjust
F174-1 support weldment rod ends per § 53-31 as required.
5. Install filter and cage assemblies per § 71-22.
6. Install tailcone cowling assembly per § 53-23. Install engine cowling assembly per § 53-21.

APR 2017 Chapter 63 Main Rotor Drive System Page 63.1

63-11 (Engine Driveline) Forward Flex Plate Shimming

NOTE

The engine driveline is shimmed for 0.040 / 0.000 inch

compressive preload. Preload is alleviated by upward movement
of main gearbox during flight.

1. Refer to Figure 53-2. Verify F174-1 support weldment rod end engagement measures
0.93 inch from tube end to rod end centerline (nominal; both sides). Verify 0.2 inch
minimum clearance between F642 (engine) shaft weldment and firewall grommet;
verify equal gap concentrically between shaft and F453-1 box assembly hole edges.
Adjust support weldment rod end engagement per Section 53-31 as required.

2. Refer to Figure 63-1. If not previously accomplished, remove hardware securing

forward A947-2 flex plate assembly to F910-1 (main gearbox) yoke and F642 (engine)
shaft weldment forward flange. Remove flex plate, and temporarily suppport forward
portion of shaft weldment.

3. Measure flex plate thickness at bonded washers (4 places) to determine average thickness:

(1st place) inch

(2nd place) + inch
(3rd place) + inch
(4th place) + inch
Total = inch
Total ÷ 4 = inch (Flex plate average thickness)
4. a. Position F910-1 (main gearbox) yoke flange arms and F642 (engine) shaft weldment
forward flange arms at 3 o’clock and 9 o’clock positions (horizontal). Measure gap
between arms to determine average gap:

(3 o’clock position) inch

(9 o’clock position) + inch
Total = inch
Total ÷ 2 = inch (Average gap between flange arms)
b. Rotate F642 (engine) shaft weldment 180º, and repeat step a:

(3 o’clock position) inch

(9 o’clock position) + inch
Total = inch
Total ÷ 2 = inch (Average gap between flange arms)

Page 63.2 Chapter 63 Main Rotor Drive System APR 2017

63-11 (Engine Driveline) Forward Flex Plate Shimming (continued)

5. Evaluate flange straightness by calculating the difference between the 3 o’clock

positions in steps 4a and 4b. Also calculate the difference between the 9 o’clock
positions in steps 4a and 4b. If either calculated difference exceeds 0.015 inch, either
one or both flanges are bent and require replacement.

6. Using the smaller average gap from step 4a or 4b, subtract the flex plate average
thickness determined in step 3:

Smaller average gap between flange arms (step 4a or 4b) inch

Subtract flex plate average thickness (step 3) − inch
Total = inch
7. Select shims per Table 63-1 and install forward A947-2 flex plate assembly. Standard
torque hardware per § 20-32 and torque stripe per Figure 5-1. Remove F642 (engine)
shaft weldment temporary support.

WARNING

Shim both arms of flanges equally. All fasteners must meet

torque requirements given in § 20-33.

Shim required between

Shim required between
Calculated forward A947-2 flex plate and
forward A947-2 flex plate and
Dimension F642 (engine) shaft weldment
F910-1 (main gearbox) yoke
forward flange

NAS1149F0432P washer between aft A947-2 flex plate assembly and

F642 (engine) shaft weldment aft flange and/or F018-1 clutch assembly
−0.041 inch or greater
yoke may be relocated under nut as required to achieve −0.040 / 0.000
negative number
inch calculated dimension. Relocate washers as required, and repeat
steps 4 thru 7.

−0.040 / 0.000 inch None None

+0.001 / +0.029 inch NAS1149F0432P washer None

+0.030 / +0.059 inch NAS1149F0432P washer NAS1149F0432P washer

+0.060 / +0.090 inch NAS1149F0463P washer NAS1149F0432P washer

+0.091 / +0.121 inch NAS1149F0463P washer NAS1149F0463P washer

NAS1149F0432P washer between aft A947-2 flex plate assembly and

F642 (engine) shaft weldment aft flange and/or F018-1 clutch assembly
+0.122 inch or greater
yoke may be exchanged with NAS1149F0463P washer as required to
positive number
achieve −0.040 / 0.000 inch calculated dimension. Exchange washers as
required, and repeat steps 4 thru 7.

TABLE 63-1

JUL 2020 Chapter 63 Main Rotor Drive System Page 63.3

FIGURE 63-1 ENGINE DRIVELINE

Page 63.4 Chapter 63 Main Rotor Drive System JUL 2020

63-12 Clutch Assembly
A. Removal
1. Remove engine shaft weldment per § 63-10.
2. Refer to Figure 63-1. Mark F906 yoke assembly and A947-2 plate assembly, to
facilitate installation. Remove plate assembly, noting hardware removed.
3. Remove bolt securing G732 cap, spacer (if installed), and F018-1 clutch assembly
to Rolls-Royce engine model 250-C300/A1. Remove clutch assembly through
main rotor gearbox compartment.
B. Installation
1. Refer to Figure 63-1. Lubricate F018-1 clutch assembly splines using A257-1,
-9, or -12.
2. Route clutch assembly through main rotor gearbox compartment, insert clutch
assembly in Rolls-Royce engine model 250-C300/A1, and install spacer (earlier
R66s), G732 cap, and bolt at rear PTO pad. Standard torque bolt per § 20-32
and torque stripe per Figure 5-1.
3. Install A947-2 plate assembly, as removed. Standard torque fasteners per § 20-
32, and torque stripe per Figure 5-1.
4. Install engine shaft weldment per § 63-10.

APR 2017 Chapter 63 Main Rotor Drive System Page 63.5

63-20 Main Rotor Gearbox Assembly
A. Removal
1. Remove main rotor blades per § 62-10.
2. Remove tailcone cowling assembly per § 53-23.
3. Disconnect (pitot system) 15-4-N-O union near G201-1 (servo support) frame
assembly. Cap fitting and plug line.
4. Refer to Figure 63-1. Remove hardware securing F908-1 and F910-1 yoke
assemblies to plate assemblies, leaving plates attached to shaft weldments. Note
hardware removed.
5. Remove hardware securing F121-7 push-pull tube assembly to F339-1 jackshaft
weldment, and F121-5 push-pull tube assemblies to D212-5 servo assemblies.
6. Detach cable assembly from (rotor brake assembly) B112-3 spring.
7. Using back-up wrench, disconnect D205-19 and D205-20 hose assemblies from
F006-1 main rotor gearbox and D500-3 oil pump. Cap and plug fittings and hoses.
8. Disconnect F059-01 cabin harness assembly plug from F049-01 gearbox harness
assembly receptacle. Remove hardware securing A936-3 (ground) wire assembly
to F560-1 bulkhead assembly.
9. Remove D277-8 clamp or cut and discard safety wire securing Tygon® tube to
G254-1 (fuel) vent assembly, and clear tubing from workspace.
10. Install hoisting equipment per § 7-20, Part A, steps 1 thru 4; remove hoist slack.
11. Remove hardware securing F252-1 strut to F020-1 upper frame assembly. Remove
(mounting bolt) nuts and washers securing gearbox to upper frame. Remove aft
mounting bolts securing F235-13 strut assemblies to servo support frame, hardware
securing struts to upper frame, and struts.
12. Hoist gearbox (with hydraulic installation, servo support frame, and mast fairing
assembled) up and away from helicopter.

Page 63.6 Chapter 63 Main Rotor Drive System APR 2017

63-20 Main Rotor Gearbox Assembly (continued)
B. Installation

CAUTION
If F006-1 main gearbox is to be installed in a helicopter equipped
with a cargo hook or agricultural sprayer, verify gearbox has
B900-12 modification plate adjacent to the gearbox S/N data
plate, or has been overhauled (see maintenance records).

1. If installing new C653-3 (aft) or A653-2 (forward) rubber mounts, lubricate mounts
using water or A257-8 lubricant and press into gearbox ears.
2. Refer to § 7-20. Hoist F006-1 main rotor gearbox (with hydraulic installation, G201-
1 [servo support] frame assembly, and mast fairing assembled) into helicopter,
onto F020-1 upper frame assembly.
3. Install F252-1 strut and F235-13 strut assemblies, and install hardware securing
strut assemblies to upper frame. Install gearbox mounting bolts and associated
hardware, and apply light coat A257-9 anti-seize to threads. Special torque
mounting bolts per § 20-33, standard torque bolts securing struts to upper frame
per § 20-32, and torque stripe per Figure 5-1.
4. Remove hoisting equipment, and lifting fixture or nylon rope.
5. Install Tygon® tube on G254-1 (fuel) vent assembly and install D277-8 clamp.
Verify security.
6. Install hardware securing A936-3 (ground) wire assembly to F560-1 bulkhead
assembly. Connect F059-01 cabin harness assembly plug to F049-01 gearbox
harness assembly receptacle.
7. Remove caps and plugs and connect D205-19 and D205-20 hose assemblies to
gearbox and D500-3 oil pump. Using back-up wrench, special torque hose nuts
per § 20-33, and torque stripe per Figure 5-1.
8. Attach (rotor brake) D126-2 cable assembly to (rotor brake assembly) B112-3
spring. Verify 0.25 inch minimum clearance between cable assembly and vent
assembly Tygon® tube; adjust cable attachments as required.
9. Install hardware securing F121-7 push-pull tube assembly to F339-1 jackshaft
weldment, and F121-5 push-pull tube assemblies to D212-5 servo assemblies.
Standard torque hardware per § 20-32 and torque stripe per Figure 5-1.
10. Install hardware securing F908-1 and F910-1 yoke assemblies to plate assemblies,
as removed. Shim engine driveline per § 63-11, and tail rotor driveline per § 65-30.
Standard torque hardware per § 20-32, and torque stripe per Figure 5-1.
11. Install tailcone cowling assembly per § 53-23.

APR 2017 Chapter 63 Main Rotor Drive System Page 63.7

63-20 Main Rotor Gearbox Assembly (continued)
B. Installation (continued)
12. Install main rotor blades per § 62-10.

CAUTION
Prior to operation of a new, overhauled, or repaired main rotor
gearbox, inject 5–6 ounces A257-22 oil into mast tube vent hole
(not required if main gearbox has C251-3 Rev Q or subsequent
main drive shaft installed). Service gearbox per § 12-11.

63-21 Yoke and Seal Replacement

A. (Tail Rotor Drive) F908-1 Yoke Assembly and Seal Removal
1. Remove tailcone cowling assembly per § 53-23.
2. Remove hardware securing aft F305-5 inlet to scroll assembly; rest inlet on F196-
1 fan shaft.
3. Refer to Figure 63-1. Remove forward C947-3 flex plate assembly, noting
hardware removed. Remove intermediate C947-3 flex plate assembly, noting
hardware removed. Carefully maneuver fan shaft aft to access main gearbox’s
F908-1 yoke.
4. Refer to Figure 63-2. Set rotor brake. Remove and discard lockwire securing F904-
1 plug to yoke and remove plug using a 3/4-inch hex-bit socket. Visually inspect
forward C947-3 flex plate assembly and plug for damage. Order replacement
parts from RHC Customer Service if damage is found.
5. Remove hardware securing F254-1 cover with C966-8 seal to F006-1 main rotor
gearbox. Remove cover.
6. Using hydraulic press, press old seal from cover.

B. (Tail Rotor Drive) F908-1 Yoke Assembly and Seal Installation

1. Refer to Figure 63-1. Remove F266-1 spacer and replace A215-027 o-ring, as
required. Reinstall spacer.
2. Clean and dry F254-1 cover; verify open face of seal points toward gearbox and
press in new seal until completely seated.
3. Replace A215-149 o-ring, as required. Install cover assembly over pinion shaft.
4. Verify yoke and pinion splines are clean and undamaged. Coat splines of pinion
with B270-21 protectant and install F908-1 yoke assembly.
5. Refer to Figure 63-2. Apply light coat of A257-9 anti-seize to F904-1 plug
threads, install plug in gearbox, and special torque plug per MM § 20-33.

Page 63.8 Chapter 63 Main Rotor Drive System APR 2017

FIGURE 63-2 F908-1 YOKE ASSEMBLY INSTALLATION

63-21 Yoke and Seal Replacement (continued)

B. (Tail Rotor Drive) F908-1 Yoke Assembly and Seal Installation (continued)
6. In two places, install 0.020-inch diameter lockwire and safety plug to yoke with
pigtails inside recess of plug as shown.
7. Install forward C947-3 flex plate assembly, using hardware removed (replace
palnuts). Standard torque hardware per MM § 20-32 and torque stripe per MM
Figure 5-1. Ensure safety wire is not contacting flex plate.
8. Install and shim intermediate C947-3 flex plate assembly per MM § 65-30.
9. Install hardware securing aft F305-5 inlet to scroll assembly. Verify 0.10 inch
minimum gap between fanwheel assembly and inlet.
10. Install tailcone cowling assembly per § 53-23.
11. Set hall effect sender-to-magnet gap per § 63-40.

JUL 2020 Chapter 63 Main Rotor Drive System Page 63.9

63-21 Yoke and Seal Replacement (continued)
C. (Engine-Driven) F910-1 Yoke Assembly and Seal Removal
1. Remove tailcone cowling assembly per § 53-23. Remove engine cowling assembly
per § 53-21.
2. Drain main gearbox oil per § 12-11.
3. Refer to Figure 63-1. Remove hardware securing A947-2 (forward) plate
assembly to F910-1 yoke assembly, and A947-2 (aft) plate assembly to F642
shaft weldment, noting hardware removed. Support weldment to allow clearance
for yoke removal.
4. Place a wood block between firewall and yoke flange (to prevent yoke from
rotating) or engage rotor brake. Remove nut and washer securing yoke to pinion,
then remove yoke.
5. Remove rotor brake per § 63-30.
6. Remove F255 cover with C966 seal, but do not remove shims under pinion
bearing. Remove F266-2 spacer.
7. Using hydraulic press, press old seal from cover.

D. (Engine-Driven) F910-1 Yoke Assembly and Seal Installation

CAUTION
Do not remove shims under pinion bearing. Shims control
bearing preload and gear backlash.

1. Refer to Figure 63-1. Replace A215-025 o-ring, as required.

2. Clean and dry F255 cover; verify open face of seal points toward gearbox and
press in new seal until completely seated.
3. Replace A215-152 o-ring, as required. Install cover assembly over pinion shaft.
Install F266-2 spacer.
4. Install rotor brake per § 63-30.
5. Service main gearbox per § 12-11.

Page 63.10 Chapter 63 Main Rotor Drive System JUL 2020

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APR 2017 Chapter 63 Main Rotor Drive System Page 63.11

FIGURE 63-3 ROTOR BRAKE

Page 63.12 Chapter 63 Main Rotor Drive System APR 2017

63-30 Rotor Brake
A. Removal
1. Remove (engine-driven) F910-1 yoke assembly per § 63-21, Part C steps 1 thru 3.
2. Refer to Figure 63-3. Detach D126-2 cable assembly from B112-3 spring. Detach
B774-3 spring from gearbox cartridge retaining screw or rotor brake assembly link.
3. Remove hardware securing D2VW-5-1MS switch to brake assembly link.
4. Remove hardware and spacers securing brake assembly mounting bars to gearbox
cartridge. Remove G033-1 brake assembly F256-1 shield (see Figure 63-1).

B. Installation
1. Refer to Figure 63-3. Verify minimum 0.030 inch rotor brake pad thickness on
both arm assemblies.
2. Verify F910-1 yoke assembly and pinion splines are clean and undamaged. Coat
splines of pinion with B270-21 protectant.
3. Install F256-1 shield, then position G033-1 brake assembly over pinion and install
spacers and hardware securing brake assembly mounting bars to gearbox cartridge.
Standard torque screws per § 20-32 and torque stripe per Figure 5-1.
4. Install yoke on pinion shaft. Place a wood block between firewall and yoke flange
(to prevent yoke from rotating). Install pinion retaining nut and washer and special
torque nut per § 20-33. Coat nut and exposed pinion splines with B270-21
protectant. When dry, torque stripe per Figure 5-1.
5. Attach B774-3 spring to gearbox cartridge retaining screw and rotor brake assembly
link. Attach D126-2 cable assembly to B112-3 spring.
6. Install hardware securing D2VW-5-1MS switch to brake assembly link, but do
not tighten. Adjust switch to open and close when gap between B112-3 spring
lower retaining screw screw head and G110-1 arm assembly is 0.30–0.40 inch
with brake disengaged. Pivot switch about lower fastener as required and tighten
fasteners to set gap. Function check rotor brake light.
7. Install hardware securing A947-2 (forward) plate assembly to F910-1 yoke
assembly, and A947-2 (aft) plate assembly to F642 shaft weldment. Shim engine
driveline per § 63-11. Standard torque hardware per § 20-32, and torque stripe per
Figure 5-1.
8. Install tailcone cowling assembly per § 53-23. Install engine cowling assembly per
§ 53-21.

APR 2017 Chapter 63 Main Rotor Drive System Page 63.13

63-31 Pad Replacement
A. Arm Removal

NOTE
Rotor brake pad minimum thickness is 0.030 inch on both
arm assemblies. Replace arm assemblies when pads are worn
beyond limit.

1. Remove rotor brake per § 63-30.

2. Remove hardware and spacers securing G109-1 arm assembly to (2) G111-1
bars and G113-1 & -2 links. Remove D774-4 spring.
3. Remove hardware and spacers securing G110-1 arm assembly to (2) G111-1
bars and B112-2 lever. Loosen fastener securing G113-1 & -2 links to B112-2
lever.

B. Arm Installation
1. Refer to Figure 63-3. Lubricate spacers with A257-1 grease and install in new
G110-1 arm assembly. Install hardware securing G110-1 arm assembly to (2)
G111-1 bars and B112-2 lever, but do not torque.
2. Lubricate spacers with A257-1 grease and install in new G109-1 arm assembly.
Install D774-4 spring, and install hardware securing G109-1 arm assembly to (2)
G111-1 bars and G113-1 & -2 links. Standard torque all bolts and torque stripe
per Figure 5-1.
3. Install rotor brake per § 63-30.

63-40 Rotor RPM

1. Remove tailcone cowling assembly per § 53-23.
2. Refer to Figure 63-1. Measure gap between both F908-1 yoke assembly magnets at
each 103SR13A-3 (Hall effect) sender. Verify gap is between 0.030 ± 0.010 inch.
3. As required, loosen sender jam nuts and adjust to obtain 0.030 ± 0.010 inch gap.
Special torque jam nuts per § 20-33 and torque stripe per Figure 5-1.
4. Install tailcone cowling assembly per § 53-23.

Page 63.14 Chapter 63 Main Rotor Drive System APR 2017

CHAPTER 64

TAIL ROTOR
Section Title Page

64-00 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64.1

64-10 Tail Rotor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64.1
64-11 Static Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64.5
64-20 Tail Rotor Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64.8
64-30 Tail Rotor Blade Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . 64.11
64-31 Scratches and Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64.11
64-32 Dents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64.13
64-33 Erosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64.14
64-34 Root Fitting Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64.14
64-35 Nicks and Notches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64.14
64-36 Painting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64.14
64-40 Tail Rotor Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64.17
64-41 Bearing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64.17
64-42 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64.17

APR 2019 Chapter 64 Tail Rotor Page 64.i

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Page 64.ii Chapter 64 Tail Rotor APR 2019

CHAPTER 64

TAIL ROTOR

64-00 Description
The R66 tail rotor assembly is a conventional, two-bladed teetering rotor system.
Tail rotor blades are constructed of a wrap-around aluminum skin, bonded to aluminum
honeycomb and a forged aluminum root fitting. Self-lubricating spherical bearings in the
root fitting allow blades to change pitch.
Tail rotor blades are assembled to the hub with a fixed precone angle.
The tail rotor aluminum hub mounts to the gearbox output shaft by teeter hinge. Elastomeric
bearings in the hub allow the rotor to teeter. The tail rotor hub teetering stop is a urethane
bumper, attached to the output shaft.

64-10 Tail Rotor Assembly

A. Removal
1. Refer to Figure 64-1. Tag each pitch link with corresponding blade serial number
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 dynamic
balancing. Reinstall hardware as removed.

2. Remove nut and A141-14 washer securing C119-2 bumper to tail rotor gearbox
output shaft.
3. Remove teeter hinge bolt, then slide tail rotor assembly and bumper off of shaft.

NOTE
Protect tail rotor assembly from damage when maintenance is
performed on workbench.

APR 2019 Chapter 64 Tail Rotor Page 64.1

FIGURE 64-1 TAIL ROTOR INSTALLATION

Page 64.2 Chapter 64 Tail Rotor APR 2019

64-10 Tail Rotor Assembly (continued)

B. Installation
1. Refer to Figure 64-1. Position tail rotor assembly on tail rotor gearbox output shaft.
Verify tail rotor is installed for clockwise rotation when viewed from left side of aircraft.
Verify blades cone toward tail rotor gearbox.

2. Remove tags, and match tail rotor blade serial number to corresponding pitch link.
Install teeter hinge bolt; tighten nut until elastomeric bearing metal spacers contact
output shaft, but do not torque.

3. Install dynamic balancing hardware securing tail rotor blades to pitch links, as removed.
Standard torque nuts & palnuts per Section 20-32, and torque stripe per Figure 5-1.

NOTE

If dynamic balancing hardware information is unknown, install

standard hardware for initial dynamic check.

4. Fabricate a tracking aid using 1x12-inch aluminum sheet; make a 90º bend 2 inches
from one end. With tail rotor horizontal, tape tracking aid to tailcone near blade tip.

5. Rotate tail rotor drive shaft and mark tracking aid where each blade tip drain hole
passes. Adjust (teeter) tail rotor until both blade tips pass the same point within 0.125
inch. Special torque teeter hinge bolt per Section 20-33. Recheck track. Repeat step
until blades are tracked.

6. Install palnut, standard torque per Section 20-32, and torque stripe per Figure 5-1.
Remove tracking aid.

7. Teeter tail rotor back and forth. Verify teeter hinge bolt, bearing metal spacers, washers,
and nuts remain stationary when tail rotor is teetered.

8. Install C119-2 bumper, A141-14 washer, and nut. Standard torque nut per Section 20-
32 and torque stripe per Figure 5-1.

9. Dynamically balance tail rotor per Section 18-20.

25 OCT 2010 R66 Maintenance Manual Chapter 64 Tail Rotor Page 64.3
FIGURE 64-2 CHORDWISE STATIC BALANCE

Page 64.4 Chapter 64 Tail Rotor R66 Maintenance Manual 25 OCT 2010
64-11 Static Balance

NOTE
Tail rotor assembly received from RHC was statically-balanced
at factory.

A. Chordwise Static Balance

1. Refer to Figure 64-2. Install MT179‑4 balance bar into tail rotor assembly. Install
teeter hinge bolt, and special torque nut to 350 in.-lb. Using a carpenters square,
adjust balance bar until approximately perpendicular to hub.
2. Place tail rotor assembly with balance bar on Anderson 20 or equivalent balancing
stand. Hold tail rotor assembly vertically, then allow to fall. If the blade falls
leading edge first, the top blade is the heavy blade. If the blade falls trailing edge
first, the top blade is the light blade.
3. To simulate pitch link attachment, assemble hardware as shown and install
in blade pitch horns. Install standard washer, nut, and palnut on heavy blade
fastener. Standard torque hardware per § 20-32.
4. Chordwise balancing is achieved by varying NAS6604 bolt length and nut-side
washers on light blade fastener. Select bolt length and washers for balancing,
and to meet torque requirements per § 20-30. Standard torque hardware per §
20-32, and repeat step 2.
5. Blades are balanced chordwise when blade does not fall when positioned vertically
on balancing stand. Repeat step 4, adjusting bolts and washers until blades are
balanced.
6. Perform spanwise static balance per § 64-11 Part B.

JUL 2020 Chapter 64 Tail Rotor Page 64.5

FIGURE 64-3 SPANWISE STATIC BALANCE

Page 64.6 Chapter 64 Tail Rotor JUL 2020

64-11 Static Balance (continued)
B. Spanwise Static Balance

CAUTION
Verify four washers installed under each blade’s outboard
fastener prior to tail rotor assembly installation or dynamic
balance.

1. Refer to Figure 64-3. Install standard hardware for initial spanwise static balance
check. Standard torque fasteners per § 20-32.
2. Install MT179‑4 balance bar into tail rotor assembly. Install teeter hinge bolt, and
special torque nut to 350 in.-lb. Using a carpenters square, adjust balance bar
until approximately perpendicular to hub.
3. Place tail rotor assembly with balance bar on Anderson 20 or equivalent balancing
stand. Hold tail rotor assembly horizontally, then allow to fall. The falling blade
is the heavy blade; the rising blade is the light blade.
4. Spanwise balancing is achieved by varying nut-side washer size on light blade
outboard fastener. Four washers are required under outboard fastener nuts; place
largest washers closest to hub assembly. Select washers for balancing, standard
torque hardware per § 20-32, and repeat step 3.
5. Blades are balanced spanwise when blade does not fall when positioned horizontally
on balancing stand. Repeat step 4, adjusting outboard fastener washers until
blades are balanced.
6. Recheck chord and spanwise balance. Tail rotor assembly must be statically
balanced within 4 inch-grams. Remove MT179-4 balance bar.

APR 2019 Chapter 64 Tail Rotor Page 64.7

64-20 Tail Rotor Blades

NOTE
Protect tail rotor assembly from damage when maintenance is
performed on workbench.

A. Removal
1. Remove tail rotor assembly per § 64-10.
2. Refer to Figure 64-1. Remove hardware securing F029 blade assemblies to G062‑1
hub assembly. Remove blades, spacers, and hardware; do not remove C138-2
bushings unless required.
B. Installation

CAUTION
Both tail rotor blades must be same part number, either F029-1
or F029-2.
CAUTION
Tail rotor blades are a matched set. If only one blade is being
replaced, contact RHC Customer Service with airworthy blade
serial number for a matching replacement blade.

1. Inspect tail rotor hub per § 64-30, as required.

2. Refer to Figure 64-1. If removed, apply light coat of approved primer per § 20-70
to outer surface of C138-2 bushings; while primer is wet, press bushings flush
with inboard side of hub inboard arm (bushings will seat properly with fastener
torque applied).

CAUTION
F137-2 spacer creates blade precone angle and must be
installed on the outboard side of blade, on the blade outboard
(spanwise) fitting.

3. Install tail rotor blades and spacers in hub. Assemble blades (if viewed from left side
of aircraft) for clockwise rotation, to cone toward tail rotor gearbox. Install hardware
securing blades to hub; install standard hardware on outboard fasteners for initial tail
rotor assembly static balance check. Tighten fasteners, but do not torque.
4. Touch-up bolt heads using approved paint per § 20-70.
5. Perform tail rotor assembly static balance per § 64-11.

Page 64.8 Chapter 64 Tail Rotor APR 2019

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APR 2019 Chapter 64 Tail Rotor Page 64.9

FIGURE 64-4 SCRATCHES AND CORROSION

Page 64.10 Chapter 64 Tail Rotor APR 2019

64-30 Tail Rotor Blade Inspection and Repair
This blade repair procedure outlines the repair limits, methods and materials used for
repairing tail rotor blades. Repairs are limited to blending out scratches, dents, nicks,
removing corrosion, and refinishing the blades. The inspections, repairs and limitations
contained herein refer to damage sustained in service, including damage during shipping
and handling (manufacturing irregularities are treated separately by the factory). In-service
damage will generally exhibit paint scuffing or scratches and often times freshly-exposed
metal in the form of scratches in the finish. If there are any questions as to the possibility
of a manufacturing irregularity, 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.

Refer to § 62-40 for measuring blade damage.

64-31 Scratches and Corrosion

1. Refer to Figure 64-4. Verify damage does not exceed the following limits:
a. 0.008 inch maximum damage between RS 18.00 & RS 28.43 (F029-2) or RS
30.00 (F029-1).
b. 0.005 inch maximum damage more than 15° spanwise between RS 18.00 & inboard.
c. 0.008 inch maximum damage less than 15° spanwise between RS 18.00 & inboard.
2. Refer to § 62-50 (main rotor) for repair procedures for damage within limits. Blend out
scratches or corrosion on skins with a 0.10 inch blend radius.

APR 2019 Chapter 64 Tail Rotor Page 64.11

FIGURE 64-5 DENTS

Page 64.12 Chapter 64 Tail Rotor APR 2019

64-32 Dents

CAUTION
Tap-test dented areas in honeycomb. If any voids are found
associated with dents, contact RHC Customer Service.
Tap-test voids, debonds, and dents in blades using an AN970‑4
washer or 1965-or-later U.S. quarter dollar coin in good condition.
CAUTION
When dented areas are found, inspect opposite side of the blade
for a bulge. Replace blade with a bulge greater than 0.010 inch
opposite a dent.
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.
WARNING
Any damaged tail rotor blade that cannot be repaired within the
limits of this section must be removed from service immediately
and marked "scrap."

A. Skins
1. Refer to Figure 64-5. Smooth, round bottom dents with 0.060 inch minimum
radius may be repaired when damage does not exceed the following limits:
a. 0.010 inch maximum depth between leading edge and 0.75 inch aft
(chordwise).
b. 0.75 inch aft (chordwise) of leading edge:
i. 0.090 inch maximum dent depth between RS 21.00 and RS 27.43
(F029-2) or RS 29.00 (F029-1).
ii. 0.030 inch maximum dent depth between RS 21.00 and inboard.
c. 0.030 inch maximum depth between trailing edge and 0.40 inch forward
(chordwise).
d. 0.008 inch maximum depth between RS 27.43 and 28.43 (F029-2) or RS
29.00 and RS 30.00 (F029-1).
e. 0.008 inch maximum depth over the skin-to-root fitting bond joint.
f. No dents are permitted on carbon fiber bonded area.
2. Refer to § 62-50 (main rotor) for repair procedures for damage within limits.

APR 2019 Chapter 64 Tail Rotor Page 64.13

64-33 Erosion
Replace any blade where erosion has caused deformation or ripples in the leading edge.

64-34 Root Fitting Damage

1. Verify damage does not exceed the following limits:
a. No repairs permitted within 1.5-inch diameter circle from center of spherical bearing.
b. 0.040 inch maximum depth on other root fitting exposed areas.
2. Refer to § 62-50 (main rotor) for repair procedures for damage within limits. Blend out
root fitting damage with a minimum 1.0 inch blend radius.

64-35 Nicks and Notches

A. Trailing Edge
1. Verify damage does not exceed the following limits:
a. 0.050 inch maximum in the extreme trailing edge.
2. Refer to § 62-50 (main rotor) for repair procedures for damage within limits. Blend
out nicks and notches in blade trailing edge for 1.0 inch minimum each side of nick
or notch.

64-36 Painting
Refer to Figure 64-4. See § 62-52 (main rotor) for painting procedures.

Page 64.14 Chapter 64 Tail Rotor APR 2019

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APR 2019 Chapter 64 Tail Rotor Page 64.15

FIGURE 64-6 ELASTOMERIC BEARING REMOVAL

FIGURE 64-7 ELASTOMERIC BEARING INSTALLATION

Page 64.16 Chapter 64 Tail Rotor APR 2019

64-40 Tail Rotor Hub

64-41 Bearing Replacement

A. Removal
1. Remove tail rotor assembly per § 64-10.
2. Remove tail rotor blades per § 64-20.
3. Refer to Figure 64-6. Press bearing(s) from hub using MT556-11 bearing removal
(and installation) tools.
B. Installation
1. Inspect tail rotor hub per § 64-42.

CAUTION
Elastomeric bearings are a slight press fit in tail rotor hub
bores. Inspect bores for fretting; if fretting is detected, hub is
unairworthy.

2. Refer to Figure 64-7. Using Q-tip, apply light coat of approved primer per § 20-
70 to bottom of hub bearing bore. Apply a thin line of primer to center of bearing
outside diameter. While primer is wet, press bearing into hub using MT556-11
bearing removal and installation tools. Wipe away excess primer.
3. Repeat steps for second bearing, as required.

64-42 Inspection
1. Remove tail rotor blades per § 64-20, and inspect blades per § 64-30.
2. Remove elastomeric bearings per § 64-41.
3. Clean G062-1 tail rotor hub using approved solvent per § 20-70.
4. Visually inspect for indications of damage, wear, nicks, dings, and corrosion. Check
arms for straightness, bolt holes for elongation, and bearing bores for fretting or galling.
Corrosion is not permitted on clamp-up surfaces.
5. For suspect areas, locally remove paint from hub using approved paint stripper per §
20-70; dye penetrant or fluorescent penetrant inspect per § 20-40.
6. Touch-up bare metal using approved materials per § 20-70.
7. Install elastomeric bearings per § 64-41.
8. Install tail rotor blades per § 64-20.

APR 2019 Chapter 64 Tail Rotor Page 64.17

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Page 64.18 Chapter 64 Tail Rotor APR 2019

CHAPTER 65

TAIL ROTOR DRIVE SYSTEM

Section Title Page

65-00 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65.1
65-10 Tail Rotor Drive Fan Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65.1
65-20 Tail Rotor Drive Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 65.3
65-21 Runout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65.5
65-22 Damper Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 65.7
65-30 (Tail Rotor Driveline) Intermediate Flex Plate Shimming . . . . . . . . . . 65.8
65-40 Tail Rotor Gearbox Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65.10
65-41 Output Shaft Seal Replacement . . . . . . . . . . . . . . . . . 65.11
65-42 Input Shaft Seal Replacement . . . . . . . . . . . . . . . . . . . 65.12

SEP 2012 R66 Maintenance Manual Chapter 65 Tail Rotor Drive System Page 65.i
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Page 65.ii Chapter 65 Tail Rotor Drive System R66 Maintenance Manual SEP 2012
CHAPTER 65

TAIL ROTOR DRIVE SYSTEM

65-00 Description

The tail rotor driveline consists of an intermediate shaft running aft from the main gearbox
and a long tail rotor driveshaft which runs the length of the tailcone. Flexible couplings are
located at both ends of the intermediate shaft. The long tail rotor driveshaft has a support
bearing at its front end and a damper bearing approximately one-third of the way aft on the
shaft. The cooling fan is mounted to the intermediate shaft. The tail gearbox contains a
single 90º splash-lubricated spiral-bevel gearset which increases speed to tail rotor RPM.

65-10 Tail Rotor Drive Fan Shaft

Refer to R66 Illustrated Parts Catalog (IPC) Figure 65-1.

CAUTION

Do not damage F196-1 fan shaft aft yoke or G174-1 fanwheel

assembly mid plate during fan shaft removal or installation.

A. Removal

1. Remove tailcone cowling assembly per § 53-23.

2. Refer to Figure 65-1. Remove hardware securing F252-1 strut assembly to upper
frame assembly and remove strut.

3. Remove hardware securing intermediate C947-3 flex plate assembly to F196-1 (tail
rotor) fan shaft aft flange and D224 tail rotor drive shaft assembly forward yoke, noting
hardware removed. Remove flex plate, and temporarily support aft portion of fan shaft.

4. Remove hardware securing fan shaft to forward C947-3 flex plate assembly.

5. Remove hardware securing fan shaft to G174-1 fanwheel assembly. Carefully pull
fan shaft forward through fanwheel assembly, rotating yoke as necessary. Remove
temporary support.

B. Installation

1. Refer to Figure 65-1. Route F196-1 fan shaft aft through fanwheel assembly, rotating
yoke as necessary. Install hardware securing fan shaft to G174-1 fanwheel assembly.
Standard torque nuts and palnuts per § 20-32, and torque stripe per Figure 5-1.

2. Install hardware securing fan shaft to forward C947-3 plate assembly. Standard
torque nuts and palnuts per § 20-32, and torque stripe per Figure 5-1. Shim tail rotor
driveline per § 65-30.

3. Install F252-1 strut assembly and hardware securing strut to upper frame assembly.
Standard torque nuts per § 20-32 and torque stripe per Figure 5-1.

4. Install tailcone cowling assembly per § 53-23.

MAY 2015 Chapter 65 Tail Rotor Drive System Page 65.1

FIGURE 65-1 TAIL ROTOR DRIVELINE

Page 65.2 Chapter 65 Tail Rotor Drive System MAY 2015

65-20 Tail Rotor Drive Shaft Assembly

Refer to R66 Illustrated Parts Catalog (IPC) Figure 65-3.

A. Removal

1. Remove C023 tailcone assembly per Section 53-40.

2. Refer to Figure 65-1. Remove hardware securing F172-3 (bearing) housing to F193-2
hanger.

3. Refer to Figure 65-3. Using a 3-foot extension, remove bolts securing C041-12
damper assembly arm to D072-1 bulkhead assembly angle. Support forward end of
D224 drive shaft assembly.

4. Remove hardware securing A558-2 cover to tailcone and remove cover.

5. Support aft end of drive shaft, and remove hardware securing drive shaft to aft C947-3
plate assembly, noting hardware removed. Carefully pull drive shaft forward through
tailcone.

B. Installation

1. Refer to Figure 65-1. Route D224 drive shaft assembly through inside of tailcone.
Support drive shaft as required.

2. Install hardware securing drive shaft to aft C947-3 plate assembly, as removed, and
remove support. Standard torque fasteners per § 20-32 and torque stripe per Figure
5-1. Install A558-2 cover.

3. Refer to Figure 65-3. Remove forward A231 (tailcone) plug assembly. Estimate
longitudinal gap (or interference) between C041-12 damper assembly arm and D072-
1 bulkhead assembly angle. If gap (or interference) exceeds 0.12 inch, contact RHC
Technical Support. If gap (or interference) is less than 0.12 inch, verify correct damper
orientation. Using a 3-foot extension, install bolts securing damper to bulkhead angle.
Standard torque bolts per § 20-32 and torque stripe per Figure 5-1. Install plug
assembly.

4. Install hardware securing F172-3 (bearing) housing to F193-2 hanger, and remove
support. Standard torque bolts per § 20-32 and torque stripe per Figure 5-1.

5. Install C023 tailcone assembly per § 53-40.

MAY 2015 Chapter 65 Tail Rotor Drive System Page 65.3

FIGURE 65-2 RUNOUT

Page 65.4 Chapter 65 Tail Rotor Drive System MAY 2015

65-21 Runout

1. Remove A231 (tailcone) plug assemblies.

2. Assemble MT260-6 tail rotor drive shaft runout tool and a calibrated dial indicator.

3. Refer to Figure 65-2. Using appropriate combination of extension(s), insert tool

through tailcone inspection hole. Verify foot squarely contacts tail rotor drive shaft
when pressing dial indicator firmly against inspection hole edges. Have a second
person rotate rotor system by turning tail rotor hub.

4. Rotate rotor system slowly, smoothly, and for several revolutions until the technician
is able to determine the average indicated movement. Maximum runout is 0.025 inch.

5. Repeat steps at each inspection hole. Record values as required (recommended during
100-hour or annual inspection).

FIGURE 65-3 DAMPER ORIENTATION

MAY 2015 Chapter 65 Tail Rotor Drive System Page 65.5

FIGURE 65-4 DAMPER ASSEMBLY

Page 65.6 Chapter 65 Tail Rotor Drive System MAY 2015

65-22 Damper Assembly
Refer to R66 Illustrated Parts Catalog (IPC) Figure 65-7.
A. Disassembly
1. Remove tail rotor drive shaft per § 65-20, if not previously accomplished.
2. Refer to Figure 65-4. Remove hardware securing C041-11 bearing assembly and
C041-13 arm to C041-3 link.
B. Inspection and Assembly
1. Refer to Figure 65-4. Inspect condition of components. Verify no wear on Teflon®
(dark gray) face of C041-5 washers. Verify no wear or grooves on A141-36
washers, A141-37 washers, and link. Replace components as required.

CAUTION
Install C041-5 washers with Teflon® face toward C041-3 link and
toward A141-36 washer (remove protective coating, if installed).
CAUTION
Install C041-6 spring washer with concave face toward C041-5
washer.
2. Assemble damper. Install hardware securing C041-11 bearing assembly and
C041-13 arm to C041-3 link. Align component holes on A041-10 dowel pin(s).
Standard torque nuts and palnuts per § 20-32 and torque stripe per Figure 5-1.
3. Attach a calibrated spring scale to Point A. Holding link, verify force required to
rotate arm about Point B is 3.5 - 5.8 lb. Adjust as required per Part C.
4. Attach a calibrated spring scale to Point B. Holding bearing assembly, verify force
required to rotate link about point C is 2.1 - 3.6 lb. Adjust as required per Part C.
C. Friction Adjustment

CAUTION
Do not adjust damper drag by changing bolt torque.
1. Refer to Figure 65-4. If friction is less than required:
a. Disassemble C041-12 damper assembly per Part A. Bend C041-6 spring
washers to 0.065 - 0.078 inch total height; inspect and reassemble damper
assembly per Part B.
b. If friction is less than required after correcting spring washer height, disassemble
damper assembly per Part A. Lap A105-12 journals, as required; inspect and
reassemble damper assembly per Part B.
2. If friction is greater than required:
a. Disassemble damper assembly per Part A. Flatten C041-6 spring washers
slightly; inspect and reassemble damper assembly per Part B.
3. Install tail rotor drive shaft per § 65-20.
MAY 2015 Chapter 65 Tail Rotor Drive System Page 65.7
65-30 (Tail Rotor Driveline) Intermediate Flex Plate Shimming

NOTE

The tail rotor driveline is shimmed for minimal preload.

1. Refer to Figure 65-1. If not previously accomplished, remove hardware securing

intermediate C947-3 flex plate assembly to F196-1 (tail rotor) fan shaft aft flange and
D224 tail rotor drive shaft assembly forward yoke. Remove flex plate, and temporarily
support aft portion of fan shaft.

2. Measure flex plate thickness at bonded washers (4 places) to determine average thickness:

(1st place) inch

(2nd place) + inch
(3rd place) + inch
(4th place) + inch
Total = inch
Total ÷ 4 = inch (Flex plate average thickness)
3. a. Position F196-1 fan shaft aft flange arms and D224 tail rotor drive shaft assembly
forward yoke flange arms at 3 o’clock and 9 o’clock positions (horizontal). Measure
gap between arms to determine average gap:

(3 o’clock position) inch

(9 o’clock position) + inch
Total = inch
Total ÷ 2 = inch (Average gap between flange arms)
b. Rotate D224 tail rotor drive shaft assembly 180º, and repeat step a:

(3 o’clock position) inch

(9 o’clock position) + inch
Total = inch
Total ÷ 2 = inch (Average gap between flange arms)
4. Evaluate flange straightness by calculating the difference between the 3 o’clock
positions in steps 3a and 3b. Also calculate the difference between the 9 o’clock
positions in steps 3a and 3b. If either calculated difference exceeds 0.015 inch, either
one or both flanges are bent and require replacement.

Page 65.8 Chapter 65 Tail Rotor Drive System MAY 2015

65-30 (Tail Rotor Driveline) Intermediate Flex Plate Shimming (continued)

5. Using the smaller average gap from step 3a or 3b, subtract the flex plate average
thickness determined in step 2:

Smaller average gap between flange arms (step 3a or 3b) inch

Subtract flex plate average thickness (step 2) − inch
Total = inch
6. Select shims per Table 65-1 and install intermediate C947-3 flex plate assembly.
Standard torque nuts and palnuts per § 20-32 and torque stripe per Figure 5-1. Remove
F196-1 (tail rotor) fan shaft temporary support.

WARNING

Shim both arms of flanges equally. All fasteners must meet

torque requirements given in § 20-33.

Shim required between

Shim required between
Calculated intermediate C947-3 flex plate
intermediate C947-3 flex plate
Dimension and D224 tail rotor drive shaft
and F196-1 fan shaft aft flange forward yoke

NAS1149F0432P washer between forward C947-3 flex plate

assembly and F908-1 yoke assembly and/or F196-1 fan shaft
−0.017 or greater forward flange may be relocated under nut as required to achieve
negative number −0.016 / +0.016 inch calculated dimension. Relocate washers
as required, and repeat steps 3 thru 6.

−0.016 / +0.016 in. None None

+0.017 / +0.047 in. NAS1149F0432P washer None

+0.048 / +0.079 in. NAS1149F0432P washer NAS1149F0432P washer

+0.080 / +0.110 in. NAS1149F0463P washer NAS1149F0432P washer

+0.111 / +0.141 in. NAS1149F0463P washer NAS1149F0463P washer

NAS1149F0432P washer between forward C947-3 flex plate

assembly and F908-1 yoke assembly and/or F196-1 fan shaft
+0.142 or greater forward flange may be exchanged with NAS1149F0463P washer
positive number as required to achieve −0.016 / +0.016 inch calculated dimension.
Exchange washers as required, and repeat steps 3 thru 6.

TABLE 65-1 TAIL ROTOR DRIVELINE

7. Measure fanwheel-to-inlet gaps per § 79-11.

MAY 2015 Chapter 65 Tail Rotor Drive System Page 65.9

65-40 Tail Rotor Gearbox Assembly

Refer to R66 Illustrated Parts Catalog (IPC) Figure 65-9.

A. Removal

NOTE

Drain tail rotor gearbox oil per § 12-21 prior to gearbox removal,
or keep gearbox vertical after removal to avoid oil escape thru
filler-vent plug.

1. Remove hardware securing push-pull tube assembly to bellcrank assembly.

2. As required, remove tail rotor assembly per § 64-10. As required, remove hardware
securing bellcrank to tail rotor gearbox assembly output cartridge. Slide (assembled)
bellcrank, pitch control assembly, and pitch links off of gearbox output shaft.

3. Remove hardware securing A558-2 cover to tailcone and remove cover.

4. Support aft end of D224 drive shaft assembly, and remove hardware securing gearbox
input yoke to aft C947-3 plate assembly, noting hardware removed.

5. Cut and discard ty-raps as required and disconnect chip detector wiring at plastic
connector.

6. Remove hardware securing gearbox to tailcone casting and remove gearbox.

B. Installation

1. Position tail rotor gearbox assembly on tailcone casting and install mounting hardware.
Special torque screws per § 20-33 and torque stripe per Figure 5-1.

2. Connect chip detector wiring at plastic connector and install ty-raps, as required.
Cinch ty-raps until snug without over-tightening, and trim tips flush with heads.

3. Install hardware securing gearbox input yoke to aft C947-3 plate assembly, and remove
support. Shim tail rotor driveline per § 65-30. Standard torque bolts per § 20-32 and
torque stripe per Figure 5-1. Install A558-2 cover.

4. If removed, slide (assembled) bellcrank assembly, pitch control assembly, and pitch
links onto gearbox output shaft. Install hardware securing bellcrank to gearbox output
cartridge. Standard torque bolts per § 20-32 and torque stripe per Figure 5-1. Shim
pitch control per § 67-62, as required.

5. Install hardware securing push-pull tube assembly to bellcrank. Standard torque

fastener per § 20-32 and torque stripe per Figure 5-1.

6. If removed, install tail rotor assembly per § 64-10.

7. Service tail rotor gearbox per § 12-21, as required.

Page 65.10 Chapter 65 Tail Rotor Drive System MAY 2015

65-41 Output Shaft Seal Replacement

Refer to R66 Illustrated Parts Catalog (IPC) Figure 65-13.

1. Remove tail rotor assembly per Section 64-10.

2. Remove hardware securing push-pull tube assembly to bellcrank assembly.
3. Remove hardware securing bellcrank to tail rotor gearbox assembly output cartridge.
Slide (assembled) bellcrank, pitch control assembly, and pitch links off of gearbox output
shaft.
4. Cut and discard safety wire securing C112-2 cap retaining hardware. Remove hardware
securing cap to gearbox and remove cap with C966-2 seal and C215-133 o-ring.

CAUTION

Do not remove shims between cap and gearbox assembly.

Shims control output shaft drag.

5. Using hydraulic press, press old seal from cap. Remove and discard o-ring. Clean and
dry cap, especially seal seating surface and o-ring groove.
6. Verify open face of seal points toward gearbox and press new seal into cap bore 0.160
inches from external surface. Lightly coat new o-ring with A257-22 oil and install in
cap.
7. Lightly coat output shaft seal seating area with A257-22 lubricant and slide cap onto
shaft. Install hardware securing cap to gearbox and special torque bolts per Section 20-
33. Install 0.032-inch diameter lockwire through hardware and safety in pairs.
8. Slide (assembled) bellcrank assembly, pitch control assembly, and pitch links onto
gearbox output shaft. Shim pitch control per Section 67-62, as required.
9. Install hardware securing push-pull tube assembly to bellcrank. Standard torque fastener
per Section 20-32 and torque stripe per Figure 5-1.
10. Install tail rotor assembly per Section 64-10.

SEP 2012 R66 Maintenance Manual Chapter 65 Tail Rotor Drive System Page 65.11
65-42 Input Shaft Seal Replacement

Refer to R66 Illustrated Parts Catalog (IPC) Figure 65-13.

1. Remove tail rotor gearbox per Section 65-40. Tail rotor assembly and pitch control
assembly removal are not required.

2. Remove and discard cotter pin securing tail rotor input yoke retaining nut. On a suitable
work bench, place a wood block between yoke and gearbox housing to prevent tail rotor
rotation; remove castellated nut, washer, and yoke.

3. Cut and discard safety wire securing C112-1 cap retaining hardware. Remove hardware
securing cap to gearbox and remove cap with A966-3 seal and C215-140 o-ring.

CAUTION

Do not remove C141-2 washer between cap and bearing.

4. Using hydraulic press, press old seal from cap. Remove and discard o-ring. Clean and
dry cap, especially seal seating surface and o-ring groove.

5. Verify open face of seal points toward gearbox and press new seal into cap bore 0.25
inch from external surface. Lightly coat new o-ring with A257-22 oil and install in
cap.

6. Install cap, and hardware securing cap to gearbox; special torque bolts per Section 20-
33. Install 0.032-inch diameter lockwire through hardware and safety in pairs.

7. Install input yoke, washer, and castellated nut onto gear shaft. Place wood block
between yoke and gearbox housing to prevent tail rotor rotation, special torque nut per
Section 20-33, and install new MS24665-210 cotter pin.

8. Install tail rotor gearbox per Section 65-40.

Page 65.12 Chapter 65 Tail Rotor Drive System R66 Maintenance Manual SEP 2012
CHAPTER 67

FLIGHT CONTROLS
Section Title Page

67-00 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67.1

67-10 Cyclic Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67.1
67-11 Cyclic Control Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67.1
67-12 Cyclic Grip Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67.4
67-13 Cyclic Friction Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67.6
67-20 Collective Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67.6
67-21 Collective Stick Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67.6
67-22 Collective Friction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67.8
67-30 Jackshaft and Strut Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67.8
67-31 Jackshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67.8
67-40 Swashplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67.9
67-41 Swashplate Tilting Friction Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 67.11
67-42 Upper and Lower Scissor Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . 67.11
67-50 Tail Rotor Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67.13
67-51 Pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67.13
67-52 Pitch Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67.14
67-60 Bellcranks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67.15
67-61 C317-5 or C317-9 Bellcrank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67.15
67-62 C317-7 Bellcrank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67.16
67-63 F316-1 Bellcrank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67.17
67-64 A331-4 Bellcrank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67.18
67-65 A120-5 Bellcrank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67.18

MAY 2015 Chapter 67 Flight Controls Page 67.i

Intentionally Blank

Page 67.ii Chapter 67 Flight Controls MAY 2015

CHAPTER 67

FLIGHT CONTROLS

67-00 Description
Dual controls, which are removable on the left side, are standard equipment. All primary
controls are actuated through push-pull tubes and bellcranks. Bearings used throughout the
control system are either sealed ball bearings or have self-lubricated Teflon® liners.
R66 flight controls operate conventionally. The cyclic stick appears different, but the grip
moves the same as in other helicopters due to the free hinge at the center pivot. The cyclic
grip is free to move vertically allowing the pilot to rest his forearm on his knee if he chooses.
The collective control is also conventional. A twist grip provides input to the engine fuel
control, and raising or lowering the collective provides power turbine governor inputs via an
interconnecting linkage.
Pilot-side tail rotor pedals are adjustable. To adjust, extract quick-release pin on each pedal by
depressing button and pulling. Slide pedal fore or aft to most comfortable of three adjustment
positions, and reinstall quick-release pin. Verify pins secure before flight.
See R66 Pilot's Operating Handbook (POH) Section 7 for instructions to remove (removable)
flight controls.
See Section 67-50 for hydraulic system description.

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.
67-10 Cyclic Controls
Refer to R66 Illustrated Parts Catalog (IPC) Chapter 67.
67-11 Cyclic Control Assembly
A. Removal
1. Refer to Section 6-70. Remove F794-1 (forward) and F794-2 (aft) belly panels,
F680-3 (pilot collective) and F445-1 (forward tunnel) cover assemblies, and F461-1
(collective cross tube) and F463-1 (aft tunnel) cover assemblies. Open upper console,
disconnect OAT gage and hourmeter wiring connectors, and remove radio faceplate.
Remove plastic hole plug from vertical keel panel beneath RH, aft seat.
2. Turn cyclic friction OFF. Gently punch out cyclic friction knob spring pin and remove
knob. Remove hardware securing F444-1 cover assembly to F338-1 box, unsnap
boot, and lift cover assembly to expose wire harness connectors. Disconnect anti-
ice, pitot heat, and ELT switch (if installed) wiring. Snap boot together at top of
cyclic stick to secure cover. Install pin on cyclic friction shaft to retain spacers.
3. Refer to Figure 67-1. Unhook D918-1 cord assembly from C069-8 (cyclic) stick
assembly and D918-2 cord assembly from C177-5 pivot assembly.
4. Disconnect wiring exiting D320-8 stick at connectors near bottom of stick.

MAR 2012 R66 Maintenance Manual Chapter 67 Flight Controls Page 67.1
FIGURE 67-1 MAIN ROTOR FLIGHT CONTROLS

Page 67.2 Chapter 67 Flight Controls R66 Maintenance Manual MAR 2012
67-11 Cyclic Control Assembly (continued)

A. Removal (continued)

5. Remove hardware securing C121-1 push-pull tube assembly to D320-8 stick

assembly. Remove hardware securing C319-5 torque tube assembly to C177-5
pivot assembly. Move push-pull tube and torque tube assemblies aft, and protect
from scratching.
6. Disconnect, but do not remove, two bolts securing cyclic friction assembly to cabin.
Apply some cyclic friction to keep plates assembled.
7. Remove screws securing F338-1 cyclic box to cabin. Lift and remove cyclic control
assembly with attached cyclic box and friction assembly. Install nuts onto two
cyclic friction assembly bolts, hand tight, to retain bolts and spacers.
8. Remove hardware securing both outboard, vertical F121-5 push-pull tube assemblies
and C130-47 spacer to D696-6 yoke assembly.
9. Remove hardware securing center, vertical F121-7 push-pull tube assemblies to
C958-6 bellcrank.
10. Remove hardware securing G205-1 fork assembly to F334-1 support assembly.
11. Pull D175-5 cyclic pivot assembly (torque tube, yoke, bellcranks, fork, and push-pull
tube assembly) aft through belly.
B. Installation

1. Refer to Figure 67-1. Verify center-to-center distance between rod end and spherical
bearings in G205-5 fork is 5.40 ± 0.03 inches; adjust as required. Standard torque
jam nut and palnut per Section 20-32. Install C175-5 cyclic pivot assembly (torque
tube, yoke, bellcranks, fork, and push-pull tube assemblies) thru aft belly.
2. Connect G205-1 fork assembly to F326-1 bellcrank and standard torque bolt per
Section 20-32.
3. Connect lower end of center F121-7 push-pull tube to C958-6 bellcranks and standard
torque bolt per Section 20-32.
4. Connect lower ends of both outboard F121-6 push-pull tubes to D696-6 yoke using
a NAS6605-46 bolt and C130-47 spacer and standard torque per Section 20-32.
Install plastic hole plug in vertical keel panel beneath RH, aft seat.
5. Remove temporary nuts from cyclic friction assembly bolts. Position cyclic box
with attached cyclic control and friction assemblies between keel panels. Install all
screws fastening cyclic box to cabin. Fasten cyclic friction assembly to cabin and
standard torque bolts per Section 20-32.
6. Connect C319-5 torque tube assembly to C177-5 pivot and standard torque bolts
per Section 20-32.
7. Connect forward end of C121-1 push-pull tube to D320-8 cyclic stick and standard
torque bolts per Section 20-32.

25 OCT 2010 R66 Maintenance Manual Chapter 67 Flight Controls Page 67.3
67-11 Cyclic Control Assembly (continued)
B. Installation (continued)
8. Connect all electrical plugs at bottom of cyclic stick. Ensure protective sleeving
covers maximum amount of wiring possible and sleeving ends are secured with
lacing tape.
9. Connect D918-1 cord to D320-8 cyclic stick. Connect D918-2 cord to C177-5
pivot.
10. Move cyclic control through all positions and verify operating and no binding.
11. Install radio face plate, connect OAT gage and hourmeter wiring connectors, and ty-
rap as required. Close and secure upper console.
12. Connect cyclic box cover anti-ice, pitot heat (if installed), and ELT (if installed) switch
wiring connectors and secure cover.
13. Install cyclic friction knob and secure with spring pin. Close and secure cyclic stick
boot.
14. Install F794-1 (forward) and F794-2 (aft) belly panels, F680-3 (pilot collective) and
F445-1 (forward tunnel) cover assemblies, and F461-1 (collective cross tube) and
F463-1 (aft tunnel) cover assemblies.

67-12 Cyclic Grip Assembly

A. Removal

NOTE

This may be accomplished without removal of complete cyclic

assembly from rotorcraft.
1. Remove forward belly panel.
2. Refer to Figure 67-1. Disconnect wiring connectors attached to wiring exiting base
of D320-8 cyclic stick. Using pin extractor, remove pins from housings (wires
112, 138, & 355 may remain installed) and retain housings. Remove lacing tape
from both ends of protective sleeving covering wires exiting base of stick assembly.
Attach a 3 foot length of safety wire or wire lacing tape to one removed pin.
3. As required, rotate grip assembly by pushing in on spring-loaded stop pin so exposed
wire loom does not wrap around top of D320-8 cyclic stick. Remove circular plug,
D684-1 spring, cotter pin, castellated nut, and washer where grip assembly attaches
to D320-8 cyclic stick.
4. Remove grommet atop cyclic stick at grip assembly wiring entrance. With a soft-
faced hammer, gently tap cyclic grip assembly pivot and remove grip assembly and
attached wiring from stick assembly. Ensure safety wire or lacing attached to internal
wiring protrudes from top and bottom of stick assembly. Also, ensure pivot bearings
remain with stick assembly.

NOTE

Do not damage bearings while removing.

Page 67.4 Chapter 67 Flight Controls R66 Maintenance Manual 25 OCT 2010
67-12 Cyclic Grip Assembly (continued)

B. Installation

1. Refer to Figure 67-1. Ensure protective sleeving covers wires exiting grip assembly
with one grommet in grip and one (for cyclic stick) on wire bundle (spare grommets
may be installed if desired).

2. Slide grip assembly into bearings in stick assembly. Install washer, castellated nut
and cotter pin.

CAUTION

Tighten castellated nut only until there is no axial movement of

bearings and cyclic grip assembly. Overtightening nut will dam-
age bearings.

3. Install D684-1 spring so that when grip assembly is rotated one turn clockwise, with
co-pilot grip removed, pilot grip (tube) will float just above horizontal and stay full-up
when placed full-up. Install circular plug.

4. Temporarily attach grip assembly wiring to safety wire (or lacing) exiting atop cyclic
stick. Carefully pull wires thru cyclic stick. Install grommet, included with grip
assembly wiring, into cyclic stick wiring entrance hole. Remove safety wire (or
lacing).

5. Position protective sleeving on wiring exiting cyclic stick bottom to cover maximum
amount of wiring possible. Secure sleeving ends with lacing tape.

6. Install pins on each wire into proper position in housings. Refer to Figure 98-2 for
pin positions.

7. Connect cyclic and airframe wiring and ty-rap. Move cyclic control through all
positions and verify clearance and no binding.

8. Turn BATTERY switch on and verify correct function of all switches on grip assembly
and cyclic stick.

9. Install forward belly panel.

25 OCT 2010 R66 Maintenance Manual Chapter 67 Flight Controls Page 67.5
67-13 Cyclic Friction Assembly

NOTE

The cyclic friction assembly is located below the forward left

corner of the cyclic box. Turning friction knob clockwise applies
friction to both longitudinal and lateral cyclic axes. Adjustment
is required if friction cannot be applied.
A. Friction Adjustment
1. Turn friction knob counter-clockwise until it stops.
2. Remove roll pin connecting knob to shaft.
3. Lift knob off shaft.
4. Install NAS1149F0432P or NAS1149F0463P washers under knob washer, as
required, so knob rotates 1/8 to 1 turn before adding friction. With friction off, force
at grip to move cyclic shall not exceed 1.75 pounds longitudinal and lateral within
hydraulic servo deadbands.
5. Replace knob and install roll pin.
6. Move flight controls throughout complete travel. Verify no binding.
67-20 Collective Control
67-21 Collective Stick Assembly
A. Removal
1. Refer to Figure 67-1. Disconnect A333-1 collective-travel stop from F348-1 anchor
by removing NAS6603 bolt at bottom of stop. Position stop parallel to collective
stick and apply collective friction.
2. Refer to Figure 6-8. Remove F445-1 forward tunnel cover, F680-3 pilot's collective
cover, F680-1 co-pilot's collective cover, F463-1 mid-tunnel cover, and F461-1
collective cross tube cover.
3. Pivot pilot's seat bottom to the open position. Remove bolt securing inboard end of
collective stick to pilot's seat structure. Refer to Figure 76-1. Disconnect throttle
control inner wire from A462-4 fitting at outboard end of collective. Remove three
screws securing C522-10 throttle control to collective cross tube.
4. Disconnect wiring exiting aft end of center collective stick from airframe harness
connector. Remove ty-raps as required.
5. Disconnect forward end of F121-1 push-pull tube from collective stick assembly.
6. Remove bolt securing outboard end of collective stick to F303-1 support. Remove
two remaining screws securing F303-1 support to cabin. Slide support, with attached
micro-switches, down to allow aft movement of collective stick.
7. Pivot pilot's seat bottom to the open position. Remove bolt securing collective stick
assembly to pilot's seat structure.
8. Carefully move collective stick assembly aft and remove from helicopter.

Page 67.6 Chapter 67 Flight Controls R66 Maintenance Manual 25 OCT 2010
67-21 Collective Stick Assembly (continued)
B. Installation
1. Refer to Figure 67-1. Position A333-1 collective-travel stop parallel to collective
stick and apply collective friction. From aft side of co-pilot's seat, carefully
position collective stick assembly in helicopter.
2. Pivot pilot's seat bottom to the open position. Install bolt from inside pilot's seat
structure thru bearing block into tunnel and secure to inboard end of collective stick
assembly. Standard torque bolt, install palnut, and torque stripe per Figure 5-1.
3. At outboard end of collective stick, slide F303-1 support, and attached micro-switches,
up behind collective cross tube and secure support to cabin with two screws.
4. Install journal in outboard pivot bearing of collective stick assembly. Position journal
& bearing between flanges of F303-1 support and insert NAS6604 bolt. Standard
torque bolt per § 20-32, install palnut, and torque stripe per Figure 5-1.
5. Connect forward end of F121-1 push-pull tube to collective stick assembly with
NAS6604 bolt head on outboard (right) side (nut side inboard). Standard torque
bolt per § 20-32, install palnut, and torque stripe per Figure 5-1.
6. Refer to Figure 6-8. Slide F680-3 collective cover over center collective stick aft
of friction assembly.
7. Insert A130-4 spacer into lower end of A333-1 collective-travel stop. Position
spacer and stop in F348-1 anchor. Install NAS1149F0432P and 0463P washers
on spacer on either side of stop as required to obtain 0.001/0.035 inch axial
play and align stop with collective. Secure stop to anchor with NAS6603 bolt,
standard torque per § 20-32, install palnut, and torque stripe per Figure 5-1.
Move collective up & down and verify no binding of stop.

CAUTION
NAS6604-9 bolt connecting forward end of F121-1 push-pull
tube to collective must be installed so bolt head is toward right
side of helicopter. Refer to Figure 67-1.

8. Connect wiring exiting center collective stick to airframe wire harness connector.
Secure connector to airframe harness with Ty-raps as required. Move collective
up & down and verify wiring clearance with no strain.
9. Refer to Figure 76-1. Secure C522-10 throttle control to collective cross tube
with three clamps and screws. Position control inner wire in A462-4 fitting and
rig per § 76-11.
10. Refer to Figure 6-8. Install and secure F445-1 forward tunnel cover, F680-3
pilot's collective cover, F680-1 co-pilot's collective cover, F463-1 mid-tunnel
cover, and F461-1 collective cross tube cover.
11. Adjust collective friction per § 67-22.

APR 2017 Chapter 67 Flight Controls Page 67.7

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

67-30 Jackshaft and Strut Assembly

67-31 Jackshaft
A. Removal

NOTE
Rigging check is not necessary if jackshaft support rod end and
push-pull tube lengths are not altered.

1. Disconnect push-pull tubes from F339-1 jackshaft.

2. Disconnect two bolts connecting jackshaft to G201-1 frame.
3. Remove jackshaft.

B. Installation
1. Ensure A105-6 journal is installed in jackshaft aft support on G201-1 frame.
Position F339-1 jackshaft on G201-1 frame and install bolts. Standard torque
bolts per § 20-32, install palnuts, and torque stripe per Figure 5-1.
2. Insert bolt forward thru forward jackshaft arm and connect to upper end of F121-
7 push-pull tube. Install A115-1 spacer, A214-3 washer and nut. Standard
torque bolt per § 20-32, install palnut, and torque stripe per Figure 5-1.
3. Insert bolt aft thru aft jackshaft arm and connect to lower rod end on C343-8
tube. Install A115-1 spacer, A214-3 washer and nut. Standard torque bolt per
§ 20-32, install palnut, and torque stripe per Figure 5-1.
4. Verify no binding and/no interference with control system exists throughout flight
control travel.

Page 67.8 Chapter 67 Flight Controls APR 2017

67-40 Swashplate
A. Removal

NOTE
Rigging check is not required if push-pull tube rod end center-
to-center dimension does not change.

1. Remove main rotor blades and hub per §§ 62-10 and 62-20.
2. Atop of C251 main rotor drive shaft, remove D226 brackets, D151 teeter stops, and
C150 droop stops by removing NAS6608 bolt.
3. Disconnect upper C204 arm from C203 yokes.
4. Disconnect and remove C203 yokes, A210 key, and chord arm weights.
5. Remove swashplate boot by cutting plastic ty-raps.
6. Disconnect three push-pull tubes and A205 fork assembly from lower (non-rotating)
swashplate.
7. Lift swashplate with attached fork and pitch links off slider tube and remove from
helicopter.
B. Installation
1. Install swashplate onto slider tube assembly. Connect lower scissors’ fork to left side
of middle of three lugs on lower, non-rotating swashplate. Connect aft push-pull tube
to right side of aft, single lug on lower swashplate. Standard torque bolts per § 20-32.
Install palnuts and standard torque per § 20-32.
2. Verify swashplate tilting friction per § 67-41; adjust as required.
3. Slide swashplate boot over main rotor drive shaft and set in place.
4. Install C203 yokes on C251 main rotor drive shaft upper flange using A210 key to
index yokes to shaft. Finger tighten clamping hardware.

NOTE
Round edge of A210 key to fit into drive shaft flange indexing slot.

5. Standard torque NAS6605 bolt thru yokes and A210 key first per § 20-32. Install
palnuts and standard torque per § 20-32.
6. Standard torque bolt thru yokes opposite A210 key per 20-32. A slight gap between
yokes opposite A210 key is normal.
7. Install previously removed chord arm weights and standard torque bolt per § 20-32.
Install palnut, standard torque per §20-32, and torque stripe per Figure 5-1.

APR 2017 Chapter 67 Flight Controls Page 67.9

67-40 Swashplate (continued)
B. Installation (continued)
8. If required, fill remainder of rod end threaded hole in upper A205 fork with B270-4 or
–13 sealant (see § 20-70).
9. With bolt heads in direction of rotation, connect upper A205 fork to upper C204
arm and connect arm to C203 yokes. Standard torque bolts per § 20-32. Verify
0.001/0.005 inch axial play in both pivots; adjust C117 shim thickness between nut-
side journal & thrust washer as required. Verify bolt, arm, and clamped hardware in
upper scissor’s pivots rotate together. Install palnuts, standard torque per § 20-32,
and torque stripe per Figure 5-1.
10. Verify bolt, arm, and clamped hardware in lower scissor’s pivots rotate together.
Connect forward push-pull tube rod ends to remaining lower lugs on swashplate and
standard torque bolts per § 20-32. Install palnut, standard torque per § 20-32, and
torque stripe per Figure 5-1.
11. Connect upper A205 fork rod end and lower rod end of C258 pitch link to interrupter-
side swashplate ear and standard torque bolt per § 20-32. Install palnut, standard
torque per § 20-32, and torque stripe per Figure 5-1.
12. Position swashplate boot on rotating swashplate with inner lip contacting C203 yoke.
Secure with ty-raps.
13. Attach two A255-3 counterweights and lower rod end of C258 pitch link to swashplate
ear opposite interrupter and standard torque bolt per § 20-32. Install palnut, standard
torque per § 20-32, and torque stripe per Figure 5-1.
14. Install main rotor hub and blades per §§ 62-10 and 62-20.
15. Verify safety washers (or counterweight) and C115 spacers installed on all rod ends
per Figure 5-1. Torque stripe fasteners per Figure 5-1.
16. Verify no interference with control movement throughout flight control travel and
swashplate movement corresponds with cyclic and collective movement.
17. Track and balance main rotor per § 18-10.

Page 67.10 Chapter 67 Flight Controls APR 2017

67-41 Swashplate Tilting Friction Adjustment

Swashplate tilting friction is established by C197-1 through C197-6 shims controlling

clamping force of Teflon®-lined sleeves on the ball assembly.

1. Mark for reassembly and disconnect boot, pitch links and drive linkage (scissors) from
upper swashplate and both forward push-pull tubes from lower swashplate.

2. Align upper swashplate arms with lateral axis of helicopter and center cyclic stick.
Using MT359-1 spring scale (or equivalent) connected to upper swashplate arm
bolt hole, pull down and note scale reading while swashplate is moving; do not use
breakaway reading. Force required to tilt swashplate must be free-without-looseness
minimum to 5 pounds maximum.

3. To adjust friction, remove outer screws from upper swashplate and raise and secure
retainers to allow access to inner screws on lower, non-rotating swashplate. Remove
inner screws securing sleeve to lower swashplate.

4. Raise sleeve and measure thickness of C197 shim stack. Adjust shim stack thickness
as required to achieve proper tilting friction. Decreasing shim stack thickness increases
tilting friction while increasing spacer stack thickness decreases tilting friction. Install,
and special torque per § 20-33, all inner screws on lower swashplate and at least two
screws thru retainers in upper swashplate prior to measuring tilting friction.

5. Connect both forward push-pull tubes to lower swashplate and standard torque per §
20-32. Install palnut, special torque per § 20-33, and torque stripe per Figure 5-1.

6. Connect both pitch links and drive linkage to upper swashplate (interrupter on same
side as drive linkage) and standard torque per § 20-32. Install palnuts, special torque
per § 20-33, and torque stripe per Figure 5-1.

67-42 Upper and Lower Scissor Assemblies

A. Bearing Removal

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.

B. Bearing Installation

1. Clean mating surfaces of A205 fork or C203 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 C648-2 bearing while supporting backside of fork or yoke.

MAY 2015 Chapter 67 Flight Controls Page 67.11

FIGURE 67-3 TAIL ROTOR FLIGHT CONTROLS

Page 67.12 Chapter 67 Flight Controls MAY 2015

67-50 Tail Rotor Controls

67-51 Pedals
A. Removal
1. Peel back carpet as required to access pedal covers per § 25-30 Part D.
2. Remove screws securing pedal covers to cabin floor and remove covers.
3. Remove screws securing upper console to side panels; pivot console up and aft.

CAUTION
Do not change the length of or remove rod ends from C343-11
and -13 push-pull tube assemblies.

4. Remove hardware securing D755 pedal assemblies to C343-11 and -13 push-pull
tube assemblies.

NOTE
Pedal bearing blocks (upper and lower) are a machined, matched
set as indicated by matching letter or number on the upper
and lower portion of blocks. DO NOT mix them or alignment
problems may develop on installation.

5. Remove bolts securing A318-1 and -2 bearing block halves together and remove
lower bearing blocks.
6. Remove pedal assemblies one at a time by lifting one end and lowering other into
chin. Remove pedals thru pilot-side opening.

NOTE
On reassembly, the right pedal assembly is mounted forward in
the bearing blocks and the left is mounted aft.

B. Installation
1. Fill the grooves in the pedal bearing blocks with A257-1 grease.
2. Install the pedal assemblies into the bearing blocks and torque bearing block
attach bolts per § 20-32.

NOTE
If a force greater than 5 lbs is required to move pedals, check
the bearing blocks to ensure they are matched correctly.

JUL 2020 Chapter 67 Flight Controls Page 67.13

67-51 Pedals (continued)
B. Installation (continued)
3. Connect both pedal assemblies to the push-pull tubes and torque the NAS6604-9
bolts to per § 20-32 and install palnuts.
4. Move the pedals through the full range of travel to ensure there is no interference
or binding.
5. Secure console. Install the pedal covers and carpeting. Use B270-7 or -8 adhesive
to attach carpeting.

67-52 Pitch Control

A. Removal
1. Remove tail rotor assembly per § 64-10. 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.
2. Disconnect and remove A120-5 aft bellcrank per § 67-65.
3. Remove C031-1 pitch control from tail rotor output shaft. Clean output shaft.
B. Installation
1. Verify inner bore of C031-1 pitch control is clean. Scrub interior of pitch control
bore with clean, dry toothbrush followed by lint-free wipe; do NOT use, or immerse
in, solvent due to potential compromise of oil-impregnated bushings. Slide pitch
control assembly onto clean output shaft.
2. With pitch control's input stud thru short arm of A120-5 bellcrank assembly,
position bellcrank on tail rotor gearbox and install NAS6604-25 bolt, one AN960-
416L washer under bolt head, two MS20002-4 washers, one on each side of
bearing and MS21042-L4 nut. Tighten but don’t torque at this time.
3. Measure vertical gap between A120-5 bellcrank arm and flange on pitch control
stud. Install sufficient C117-34, - 35 and -36 washers between bellcrank and
stud to fill gap within ± 0.003 inch. Install one NAS1149F0432P washer and
MS21042-L5 nut on protruding end of stud. Torque nut to 200 in.-lb plus nut drag
while holding stud from rotating. Install palnut and special torque per § 20-33.
4. Standard torque bolt thru A120-5 bellcrank pivot per § 20-32 and install palnut
and special torque per § 20-33.
5. Attach aft end of C121-17 push-pull tube to A120-5 bellcrank and standard
torque bolt per § 20-32.
6. Install hardware securing pitch links. Note that an optional A215-012 o-ring may
be installed between A214-3 washer and A115-1 spacer at pitch control ears
(refer to IPC). Standard torque bolts and palnuts per § 20-32, and torque stripe
per Figure 5-1.
7. Install tail rotor assembly per § 64-10.

Page 67.14 Chapter 67 Flight Controls JUL 2020

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

CAUTION
Do not change the length of or remove rod ends from C343-11
and -13 push-pull tube assemblies.
3. Remove hardware securing C343-11 and C343-13 push-pull tube assemblies and
F121-9 push-pull tube assembly to C317-5 or C317-9 bellcrank assembly.
4. Remove hardware securing F349-1 support assembly to side panels and remove
support with attached bellcrank.
5. Remove hardware securing bellcrank to support and remove bellcrank (carefully
remove journals from bellcrank bearing).
B. Installation
1. Insert journals inside C317-5 or C317-9 bellcrank assembly’s bearing. Align
washers and bellcrank with F349-1 support assembly flange holes and install
hardware. Standard torque nut and palnut per § 20-32 and torque stripe per Figure
5-1.
2. Position support with attached bellcrank in helicopter and install hardware securing
support to side panels. Verify security.
3. Verify C343-11 push-pull tube's rod end center-to-center dimension is 5.82 ± 0.03
inches and C343-13 push-pull tube’s rod end center-to-center dimension is 5.30
± 0.03 inches. Install hardware securing push-pull tubes to bellcrank. Standard
torque nuts and palnuts per § 20-32 and torque stripe per Figure 5-1.
4. Install hardware securing F121-9 push-pull tube assembly to bellcrank. Standard
torque nut and palnut per § 20-32 and torque stripe per § 20-33.
5. Perform tail rotor flight control rigging per § 18-50.
6. Actuate pedals through full control travel and verify smooth operation without
binding.
7. Pivot upper console forward and down. Position avionics tray and face plate in
helicopter and install hardware securing trays and plate to side panels. Verify
security.
8. Install avionics in center console per Chapter 97. Install screws securing console
to side panels and verify console security.

MAY 2015 Chapter 67 Flight Controls Page 67.15

67-62 C317-7 Bellcrank

A. Removal

1. Refer to § 6-70. Remove F794-2 aft belly cover, F932-1 middle seat backrest
assembly, and F474-2 middle seat cover.

2. Disconnect F121-9 and F121-11 push-pull tubes from the C317-7 bellcrank.

3. Remove nuts and accompanying washers securing NAS6604-67 bolt in F334-

1 support assembly. Withdraw bolt sufficient to remove C317-7 bellcrank and
remove bellcrank, two A141-3 washers, and two A105-3 journals.

B. Installation

1. Install two A105-3 journals in C317-7 bellcrank's pivot bearing bore. With 3/16
inch rigging pin hole aft and an A141-3 washer against outboard face of each
journal, install bellcrank on F334-1 support assembly and retain with NAS6604-67
bolt.

2. Install two NAS1149F0463P and one NAS1149F0432P washer followed by

MS21042L4 nut on NAS6604-67 bolt. Standard torque bolt per § 20-32. Install
palnut, special torque per § 20-33, and torque stripe per Figure 5-1.

3. Connect F121-9 push-pull tube assembly to C317-7 bellcrank and standard torque
bolt per § 20-32. Install palnut, special torque per § 20-33, and torque stripe per
Figure 5-1.

4. Move pedals full travel. Verify smooth movement and no interference.

5. Install F794-2 aft belly cover, F932-1 middle seat backrest assembly, and F474-2
middle seat cover.

Page 67.16 Chapter 67 Flight Controls MAY 2015

67-63 F316-1 Bellcrank

A. Removal

1. Remove main rotor gearbox per § 63-20.

2. Disconnect F121-11 push-pull tube from F316-1 bellcrank assembly.

3. Disconnect F121-13 push-pull tube from F316-1 bellcrank assembly.

4. Remove nuts and spacer from outboard end of C494-2 shaft. Move shaft slightly
inboard and remove washer from between frame tab and bellcrank.

5. Remove spring pin, castellated nut, and washers from inboard end of C494-2
shaft. Move shaft slightly outboard and remove washer from between bellcrank
and inboard support.

6. Remove bellcrank.

B. Installation

1. Install one A141-3 washer on C494-2 shaft adjacent to both inboard and outboard
end of F316-1 bellcrank.

2. Install bellcrank with washers in helicopter with longer arm pointing up.

3. On inboard end of C494-2 shaft, install two NAS1149F0463P washers followed

by MS17825-4 castellated nut. Tighten nut until it aligns with hole in shaft and
install new MS16562-14 spring pin.

4. On outboard end of shaft install C130-34 spacer and MS21042L4 nut. Special
torque nut to 90 in.-lb. Install palnut and special torque per § 20-33. Torque
stripe inboard and outboard nuts per Figure 5-1.

5. Connect F121-13 push-pull tube to bellcrank and standard torque bolt per § 20-32.
Install palnut, special torque per § 20-33, and torque stripe per Figure 5-1.

6. Connect F121-11 push-pull tube to bellcrank and standard torque bolt per § 20-32.
Install palnut, special torque per § 20-33, and torque stripe per Figure 5-1.

7. Move pedal full travel. Verify smooth movement and no interference.

8. Install main rotor gearbox per § 63-20.

MAY 2015 Chapter 67 Flight Controls Page 67.17

67-64 A331-4 Bellcrank

A. Removal

1. Disconnect F121-13 and C121-17 push-pull tubes from A331-4 bellcrank.

2. Disconnect NAS6604-35 attach bolt and remove bellcrank and two A105-3
journals.

B. Installation

1. Install two A105-3 journals in C331-4 bellcrank's pivot bearings. Install an

NAS1149F0432P washer under head of an NAS6604-35 bolt followed by an
A141-3 washer and insert bolt thru journals. Install an A141-3 washer on bolt
against journal face, followed by an NAS1149F0432P washer.

2. Install bellcrank, with straight side aft, on F020-1 frame's boss, and secure to
frame with an NAS1149F0432P washer and MS21042L4 nut. Standard torque
bolt per § 20-32. Install palnut, special torque per § 20-33, and torque stripe per
Figure 5-1.

67-65 A120-5 Bellcrank

A. Removal

1. Remove hardware securing C121-17 push-pull tube assembly to A120-5 bellcrank

assembly.

2. Disconnect bellcrank pivot from C021-1 tail rotor gearbox.

3. Remove nut holding bellcrank to the pitch control. Remove bellcrank and reinstall
nut, and shims found between bellcrank and pitch control.

B. Installation

1. Install pitch control per § 67-62.

Page 67.18 Chapter 67 Flight Controls MAY 2015

CHAPTER 71

POWERPLANT

Section Title Page

71-00 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71.1

71-10 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71.3
71-11 Preparing Engine for Rolls-Royce Maintenance Facility . . . . . . . . . . . . . . . 71.7
71-12 Preparing Engine for Helicopter Installation . . . . . . . . . . . . . . . . . . . . . . . 71.7B
71-20 Induction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71.11
71-21 Air Filter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71.11
71-22 Cage Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71.17
71-23 Engine Inlet Bellmouth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71.17
71-30 Exhaust Weldment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71.19
71-40 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71.20
71-41 Starter-Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71.20
71-42 Generator Control Unit (GCU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71.20
71-43 Engine Monitoring Unit (EMU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71.21

JUL 2020 Chapter 71 Powerplant Page 71.i

Intentionally Blank

Page 71.ii Chapter 71 Powerplant JUL 2020

CHAPTER 71

POWERPLANT

71-00 Description
One Rolls-Royce model 250-C300/A1 (commercial designation RR300) free-turbine
turboshaft engine powers the helicopter. The engine is equipped with an ignition exciter,
igniter, starter-generator, two tachometer senders, and additional powerplant instrument
senders.
A direct drive, squirrel-cage style cooling fan is mounted to the intermediate shaft and
supplies cooling air to the engine and gearbox oil coolers.
Induction air enters through multiple openings in the upper fuselage cowlings and flows into
a plenum forward of the firewall. The plenum contains a radial-flow air filter at the engine
compressor inlet. The standard filter element is foam. A high-efficiency filter element with
pleated media is optional. The high-efficiency filter includes a sight gage inside the upper
left cowl door with provides an indication of filter dirt load.

NOTE
The high-efficiency filter is recommended for operating in dusty
conditions. The filter may not filter fine sand or dust, resulting
in reduced engine life.

If the air filter becomes blocked, spring-loaded doors at the front of the filter housing open
allowing unfiltered air to the engine. The AIR FILTER annunciator illuminates when filter
bypass is occurring.
Periodically performing power assurance checks may provide indication of engine
deterioration or air filter blockage. Maintenance actions such as air filter cleaning and
compressor wash should be performed if aircraft fails power assurance check.
A temperature switch is mounted to the firewall above the engine to detect a fire in the
engine compartment. Abnormally high temperature causes the ENGINE FIRE annunciator
to illuminate.

JUL 2020 Chapter 71 Powerplant Page 71.1

FIGURE 71-1 ENGINE - RIGHT SIDE

Page 71.2 Chapter 71 Powerplant JUL 2020

71-10 Engine

NOTE
The electronic monitoring unit (EMU) is a serialized component
assigned to the engine. When removing the engine, remove the
engine's EMU per § 71-43, as required.

A. Removal
1. Remove engine cowling assembly per § 53-21.
2. Refer to Figures 71-1 and 71-2. Verify heat shrink stamping is legible (or mark wires
and cables) and remove hardware securing wires and cables to starter-generator
studs. Disconnect (cabin) electrical harness from (engine) electrical harness at
F577-1 bracket assembly. Disconnect cabin harness "TMP" (torquemeter oil
pressure) and "MOP" (main oil pressure) plugs from engine senders; disconnect
cabin harness plug from N2 speed sensor.
3. Pull fuel shut off valve OFF. Disconnect B283-12 (fuel) hose assembly B-nut from
engine fuel inlet fitting. Cap fitting and plug line.
4. Remove hardware securing MS21919WDG clamp to firewall, and loosen B277-32
clamps securing A785-37 hose to inducer bleed port and G918-1 box assembly.
Remove hose and clamps. Install cover on inducer bleed port and tape box assembly
to protect openings from contaminants.
5. Remove hardware securing G391-1 (customer air) line assembly clamps. Loosen
line assembly B-nut from G391-5 line assembly union and disconnect B-nut from
engine compressor union. Cap fitting and plug line.
6. Drain engine oil per § 12-60; drain engine oil per RR300 Operation and Maintenance
Manual (OMM). Refer to Figure 79-3. Remove hardware securing F723 oil line
assembly clamps. Loosen F723-1, F723-2, and F723-3 line assembly B-nuts from
F649-1 oil cooler and G689-1 oil tank assembly unions; disconnect B-nuts from
engine fittings. Cap fittings and plug lines.
7. Refer to Figure 63-1. Remove hardware securing F018-1 clutch assembly yoke to
(aft) A947-2 plate assembly, noting hardware removed.
8. Refer to Figure 76-1. Remove fasteners securing C522-10 (throttle) and A522‑10
(fuel cutoff) control inner wires to FCU throttle and fuel cutoff levers. Remove
fasteners securing control housings and AN742-4 clamps to F577 bracket
assemblies. Refer to Figure 76-2. Remove cotter pin and washer securing C522‑11
(power turbine governor) control inner sleeve and D333-13 fitting to PTG input
lever; disconnect control from lever.
9. Remove exhaust per § 71-30.

JUL 2020 Chapter 71 Powerplant Page 71.3

71-10 Engine (continued)
A. Removal (continued)
10. Connect engine hoist to G200-1 engine lifting lug. Support engine during mounting
hardware removal.
11. Cut and discard safety wire and remove two bolts securing bottom engine mount
to F174-1 support weldment. Cut and discard safety wire and remove two bolts
(one per side) securing side engine mounts to F046 lower frames.
12. Carefully remove engine; verify F579-1 bellmouth is clear of firewall, and loose
wires, cables, fittings and line assemblies are clear of engine during separation.
Install bellmouth cover.
13. Prepare engine for Rolls-Royce maintenance facility per § 71-11, as required.

Page 71.3A Chapter 71 Powerplant JUL 2020

Intentionally Blank

JUL 2020 Chapter 71 Powerplant Page 71.3B

FIGURE 71-2 ENGINE - LEFT SIDE

Page 71.4 Chapter 71 Powerplant JUL 2020

71-10 Engine (continued)
B. Installation
1. Prepare engine for installation in helicopter per § 71-12, as required.
2. Refer to Figures 71-1 and 71-2. Connect engine hoist to G200-1 engine lifting lug.
3. Remove F579-1 bellmouth cover. Carefully install engine, inserting bellmouth through
firewall. Do not pinch loose wires or cables, or damage fittings or line assemblies.
Before installing engine mounting hardware, verify the inlet seal is centered when
pressed against the firewall, and that the seal is not twisted or pinched.
4. Install hardware securing side engine mounts to F046 frames. Standard torque
bolts (one per side) per § 20-32; install 0.032-inch diameter lockwire and safety
bolts to frames.
5. Refer to Figure 63-1. Install hardware securing F018-1 clutch assembly yoke to (aft)
A947-2 plate assembly, as removed. Perform engine driveline shimming per § 63‑11.
Standard torque nuts and palnuts per § 20-32, and torque stripe per Figure 5-1.
6. a. Install hardware securing F174-1 support weldment to bottom engine mount;
special torque bolts per § 20-33 (safety wire will be installed in step 7).
b. Verify 0.2 inch minimum clearance between F642 shaft weldment and firewall
grommet. To adjust clearance:
i. Remove two bolts securing support weldment rod ends to engine bottom
mount and remove support weldment.
ii. Adjust rod end extension on both sides as required per § 5-33, and Figures
5-1 & 5-2; ensure rod extension is no more than 1.10 inches.
iii. Repeat steps a & b until minimum shaft-to-firewall grommet clearance is
achieved.
7. Install 0.032-inch diameter lockwire & safety three bolts together per Figure 71-2
Detail A. Verify safety is correct direction.
8. Install hardware securing support weldment rod ends to lower frames, standard
torque nuts and palnuts per § 20-32, and torque stripe per Figure 5-1. Standard
torque jam nuts and palnuts securing rod ends to support weldment per § 20-32,
and torque stripe per Figure 5-1.
9. Remove engine hoist.
10. Install exhaust per § 71-30.
11. Remove cap and torque check engine compressor (customer air) union per RR300
Operation and Maintenance Manual (OMM). Remove plug and connect G391-1
line assembly B-nut to engine. Special torque B-nuts per § 20-33 and torque stripe
fittings. Install hardware securing line assembly clamps.

JUL 2020 Chapter 71 Powerplant Page 71.5

71-10 Engine (continued)
B. Installation (continued)
12. Refer to Figure 79-3. Remove caps and torque check engine (oil line) fittings
per RR300 OMM. Remove plugs and connect F723-1, F723-2, and F723-3 line
assembly B-nuts to engine. Special torque B-nuts at engine, F649-1 oil cooler, and
G689-1 oil tank assembly per § 20-33, and torque stripe fittings. Install hardware
securing line assembly clamps. Service engine oil per RR300 OMM; service engine
oil per § 12-60.
13. Remove cover and tape and install B277-32 clamps and A785-37 hose onto inducer
bleed port and G918-1 box assembly; tighten clamps. Install MS21919WDG clamp
around hose, and install hardware securing clamp and hose to firewall. Verify
security.
14. Remove cap and torque check engine fuel inlet fitting per RR300 OMM. Remove
plug and connect B283-12 (fuel) hose assembly B-nut to inlet fitting. Special torque
B-nut per § 20-33 and torque stripe per Figure 5-1. Push fuel shut off valve ON.
15. Connect (cabin) electrical harness plug to N2 speed sensor; connect cabin harness
"TMP" (torquemeter oil pressure) and "MOP" (main oil pressure) plugs to engine
senders. Connect cabin harness to (engine) electrical harness at F577-1 bracket
assembly. Install wires and cables on starter-generator studs according to stamping.
Install hardware, special torque nuts, and torque stripe per Figure 5-1.
16. Perform FCU throttle and fuel cutoff control rigging per §§ 76-11 & 76-12. Perform
PTG control rigging per § 76-21 (perform PTG rigging check during run-up).
17. Install engine EMU per § 71-43, as required.
18. Perform ground check per § 5-41. Remove the air from the engine fuel system,
then perform fuel flow check, per RR300 OMM. Perform run-up per § 5-42, and
PTG rigging check per § 76-22.
19. Install engine cowling assembly per § 53-21.

Page 71.6 Chapter 71 Powerplant JUL 2020

71-11 Preparing Engine for Rolls-Royce Maintenance Facility

NOTE
Cap and plug Rolls-Royce engine model 250-C300/A1 engine
fluid ports, electrical connectors, etc., and in removed
components, progressively during procedure to prevent foreign
object contamination.

1. Refer to Figures 71-1 and 71-2. Remove hardware securing MS21919WCH clamp(s) to
engine vertical firewall and F577-5 bracket (earlier R66s). Loosen B277 clamp(s) and
remove A729-68 tubes (if installed), breather hose/tube, and F170 fitting. Install plug.
2. Refer to Figure 76-1. Remove D930-2 spring from fuel control unit.
3. Refer to Figure 71-4. Remove hardware securing F169-2 base (and F577-5 bracket, if
installed) to exhaust collector. Remove base (and bracket) and install exhaust collector
cover.
4. To remove (engine) electrical harness:
a. Disconnect engine harness’s plug from engine magnetic plug on bottom of engine
accessory gearbox.
b. Remove hardware securing harness wire terminal to igniton exiter box stud.
c. Cut and discard ty-raps as required, and disconnect G426-1 (fuel differential
pressure) switch assembly wire from harness at connectors. Cut and discard
stand-off ty-raps at switch wire and F741-1 line assembly.
d. Remove hardware securing (2) MS21919WCH4 clamps to (bottom of) engine gearbox.
e. Disconnect harness plugs from anti-ice valve assembly solenoid, anti-ice pressure
switch assembly, and N1 speed pick-up assembly.
f. Remove hardware securing (2) MS21919WCH4 clamps to (2) engine-supplied
MS9592-050 brackets.
g. Remove hardware securing harness wire terminals to measured gas temperature
(MGT) thermocouple studs.
h. Disconnect harness plug from engine magnetic plug near oil line unions.
i. Cut and discard ty-raps as required, and disconnect D745-3 pressure switch
assembly from harness at connectors.
j. Remove hardware securing F577-1 and F577-3 bracket assemblies to (right side
of) engine gearbox. Remove harness.
5. Remove engine inlet bellmouth per § 71-23 Part A steps 2 and 3.

JUL 2020 Chapter 71 Powerplant Page 71.7

71-11 Preparing Engine for Rolls-Royce Maintenance Facility (continued)
6. Disconnect F741-1 line assembly from G426-1 switch assembly and fuel pump’s
A919-0D reducer and remove line.
7. Disconnect F727-1 line assembly from fuel pump’s AN919-2D reducer. Disconnect
F727-2 line assembly from engine fireshield’s drain fitting. Remove hardware securing
MS21919WCH4 clamp the combustion section’s plug flange and remove lines.
8. Remove AN919-0D and AN919-2D reducers, and G426-1 switch assembly, from fuel
pump.
9. Remove hardware securing F593-3 plate to bottom of engine gearbox and remove plate.
10. Remove bolt, spacer (if installed), and G732 cap securing F018-1 clutch assembly in
engine gearbox and remove clutch assembly.
11. Remove AN815-8D union from engine gearbox TANK VENT port, AN815-8D union
or CV26-77 check valve (early R66s) from OIL OUTLET port, and AN815-10D union
from OIL INLET port. Remove D745-3 pressure switch assembly from engine gearbox.
12. Cut and discard safety wire (if present) and remove hardware securing G200-1 engine
lifting lug and G200-2 cover to engine gearbox, if installed. Remove lug, cover, and
any residual B270-1 sealant.

NOTE
Removal of RHC-installed fuel-flow transducer (optional
equipment) is not required, but may be desired for use in spare
engine. Refer to § 28-23.

Page 71.7A Chapter 71 Powerplant JUL 2020

71-12 Preparing Engine for Helicopter Installation

NOTE
Remove protective caps and plugs progressively during
procedure to prevent foreign object contamination.

1. Refer to Figures 71-1 and 71-2. Position G200-1 engine lifting lug on top of engine
gearbox, as desired (optional). Install (2) NAS6605-3 bolts and (2) NAS1149F0532P
washers, special torque bolts per § 20-33, and torque stripe per Figure 5-1.
2. Install D745-3 pressure switch assembly on front of engine gearbox, special torque
switch per § 20-33, and torque stripe per Figure 5-1.
3. Install NAS617-10 packing on union and install union in engine gearbox OIL INLET
port. Special torque union per § 20-33 and torque stripe per Figure 5-1.
4. Install NAS617-8 packing on engine-side of either union or CV26-77 check valve
(early R66s) and install union or check valve (flow arrow to point away from engine)
in engine gearbox OIL OUTLET port. Special torque union or check valve per § 20-33
and torque stripe per Figure 5-1.

CAUTION
Installing CV26-77 check valve incorrectly can damage oil tank.

5. Install NAS617-8 packing on union and install union in engine gearbox TANK VENT
port. Special torque union per § 20-33 and torque stripe per Figure 5-1.
6. Inspect F018-1 clutch assembly splines and verify no evidence of galling. Also, verify
end of thread insert is 0.090 – 0.110 inch inboard from tip of splined end of clutch
housing (F018-1 Rev A thru C only); contact RHC Technical Support if thread insert
position is incorrect. Lubricate clutch splines using B270-21 protectant. Insert clutch
in engine gearbox, and install G732-1 cap, bolt, and washer at rear PTO pad. Standard
torque bolt per § 20-32 and torque stripe per Figure 5-1.
7. Install engine-supplied rear PTO pad cover, and engine-supplied nuts and spacers.
Special torque nuts per § 20-33 and torque stripe per Figure 5-1.
8. Position F593-3 plate on bottom of engine gearbox and install aft bolt, finger tight.
9. Install G426-1 switch assembly in fuel pump BF (before filter) port. Special torque
switch per § 20-33 and torque stripe per Figure 5-1.
10. Install MS29512-3 packing on AN919-0D reducer and install reducer in fuel pump AF
(after filter) port. Special torque reducer per § 20-33 and torque stripe per Figure 5-1.
11. Install MS29512-3 packing on AN919-0D reducer and install reducer in fuel pump
DRAIN port. Special torque reducer per § 20-33 and torque stripe per Figure 5-1.

JUL 2020 Chapter 71 Powerplant Page 71.7B

71-12 Preparing Engine for Helicopter Installation (continued)
12. Connect F727-1 line assembly to fuel pump’s AN919-0D reducer. Connect F727-2
line assembly to engine fireshield’s drain fitting. Install one MS21919WCH4 clamp
around each line, install hardware securing lines to combustion section’s plug flange,
and tighten screw. Special torque F727-1 line assembly nut at reducer per § 20-33
and torque stripe per Figure 5-1; special torque F727-2 line assembly at fireshield’s
drain fitting and torque stripe per Figure 5-1. Verify security.
13. Connect F741-1 line assembly to G426-1 switch assembly and fuel pump’s AN919‑0D
reducer. Special torque nuts per § 20-33 and torque stripe per Figure 5-1.
14. Install engine inlet bellmouth per § 71-23 Part B steps 1 & 2. Install bellmouth cover.
15. To install (engine) electrical harness:
a. Position F577-1 bracket assembly on engine harness’s D38999-20FC connector
so connector’s main keyway will face outboard. Install and tighten hardware;
verify security. Install bracket on (right side of) engine gearbox, special torque
nuts per § 20-33, and torque stripe per Figure 5-1.
b. Install MS21919WCH8 clamp around harness assembly and install clamp on F577-
3 bracket assembly. Install and tighten hardware. Install bracket on (right side of)
engine gearbox, special torque nuts per § 20-33, and torque stripe per Figure 5-1.
c. Connect harness to D745-3 pressure switch assembly at connectors. Verify
security. Install (2) MS3367-7-9 ty-raps to secure plug. Cinch ty-raps until snug
without overtightening and trim tips flush with heads.
d. Connect harness plug to engine magnetic plug near oil line unions. Verify plug
security.
e. Install harness wire terminals (white-to-white, green-to-green) on measured gas
temperature (MGT) thermocouple studs. Install hardware, special torque nuts per
§ 20-33, and torque stripe per Figure 5-1.
f. Verify (2) engine-supplied MS9592-050 brackets are installed on engine lube oil
filter assembly per Rolls-Royce SB RR300-72-014. Install (2) MS21919WCH4
clamps around harness assembly and install clamps on brackets. Install and
tighten hardware; verify security.
g. Connect harness plugs to anti-ice valve assembly solenoid, anti-ice pressure
switch assembly, and N1 speed pick-up assembly. Verify security.

Page 71.8 Chapter 71 Powerplant JUL 2020

71-12 Preparing Engine for Helicopter Installation (continued)
15. h. Install (2) MS21919WCH4 clamps around harness assembly and install clamps on
(bottom of) engine gearbox. Install hardware, special torque nuts per § 20-33,
and torque stripe per Figure 5-1.
i. Stand-off ty-rap G426-1 (fuel differential pressure) switch assembly’s wire from
F741-1 line assembly using MS3367-4-9 ty-raps. Connect switch wire to harness
at connectors. Install (2) MS3367-5-9 ty-raps to secure connectors to harness.
Cinch ty-raps until snug without overtightening and trim tips flush with heads.
j. Install harness wire terminal on ignition exiter box stud. Install hardware, special
torque nut per § 20-33, and torque stripe per Figure 5-1.
k. Connect harness plug to engine magnetic plug on bottom of engine gearbox.
Verify plug security.
16. Refer to Figure 71-5. Verify F169-2 (exhaust) base and engine exhaust collector
mating surfaces are clean and dry, and lay 0.25 inch bead 7020-3 ceramic putty on
top of exhaust collector flange. Position F169-2 base, F577-5 bracket (earlier R66s),
and F173-2 shield (if installed) on exhaust collector and install hardware. Verify
security. Remove excess putty. Install exhaust protective cover.
17. Refer to Figure 76-1. Install D930-2 spring.
18. Install packing (and o-rings, earlier R66s) on F170 fitting and install fitting in engine
gearbox OB VENT port. Special torque fitting per § 20-33 and torque stripe per Figure
5-1. Position engine gearbox vent tubes/hose with clamps over fitting and exhaust
weldment tube. Orient clamp screw(s) (and any slight bunching of hose, early R66s)
on top within 30°, and tighten clamps. Verify security. Position MS21919WCH
clamp(s) over tube/hose and install hardware (and spacer) securing clamps to engine
vertical fireshield (and F577-5 bracket, earlier R66s). Verify security.

JUL 2020 Chapter 71 Powerplant Page 71.9

FIGURE 71-3 INDUCTION (STANDARD FILTER SHOWN)

Page 71.10 Chapter 71 Powerplant JUL 2020

71-20 Induction

NOTE
Refer to § 12-70 for (Engine) Compressor Rinse and Wash
procedures.
CAUTION

Never operate engine without G057-1 cage assembly installed.

F771-1 (foam) filter assembly not required for flight; 146150-
101 (inlet barrier filter) filter assemblies not required for flight.
CAUTION

Do not perform maintenance near engine inlet without cage and

filter(s) or a temporary cover installed. Contact Rolls-Royce
Customer Support if foreign objects enter inlet.

71-21 Air Filter Assembly

A. Description
The standard reticulated polyurethane foam filter is installed over the G057-1 cage
assembly (refer to § 71-22) and secured with locking cords. Filter should be removed
& cleaned with water when visibly dirty; replace filter if foam is visibly damaged or
deteriorated.
The optional G058-1 inlet barrier filter cage assembly is a separate installation with
additional parts that secure the filters to the G057-1 cage assembly and that secure
the assembly to the upper frame and firewall. A filter maintenance aid helps to
determine if cleaning is required earlier than scheduled (refer to Figure 71-4 and Parts
E and F); certain operating environments require more frequent cleaning. The inlet
barrier filter may be cleaned 15 times before replacement.

APR 2019 Chapter 71 Powerplant Page 71.11

FIGURE 71-4 INDUCTION (INLET BARRIER FILTER SHOWN)

Page 71.12 Chapter 71 Powerplant APR 2019

71-21 Air Filter Assembly (continued)
B. Removal
Standard Filter:
1. Remove tailcone cowling assembly per § 53-23.
2. Refer to Figure 71-3. Vacuum exterior of F771-1 filter assembly.
3. Disconnect F049-08 (bypass) switch assembly harness from airframe harness
at connectors.
4. Loosen clamp securing tube to compresssor rinse nozzle and pull tube off of
nozzle.
5. Release cord locks, loosen cords as required, and pull filter forward off of G057-
1 cage assembly.
6. Install temporary cover over cage assembly.

Inlet Barrier Filter:

1. Remove tailcone cowling assembly per § 53-23.
2. Refer to Figure 71-4. Remove locking pin from strap assembly, release latch,
and move strap assembly aside.
3. Remove 146150-101 filter from G058-1 cage assembly brackets; handle filter
by the potting to avoid damaging pleated media.
4. Repeat steps 2 and 3 for other filter.

C. Installation
Standard Filter:
1. Refer to Figure 71-3. Remove temporary cover. Pull F771-1 filter assembly aft
over G057-1 cage assembly and tighten cords as required. Verify security.
2. Install clamp and tube on compressor rinse nozzle and tighten clamp. Verify
security.
3. Connect F049-08 (bypass) switch assembly harness to airframe harness at
connectors.
4. Turn battery switch on. Verify annunciator panel warning segment illuminates
when bypass doors are opened individually, then simultaneously. Turn battery
switch off.
5. Install tailcone cowling assembly per § 53-23.

APR 2017 Chapter 71 Powerplant Page 71.13

71-21 Air Filter Assembly (continued)
C. Installation (continued)
Inlet Barrier Filter:
1. Service inlet barrier filter per Part D.
2. Refer to Figure 71-4. Remove temporary cover. Insert 146150-101 filter in
G058-1 cage assembly brackets; handle filter by the potting to avoid damaging
pleated media. Verify filter is properly seated.
3. Latch strap assembly. Adjust strap tension as required to ensure filter security,
but without overtightening. Install locking pin.
4. Repeat steps 1 thru 3 for other filter.
5. Install tailcone cowling assembly per § 53-23.
D. Servicing
Standard Filter:
Filter should be removed & cleaned with water when visibly dirty. Replace filter if
foam is visibly damaged or deteriorated.
Inlet Barrier Filter:
1. Visually inspect each filter assembly for obvious damage; replace filter(s) as
required per Parts B and C.
2. To clean and dry each filter assembly:
a. Remove debris as practical from dirty side of filter assembly using a soft
bristle brush.

CAUTION
Use only ZOK 27 cleaner to clean filter media.
CAUTION
Do not use steam, a high-pressure washer, or compressed air to
clean filter assemblies.

b. Using a spray bottle, apply ZOK 27 cleaner to both sides of filter media
until saturated. Allow to soak for minimum 10 minutes (30 minutes or
more may be necessary for high-contaminant environments).
c. Rinse filter with clean water in opposite direction of airflow (from clean
side) using low-pressure stream. Orient filter so pleats are vertical; rinse
side-to-side starting at the top and working downward. Proceed downward
only when water runoff is clear.

Page 71.14 Chapter 71 Powerplant APR 2017

71-21 Air Filter Assembly (continued)
D. Servicing (continued)
Inlet Barrier Filter (continued):
2. d. Rinse filter in direction of airflow per step 2c.
e. Rotate filter top to bottom and perform steps 2c and 2d.

CAUTION
Do not use compressed air, or heat from any source, to dry
filter assemblies.

f. Shake off excess water. Allow filter assembly to dry at ambient temperature
(above freezing), protected from contaminants.
3. Using a permanent marker, mark cleaned filter(s) with “X” through last unmarked
indented potting number (1–15). Replace 146150-101 filter at the next service
interval after 15 cleanings.
4. For each filter: Visually inspect filter pleats for straightness. Visually inspect
filter media for small ruptures, tears, or holes. Visually inspect potting compound
for cracks, gouges, or gaps between filter and compound. Replace filter(s) as
required per Parts B and C.

CAUTION
Verify filter media is completely dry before applying oil. Use
only approved oil; never put an un-oiled filter in service.

5. Apply 4.5 oz total 100100-045 filter oil to each filter. Using squeeze bottle
with tip, apply a small stream of oil (sparingly) along entire peak of each pleat on
both sides of filter (save some for final application). Let filter sit for 30 minutes
minimum as oil “wicks” into surrounding filter media. Apply remaining oil not
to exceed quantity above to any areas that are still white or not yet uniform in
color.
6. Push yellow button to reset filter maintenance aid.

APR 2019 Chapter 71 Powerplant Page 71.15

71-21 Air Filter Assembly (continued)

E. Scheduled Inspections
Standard Filter:
Refer to § 5-45 100-Hour/Annual Inspection.
Inlet Barrier Filter:
Refer to § 5-45 100-Hour/Annual Inspection.
Service 146150-101 filters per Part D every 300 hours or 1 year, whichever
occurs first. Replace 146150-101 filters at the next service interval after 15
cleanings.
F. Special Inspections
Standard Filter:
If pilot reports AIR FILTER caution segment illuminates during engine operation,
when engine is shut down, verify proper function of bypass switch. Turn battery
switch on. Verify caution segment illuminates when bypass doors are opened
individually, then simultaneously. Turn battery switch off. If bypass switch
functions properly, replace F771-1 filter assembly per Parts B and C.
If pilot reports a failed power assurance check (refer to § 5-43), replace F771-1
filter assembly per Parts B and C.
Inlet Barrier Filter:
If pilot reports AIR FILTER caution segment illuminates during engine operation,
when engine is shut down, verify proper function of bypass switch. Turn battery
switch on. Verify caution segment illuminates when bypass doors are opened
individually, then simultaneously. Turn battery switch off. If bypass switch
functions properly, service 146150-101 filters per Part D.
If pilot reports a failed power assurance check (refer to § 5-43), service 146150-
101 filters per Part D.
If filter maintenance aid indicates in red zone, service 146150-101 filters per Part D.

Page 71.16 Chapter 71 Powerplant APR 2019

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

B. Installation
1. Remove barrier, position G057-1 or G058-1 cage assembly against firewall, and
install hardware securing cage to firewall. Verify security.
2. Install air filter assembly per § 71-21.
3. Install tail rotor drive fan shaft per § 65-10.

71-23 Engine Inlet Bellmouth

A. Removal
1. Remove engine per § 71-10.
2. Refer to Figure 71-3. Remove F579-1 bellmouth cover and loosen B277-36
clamps securing bellmouth to engine front support. Remove bellmouth and
clamps.
3. Remove hardware securing F597-1 seal and F580-1 inlet to engine front support.
Remove seal and inlet. Install cover over front support.

B. Installation
1. Refer to Figure 71-3. Remove engine front support cover, install F580-1 inlet and
F597-1 seal (drain hole on bottom) on front support, and install hardware. Verify
security.
2. Install B277-36 clamps and F579-1 bellmouth over front support flange, and
tighten clamps. Verify security.
3. Install engine per § 71-10.

JUL 2020 Chapter 71 Powerplant Page 71.17

FIGURE 71-5 EXHAUST

Page 71.18 Chapter 71 Powerplant JUL 2020

71-30 Exhaust Weldment
A. Removal
1. Remove engine cowling assembly per § 53-21.
2. Refer to Figure 71-5. Remove hardware securing F173-1 struts to F169-1 exhaust
weldment and engine, and remove struts.
3. Loosen clamp(s) securing (accessory gearbox vent) tubes/hose to exhaust; pull
tubes/hose off of exhaust weldment.
4. Remove fasteners securing exhaust weldment and F173-2 shield (if installed) to
engine exhaust collector and remove shield. Carefully lift exhaust weldment up
and off of F169-2 base flange, and remove exhaust weldment.
5. As required, remove hardware securing base and F577-5 bracket (early R66s) to
exhaust collector and remove base. Install exhaust collector cover.

NOTE
F169-1 exhaust weldment material is Type 321 CRES sheet.

B. Installation
1. Refer to Figure 71-5. If F169-2 base is installed, proceed to step 3. Verify base
and engine exhaust collector mating surfaces are clean and dry, and lay 0.25 inch
bead 7020-3 ceramic putty on top of exhaust collector flange.
2. Position F169-2 base, F577-5 bracket (earlier R66s), and F173-2 shield (if installed)
on exhaust collector and install hardware Verify security. Remove excess putty.
3. Position F169-1 exhaust weldment on base and install fasteners securing exhaust
weldment to exhaust collector.
4. Install hardware securing F173-1 struts to exhaust weldment and engine. Special
torque engine tee-bolts per § 20-33.
5. Position engine gearbox vent tubes/hose with clamps over exhaust weldment tube.
Orient clamp screw(s) (and any slight bunching of hose, early R66s) on top within
30°, and tighten clamps. Verify security. As required, position MS21919WCH
clamp(s) over tube/hose and install hardware (and spacer) securing clamps to
engine vertical fireshield (and F577-5 bracket, earlier R66s). Verify security.
6. Install engine cowling assembly per § 53-21.

JUL 2020 Chapter 71 Powerplant Page 71.19

71-40 Accessories

71-41 Starter-Generator
A. Removal
1. Remove engine cowling assembly per § 53-21.
2. Refer to Figure 71-1. Verify heat shrink stamping is legible (or mark wires and
cables) and remove hardware securing wires and cables to starter-generator studs.
3. Remove starter-generator per RR300 Series Operation and Maintenance Manual
(OMM).

B. Installation
1. Install starter-generator per RR300 Series Operation and Maintenance Manual
(OMM).
2. Refer to Figure 71-1. Install wires and cables on starter-generator studs according
to stamping. Install hardware, special torque nuts per § 20-33, and torque stripe
per Figure 5-1.
3. Install engine cowling assembly per § 53-21.

71-42 Generator Control Unit (GCU)

A. Removal
1. Open baggage compartment door. Remove hardware securing G248-1 cover
(battery compartment) to inner compartment and remove cover.
2. Disconnect F049 (GCU) electrical harness plug from GCU. Remove mounting
hardware, and remove GCU. Cap receptacles.

B. Installation
1. Open baggage compartment door. Position GCU on inner compartment shelf and
install mounting hardware. Verify security.
2. Remove caps and connect F049 (GCU) electrical harness plug to GCU.

NOTE
Verify MS3106R24-28S plug is fully-engaged in GCU receptacle.
Rotate plug collar until tight.

3. Install hardware securing G248-1 cover to inner compartment. Close and secure
baggage door.

Page 71.20 Chapter 71 Powerplant JUL 2020

71-43 Engine Monitoring Unit (EMU)

NOTE
The electronic monitoring unit (EMU) is a serialized component
assigned to the engine. When removing the engine, remove the
engine's EMU per § 71-43, as required.

A. Removal
1. Remove hardware securing F003-4 (RH) seat back assembly to cabin.
2. Disconnect F059-01 (cabin) electrical harness "EMU" plug and F049-07 (USB)
harness plug from EMU.
3. Remove hardware securing EMU to bulkhead and remove EMU. Cap receptacles.

B. Installation
1. Remove caps, position EMU on bulkhead, and install hardware. Verify security.
2. Connect F059-01 (cabin) electrical harness "EMU" plug and F049-07 (USB)
harness plug to EMU.
3. Turn battery switch on. After 10 seconds press annunciator panel test button;
verify EMU amber warning segment illuminates, and is solid, indicating normal
EMU operation. (See R66 Pilot's Operating Handbook Section 7 for complete
description.) Turn battery switch off.
4. Install hardware securing F003-4 (RH) seat back assembly to cabin.

C. Downloading EMU Data

NOTE
An EMU USB receptacle is located inside the aft right seat
baggage compartment, on the underside of the aft ledge. Use a
flashlight and mirror when inserting USB cable into receptacle.

Download summary or diagnostic data per RR300 Series Operation and Maintenance
Manual (OMM).

D. Troubleshooting
1. Turn battery switch off and disconnect battery ground cable from battery negative
terminal.
2. Open circuit breaker panel and verify integrity of fuse for EMU; replace fuse as
required. Close circuit breaker panel.
3. Access annunciator panel plug and verify connector is fully seated on G198
annunciator panel receptacle.

APR 2017 Chapter 71 Powerplant Page 71.21

71-43 Engine Monitoring Unit (EMU; continued)
D. Troubleshooting (continued)
4. Access EMU behind right, aft seatback assembly, then disconnect and reconnect
EMU electrical connector.

5. Turn battery switch off and connect battery ground cable to battery negative
terminal.

6. While observing the built-in indicator light on the EMU, turn battery switch on and
verify light illuminates but does not flash. Steady illumination of built-in indicator
light means normal EMU operation. A slow-flashing (0.5 hz) flashing light, or no
illumination, indicates EMU or monitored sensor failure; perform RR300 OMM
Task 77-51-00-200-801.

Page 71.22 Chapter 71 Powerplant APR 2017

CHAPTER 75

ENGINE AIR SYSTEMS

Section Title Page

75-00 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75.1
75-10 Engine Anti-Ice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75.1

25 OCT 2010 R66 Maintenance Manual Chapter 75 Engine Air Systems Page 75.i
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Page 75.ii Chapter 75 Engine Air Systems R66 Maintenance Manual 25 OCT 2010
CHAPTER 75

ENGINE AIR SYSTEMS

75-00 Description

This chapter includes a description of the engine anti-ice system. Refer to RR300 Series
Operation and Maintenance Manual (OMM) and manufacturer’s maintenance publications for
system-specific inspection, repair, and maintenance procedures.

The Rolls-Royce engine model 250-C300/A1 anti-ice system provides hot compressor discharge
air to the compressor front support. Areas of the front support are subject to ice formation
when the engine is operated near or below freezing temperatures and visible moisture is present.
An anti-ice switch located on the cyclic box cover is selected by the pilot in certain conditions
(see R66 Pilot's Operating Handbook).

The engine anti-ice system includes an air valve, a solenoid valve, and a pressure switch. The
air valve is mounted on top of the compressor scroll; the solenoid valve and pressure switch
are mounted on top of the compressor. When anti-ice is switched "ON", the solenoid valve de-
energizes, the pressure-activated air valve opens, the pressure switch closes which illuminates
the green anti-ice segment on the annunciator panel, and hot, compressed-air is routed to
hollow passages in the front support vanes and center hub.

Anti-ice system operation will result in some performance degradation due to hot induction air
and reduced air-volume reaching the power and gas producing turbine stages.

The anti-ice solenoid valve is electrically-closed, or powered-off. Anti-ice will automatically

function in the event of an electrical failure.

75-10 Engine Anti-Ice

See RR300 Series Operation and Maintenance Manual (OMM) for anti-ice system maintenance.

25 OCT 2010 R66 Maintenance Manual Chapter 75 Engine Air Systems Page 75.1
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Page 75.2 Chapter 75 Engine Air Systems R66 Maintenance Manual 25 OCT 2010
CHAPTER 76

ENGINE CONTROLS

Section Title Page

76-00 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76.1
76-10 Fuel Control Unit (FCU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76.1
76-11 FCU Throttle Control Rigging . . . . . . . . . . . . . . . . . . . 76.3
76-12 FCU Fuel Cutoff Control Rigging . . . . . . . . . . . . . . . . . 76.3
76-20 Power Turbine Governor (PTG) . . . . . . . . . . . . . . . . . . . . . . . . . . 76.5
76-21 PTG Control Rigging . . . . . . . . . . . . . . . . . . . . . . . . . 76.5
76-22 PTG Rigging Check . . . . . . . . . . . . . . . . . . . . . . . . . . 76.7

25 OCT 2010 R66 Maintenance Manual Chapter 76 Engine Controls Page 76.i
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Page 76.ii Chapter 76 Engine Controls R66 Maintenance Manual 25 OCT 2010
CHAPTER 76

ENGINE CONTROLS

76-00 Description
A twist grip throttle control is located on each collective stick. The controls are interconnected
and actuate the Rolls-Royce engine model 250-C300/A1 fuel control input lever via a push-
pull cable. The throttle is normally not used for control but is set either fully closed (idle
position) or fully open.
The engine incorporates a hydromechanical governor which attempts to maintain 100%
engine output shaft RPM when the throttle is in the open position. A linkage provides the
power turbine governor with collective inputs to help anticipate changing power demands.
Large power changes or varying environmental conditions may cause the governor RPM
setting to vary by a few percent. A momentary toggle switch (beep switch) on the collective
stick is provided to trim, or "beep", the governor setting to the desired RPM. The switch
controls an actuator which adjusts the linkage between the collective and power turbine
governor. Holding the beep switch up or down will change rotor RPM approximately one
percent per two seconds.
The governor controls RPM under normal conditions. It may not prevent over- or under-
speed conditions generated by aggressive flight maneuvers or rapid power changes.
Other engine controls include a push-pull fuel cutoff control on the console face, a start
button on the pilot's collective, a key-type igniter switch, and an anti-ice switch.

76-10 Fuel Control Unit (FCU)

A. Removal
1. Pull fuel valve OFF. Remove engine cowling assembly per § 53-21.
2. Refer to Figure 76-1. Remove fasteners securing C522-10 throttle and A522-10
fuel cutoff control inner wires to FCU throttle and fuel cutoff levers.
3. Remove fasteners securing control housings and AN742-4 clamps to F577 bracket
assemblies, as required.
4. Remove FCU per RR300 Series Operation and Maintenance Manual (OMM).
5. If sending FCU to repair facility, remove D930-2 spring.
B. Installation
1. If removed, install D930-2 spring.
2. Install FCU per RR300 Series Operation and Maintenance Manual (OMM).
3. Perform throttle control rigging per § 76-11.
4. Perform fuel cutoff control rigging per § 76-12.
5. Push fuel valve ON.

JUL 2020 Chapter 76 Engine Controls Page 76.1

FIGURE 76-1 FUEL CONTROL UNIT

Page 76.2 Chapter 76 Engine Controls JUL 2020

76-11 FCU Throttle Control Rigging

1. Remove engine cowling assembly per Section 53-21. Remove F461-1 collective cross
tube cover and (copilot) F680-1 collective cover assembly (see Section 6-70).
2. Refer to Figure 76-1. Verify FCU throttle lever rigging angle is 48.5° ± 7.5°. As
required, remove hardware securing serrated levers and reposition to proper angle.
Install hardware, special torque nut per Section 20-33, & torque stripe per Figure 5-1.
3. Remove palnuts and loosen nuts securing A462-4 fittings and C522-10 (throttle) control
inner wire to collective arm and to FCU throttle lever.
4. Position forward end of control housing flush-0.25 inch at or beyond edge of outboard
AN742-3 clamp and install fasteners securing housing and clamps to F764-1 collective
stick weldment.
5. Refer to detail in Figure 76-3. Rotate collective stick twist grip open. Position inner
wire 0.10-0.30 inch beyond outboard edge of fitting in collective arm, and special
torque fitting nut per Section 20-33. Install palnut, standard torque per Section 20-32,
& torque stripe per Figure 5-1.
6. Position aft end of control housing 1.10-1.30 inches beyond edge of aft AN742-4 clamp
and install fasteners securing housing and clamps to F577-3 bracket.
7. Refer to detail in Figure 76-3. Rotate twist grip closed; rotate and hold FCU throttle
lever to contact idle stop. Verify sufficient inner wire beyond aft edge of fitting, and
special torque fitting nut per Section 20-33.
8. Rotate twist grip open; verify FCU throttle lever contacts maximum throttle stop,
and 0.030-0.050 inch gap between F328-1 connecting rod and throttle stop washer.
Reposition fitting on wire as required until proper rod-to-washer gap, and FCU throttle
lever contacts maximum throttle stop with twist grip open, and idle stop with twist grip
closed.
9. Install fitting palnut, standard torque per Section 20-32, and torque stripe per Figure
5-1. Trim control wire 0.10-0.30 inch beyond aft edge of fitting.
10. Install collective cross tube cover and collective cover assembly. As required, perform
FCU fuel cutoff control rigging per Section 76-12, or install engine cowling assembly
per Section 53-21.
76-12 FCU Fuel Cutoff Control Rigging

1. Remove engine cowling assembly per Section 53-21.

2. Refer to Figure 76-1. Remove palnut and loosen nut securing A462-4 fitting and A522-
10 (fuel cutoff) control inner wire to FCU fuel cutoff lever.
3. Rotate FCU fuel cutoff lever into OFF detent; pull fuel cutoff control knob OFF (at
lower console). Position end of control housing flush-0.050 inch from forward edge of
fitting and install fasteners securing housing and AN742-4 clamps to F577-1 bracket
assembly.
4. Refer to detail in Figure 76-3. Verify sufficient inner wire beyond aft edge of fitting, and
special torque fitting nut per Section 20-33.

25 OCT 2010 R66 Maintenance Manual Chapter 76 Engine Controls Page 76.3
FIGURE 76-2 POWER TURBINE GOVERNOR

Page 76.4 Chapter 76 Engine Controls R66 Maintenance Manual 25 OCT 2010
76-12 FCU Fuel Cutoff Control Rigging (continued)

5. Push fuel cutoff control knob ON and verify FCU fuel cutoff lever-to-maximum fuel
stop clearance is 0.030-0.090 inch. Reposition fitting on wire as required until FCU
fuel cutoff lever rests in detent when control is OFF and has required clearance from
maximum fuel stop when control is ON.

6. Install fitting palnut, standard torque per Section 20-32, and torque stripe per Figure
5-1. Trim control wire 0.10-0.30 inch beyond aft edge of fitting.

7. Install engine cowling assembly per Section 53-21.

76-20 Power Turbine Governor (PTG)

Refer to R66 Illustrated Parts Catalog (IPC) Figures 76-5 and 76-7.

A. Removal

1. Remove engine cowling assembly per Section 53-21.

2. Refer to Figure 76-2. Remove cotter pin and washer securing C522-11 (power turbine
governor) control inner sleeve and D333-13 fitting to PTG input lever.

3. Remove fasteners securing control housing and AN742-4 clamps to F046-1 lower frame,
as required.

4. Remove PTG per RR300 Series Operation and Maintenance Manual (OMM).

B. Installation

1. Install PTG per RR300 Series Operation and Maintenance Manual (OMM).

2. Perform PTG control rigging per Section 76-21.

76-21 PTG Control Rigging

1. Remove engine cowling assembly per Section 53-21. Detach center back rest assembly
hook and loop tape (Velcro) at bottom; slide back rest assembly up and out of keyhole
slots. Remove F474-2 middle seat cover (see Section 6-70).

2. Refer to Figure 76-2. Verify PTG input lever rigging angle is 93.0° ± 7.5°. As required,
remove hardware securing serrated levers and reposition to proper angle. Install
hardware, special torque nut per Section 20-33, and torque stripe per Figure 5-1.

3. Refer to Figure 76-3. Remove palnut and loosen nut securing A462-4 fitting and C522-
11 (power turbine governor) control inner wire to F822-1 bellcrank assembly.

4. Position PTG pointer to indicate 45° on PTG protractor. Position aft end of control
housing 1.44-1.50 inches from forward edge of D333-13 fitting and install fasteners
securing housing and AN742-4 clamps to F046-1 lower frame.

5. Position forward end of control housing flush-0.25 inch at or below edge of bottom
AN742-3 clamp and install fasteners securing housing and clamps to F381-6 bracket.

6. Turn BATTERY switch ON. With collective stick full down, “beep” collective toggle
switch to full down. Turn BATTERY switch OFF.

25 OCT 2010 R66 Maintenance Manual Chapter 76 Engine Controls Page 76.5
FIGURE 76-3 PTG (BEEP) ACTUATOR ASSEMBLY

Page 76.6 Chapter 76 Engine Controls R66 Maintenance Manual 25 OCT 2010
76-21 PTG Control Rigging (continued)

7. Verify PTG pointer indicates 45° on PTG protractor, verify sufficient inner wire beyond
bottom edge of bellcrank fitting, and special torque fitting nut per Section 20-33.
8. Install palnut, standard torque per Section 20-32, and torque stripe per Figure 5-1. Trim
control wire 0.10-0.30 inch beyond bottom of fitting.
9. Perform PTG rigging check per Section 76-22.
10. Install engine cowling assembly per Section 53-21. Install middle seat cover. Install
back rest assembly in keyhole slots and slide down; press firmly on back rest assembly
hook and loop tape at bottom. Verify security.
76-22 PTG Rigging Check

1. Turn BATTERY switch ON.

2. Refer to Figure 76-2. With collective stick full down, “beep” collective toggle switch to
full down. Verify PTG pointer indicates between 42.5° and 47.5° on PTG protractor.
Turn BATTERY switch OFF.
3. Adjust PTG control rigging as required per Section 76-21; repeat previous steps until
PTG is rigged for proper mechanical range.
4. Run-up helicopter per R66 Pilot's Operating Handbook, Section 4. Verify “beep” range
is 97 to 103% rotor RPM with collective full down and twist grip open.
5. Adjust PTG control rigging as required per Section 76-21; repeat previous steps until
PTG is rigged for proper operational range.

25 OCT 2010 R66 Maintenance Manual Chapter 76 Engine Controls Page 76.7
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Page 76.8 Chapter 76 Engine Controls R66 Maintenance Manual 25 OCT 2010
CHAPTER 79

ENGINE OIL SYSTEM

Section Title Page

79-00 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79.1

79-10 Scroll and Fanwheel Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79.3
79-11 Fanwheel-to-Inlet Gaps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79.3
79-20 Oil Tank Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79.5
79-21 Oil Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79.6
79-22 Sight Gage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79.7
79-30 Engine Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79.7
79-40 Engine Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79.7
79-50 Engine Oil Line Assemblies and Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . 79.8

APR 2017 Chapter 79 Engine Oil System Page 79.i

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Page 79.ii Chapter 79 Engine Oil System APR 2017

CHAPTER 79

ENGINE OIL SYSTEM

79-00 Description
The R66 helicopter has a dry-sump engine oil system. Oil is stored in a remote tank
located in the main rotor gearbox compartment. Refer to Section 12-60 for oil servicing
instructions. A Rolls-Royce-supplied oil temperature sender is mounted on the inboard side
of the oil tank.
Oil circulates through the engine oil system via three oil delivery lines. Refer to Figure 79-
1. Cool oil exits the oil tank and enters the engine, hot oil exits the engine and enters the
engine oil cooler, and cooled oil exits the oil cooler and returns to the oil tank. An oil tank
vent line is plumbed to the engine accessory gearbox, which is vented to the exhaust pipe.
The engine oil cooler has an internal thermostat (thermostat initial closure 70°C, full closure
81°C) and pressure relief valve. The thermostat maintains normal system operating pressure
by allowing cool oil to bypass the heat exchanger and return to the oil tank. Higher than
normal system pressure will open a pressure relief valve. When draining the oil system,
residual oil is trapped in the bottom corner of the oil cooler due to the oil cooler installation
angle in the R66. An oil cooler drain plug allows the technician to drain trapped oil during
servicing.
The engine oil system includes an oil pump, oil filter and regulating valve, an oil sump
tank, a check valve, and two magnetic plug inserts. Refer to RR300 OMM for a complete
description of the engine oil system.

FIGURE 79-1 ENGINE OIL SYSTEM SCHEMATIC

APR 2019 Chapter 79 Engine Oil System Page 79.1

FIGURE 79-2 SCROLL AND FANWHEEL ASSEMBLIES

Page 79.2 Chapter 79 Engine Oil System APR 2019

79-10 Scroll and Fanwheel Assemblies
A. Removal
1. Remove F196-1 fan shaft per § 65-10.
2. Refer to Figure 79-2. Remove perimeter screws securing F236-1 scroll assembly
to F306-1 box assembly.
3. Remove aluminum tape sealing gaps & joints, or gently pull scroll away from box
assembly and, using a scribe or similar sharp instrument, tear aluminum tape sealing
gaps & joints. Remove scroll, with G174-1 fanwheel assembly inside, up through
frame.
4. Remove hardware securing forward or aft F305-5 inlet to scroll; remove inlet &
fanwheel. Remove damaged aluminum tape from scroll and box assembly.
B. Installation
1. Refer to Figure 79-2. Observing “AFT” orientation marking on fanwheel plate, place
G174-1 fanwheel assembly inside F236-1 scroll assembly accordingly. Position
F305-5 inlets on scroll and install hardware. Verify security.
2. Lower scroll, with fanwheel inside, through frame and install hardware securing
scroll to F306-1 box assembly. Verify security. Seal gaps & joints using A701-1
aluminum tape.
3. Install F196-1 fan shaft per § 65-10.

79-11 Fanwheel-to-Inlet Gaps

A. Measuring Gap
1. Remove tailcone cowling assembly per § 53-23.
2. Refer to Figure 79-2. Verify 0.10 inch minimum gap between G174-1 fanwheel
assembly and forward and aft F305-5 inlets. Check gap all the way around;
rotate fanwheel and check gap again (several positions). If gap is within limits at
forward and aft inlets, no further action is required.
3. Verify proper tail rotor driveline shimming per § 65-30.
4. Trim inlets as required per Part B.
5. Install tailcone cowling assembly per § 53-23.

APR 2017 Chapter 79 Engine Oil System Page 79.3

FIGURE 79-3 ENGINE OIL SYSTEM

Page 79.4 Chapter 79 Engine Oil System APR 2017

79-11 Fanwheel-to-Inlet Gaps (continued)
B. Trimming Inlets
1. Refer to Figure 79-2. Remove hardware securing F305-5 inlets to F236-1 scroll
assembly.
2. If inlets are slotted, carefully twist inlets over F196-1 fan shaft and remove inlets.
If inlets are not slotted, remove hardware securing fan shaft to C947-3 plate
assemblies, noting hardware removed, and remove inlets.
3. Refer to Figure 79-2, Detail A. Trim inlets as required to meet minimum fanwheel-
to-inlet gap. Do not exceed minimum inlet dimensions.
4. Refer to § 20-70. Smooth inlet edges and coat bare metal with primer. Touch-
up primed area using dark gray Dupont Imron polyurethane enamel in accordance
with paint manufacturer’s recommendations.
5. If inlets are slotted, carefully twist inlets over fan shaft and install hardware
securing inlets to scroll assembly (slot orientation is optional). Verify security.
6. If inlets are not slotted, install inlets around fan shaft and install hardware securing
inlets to scroll assembly. Verify security. Install hardware securing fan shaft to
plate assemblies, standard torque hardware per § 20-32, and torque stripe per
Figure 5-1.
7. Measure fanwheel-to-inlet gaps per Part A. Repeat procedure as required for
minimum 0.10 inch gap at forward and aft inlets.

79-20 Oil Tank Assembly

A. Removal
1. Drain engine oil per § 12-60.
2. Remove tailcone cowling assembly per § 53-23; open main gearbox access door.
3. Air-conditioned ships: Recover refrigerant per § 12-81. Using backup wrench,
disconnect G794-2 & G794-3 hose assemblies from G810-1 & G811-1 line
assemblies; cap fittings.
4. Refer to Figure 79-3. Remove D277-8 clamp or cut and discard safety wire securing
A729 tube to G689-1 tank assembly scupper drain. Pull tube off of drain.
5. Disconnect airframe harness from MS28034-1 oil temperature sender.
6. Disconnect F723-1, F723-3, and F723-4 line assemblies from oil tank and associate
components; cap fittings.
7. Remove nuts securing tank to firewall.
8. Remove hardware securing tank to F384-3 angles and remove tank through access
door.

APR 2017 Chapter 79 Engine Oil System Page 79.5

79-20 Oil Tank Assembly (continued)
B. Installation
1. Torque check associated oil cooler and engine unions per § 20-33.
2. Refer to Figure 79-3. Position G689-1 tank assembly in helicopter and install
hardware securing tank to F384-3 angles. Verify security.
3. Install nuts securing tank to firewall and special torque nuts per § 20-33.
4. Remove caps and connect F723-1, F723-3, and F723-4 line assemblies to tank
and associate components. Using backup wrench, special torque line nuts per §
20-33.
5. Torque stripe fittings per Figure 5-1.
6. Connect airframe harness to MS28034-1 oil temperature sender. Verify security.
7. Secure A729 tube to tank scupper drain using D277-8 clamp; verify security.
8. Service engine oil per § 12-60.
9. Air-conditioned ships: Torque check nuts at firewall per § 20-33. Remove caps and
connect G794-2 & G794-3 hose assemblies to G810-1 & G811-1 line assemblies.
Using backup wrench, special torque hose nuts per § 20-33. Charge system per §
12-81.
10. Install tailcone cowling assembly per § 53-23.

79-21 Oil Temperature Sender

A. Removal
1. Drain engine oil per § 12-60.
2. Remove tailcone cowling assembly per § 53-23.
3. Refer to Figure 79-3. Disconnect airframe harness from MS28034-1 oil
temperature sender.
4. Remove sender from G689-1 tank assembly; discard packing. Tape tank opening.
B. Installation
1. Refer to Figure 79-3. Install (new) packing on MS28034-1 oil temperature sender.
Remove tape, install sender in G689-1 tank, and special torque sender per § 20-33.
2. Connect airframe harness to sender; verify security.
3. Service engine oil per § 12-60.
4. Install tailcone cowling assembly per § 53-23.

Page 79.6 Chapter 79 Engine Oil System APR 2017

79-22 Sight Gage
A. Removal
1. Drain engine oil per § 12-60.
2. Refer to Figure 79-3. Remove B563-2 sight gage from G689-1 tank assembly.
Discard o-ring; tape tank opening.
B. Installation
1. Refer to Figure 79-3. Remove tape and verify G689-1 tank assembly interior is
free of contaminants.
2. Lubricate (new) o-ring using A257-18 lubricant. Install o-ring on B563-2 sight
gage, and install gage in tank. Special torque gage per § 20-33.
3. Service engine oil per § 12-60.

79-30 Engine Oil Cooler

A. Removal
1. Drain engine oil per § 12-60.
2. Refer to Figure 79-3. Remove hardware securing F649-1 oil cooler to F309-1 box
assembly.
3. Support oil cooler without damaging oil cooler fins. Disconnect F723-2 and F723-
4 line assemblies from oil cooler and associated components; cap fittings.
B. Installation
1. Refer to Figure 79-3. Install hardware securing F649-1 oil cooler to F309-1 box
assembly.
2. Torque check associated oil cooler and engine unions per § 20-33.
3. Remove caps and connect F723-2 and F723-4 line assemblies to oil cooler and
associated components. Using backup wrench, special torque line nuts per § 20-33.
4. Torque stripe fittings per Figure 5-1.
5. Service engine oil per § 12-60.

79-40 Engine Oil Filter

Maintain engine’s oil system per RR300 OMM.

NOTE
During engine oil filter servicing, if filter is contaminated, replace
engine oil cooler and flush oil lines.

APR 2017 Chapter 79 Engine Oil System Page 79.7

79-50 Engine Oil Line Assemblies and Fittings
A. Removal
1. Drain engine oil per § 12-60.
2. Refer to Figure 79-3. Remove hardware securing F723 line assembly clamps.
3. Disconnect line assembly from associated components; cap fittings. Remove line.
B. Installation
1. Refer to Figure 79-3. Torque check associated oil cooler and engine unions per §
20-33.
2. Remove caps and connect F723 line assembly to associated components. Using
backup wrench, special torque line nuts per § 20-33.
3. Install hardware securing line assembly clamps. Verify security.
4. Torque stripe fittings per Figure 5-1.
5. Service engine oil per § 12-60.

Page 79.8 Chapter 79 Engine Oil System APR 2017

CHAPTER 90

POLICE VERSION
Section Title Page

90-00 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.1

90-10 C023-34 Tailcone Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.5
90-20 C060-3 Interior Light Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.5
90-30 C069 Cyclic Control Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.5
90-40 C430-2 Five-Point Harness Installation (Optional) . . . . . . . . . . . . . . . . . . . 90.5
90-50 C599 Airspeed Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.5
90-60 C813 Transceiver Installation (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . 90.6
90-70 C823-16 Audio Control Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.8
90-80 C849-4 Blower Installation (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.9
90-90 D301 Ballast Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.10
90-100 F003-19 Seat Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.10
90-110 F014-5 Landing Gear Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.10
90-120 F036-3 Battery Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.10
90-130 F051-1 Camera System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.11
90-140 F060 Intercom System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.12
90-150 F075-2 EFIS Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.13
90-151 C831-12, -13, & -14 (GTN XXX-Series) GPS/NAV/COM Installation . . . . . 90.13
90-152 G060-4 (Garmin G500H) Upper Console Assembly . . . . . . . . . . . . . . . . 90.13
90-155 F075-8 EFIS Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.14
90-156 F817-9 (Garmin G500H) GDU 1060 Display (R66 Police) Installation . . . . 90.14
90-157 F818-11 (G070 Console) GTN 6XX-series GPS/NAV/COM Installation . . . 90.14
90-158 G070-7 (8-Instrument, High) Upper Console Assembly . . . . . . . . . . . . . . 90.14
90-160 F079-1 PA/Siren System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.15
90-170 F081 Searchlight Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.17
90-180 F082-21 Fairing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.18
90-190 G415-1 DVR Installation (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.18
90-200 G416 Monitor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.19
90-210 G423-1 Aux Electrical System Installation . . . . . . . . . . . . . . . . . . . . . . . . 90.21
90-220 G425-1 Wall Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.21
90-230 G437-1 Lojack Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.22
90-240 G460 Audio Control Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.23
90-250 G608 GPS Mapping System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 90.24
90-260 G685 Aux Strobe Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.26
90-270 G749-1 Console Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.27
90-280 Wiring Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.29

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Page 90.ii Chapter 90 Police Version JUL 2020

CHAPTER 90

POLICE VERSION

90-00 Description
The Police Version is equipped with a nose-mounted gyro-stablized infrared camera, a
flat screen monitor for viewing camera images, a video recorder, and a belly-mounted
searchlight. Optional FM transceivers, a PA/Siren, Lojack equipment, and a GPS mapping
system may also be installed. A dedicated, non-essential electrical bus distributes power
to police equipment, and extended landing gear provides additional ground clearance for
the camera and searchlight.
The R66 is a four-place helicopter when police equipment is installed.
Basic descriptions of police equipment and systems are given below. More detailed
information can be found in manufacturer’s documents supplied with individual pieces of
equipment.
Some aircraft have a cockpit configuration that does not include the left side cyclic grip in
order to prevent interference with the observer’s LCD monitor.
There are two basic cockpit configurations (refer to R66 Pilot’s Operating Handbook Section
9 Police Version Supplement for illustrations). One configuration uses a modified cyclic
control without a left-side grip because the flat screen monitor would interfere. The second
configuration uses the standard cyclic control with a left-side grip.
An additional circuit breaker panel on the ledge just forward of the pilot’s seat contains all
circuit breakers for police equipment. Depending on installed police options, the outboard
section of the aft row of circuit breakers may be a 14-volt bus powered by a 28- to 14-volt
converter. The police equipment master switch on the left side of the panel controls power
to all police equipment.

NOTE
Police circuit breaker panel will not be powered by police
equipment master switch unless avionics switch is also on.

Wiring for police equipment is in a separate harness and occupies portions of the main
baggage compartment, right side under seat compartments, and right rear footwell.
Protective covers isolate the wiring harness as appropriate.
Audio control panel(s) to accommodate police radios and other equipment are installed.
The audio system receives power from the audio breaker on the main (left hand) circuit
breaker panel. It is not connected to the police equipment master switch.

JUL 2020 Chapter 90 Police Version Page 90.1

FIGURE 90-1 POLICE VERSION

Page 90.2 Chapter 90 Police Version JUL 2020

90-00 Description (continued)
A transmit switch for the left front seat is provided on the floor near the observer’s right
heel. An intercom switch for the left front seat is provided either near the observer’s right
heel or at the outboard base of the seat box. An optional transmit switch for the left rear
seat is also available. The optional switch is handheld on a cord which plugs into a jack
beneath the left rear seat ICS button. Transmit functionality is tied to the selection on the
observer’s audio panel.
The center rear seat has been replaced with an arm rest and storage console.
Baggage is not permitted in the right rear under-seat compartment due to electronic
equipment and wiring in that compartment.
An interior wall has been added to the main baggage compartment to create an electronic
equipment compartment at the aft end.
Extended forward landing gear struts provide additional ground clearance for the camera
and searchlight. The ground clearance at the tail is reduced by approximately 8 inches with
the helicopter parked.
The infrared camera system consists of a gyro-stabilized, gimbal-mounted infrared/video
camera in the chin and a power junction box in the main baggage compartment behind the
interior wall. The camera is operated by the observer in the left front seat via a handheld
controller. A tray and strap forward of the circuit breaker panel are provided for controller
stowage when not in use.
A flat screen LCD monitor is located in front of the left front seat to display camera images.
For the earlier cockpit configuration, the monitor is equipped with a visor to minimize glare.
The monitor mount is hinged to retract forward and down, out of the observer’s way, when
not in use.
For the later cockpit configuration, the monitor has no visor but is easily dimmed using a
knob on its front face. The monitor mount is hinged on its inboard edge, and the monitor
folds back against the left side of the instrument console, out of the observer’s way, when
not in use.
The optional digital video recorder (DVR) is mounted just aft of the space between the front
backrests and controlled by a switch at the observer’s station. The DVR can record images
from the camera and play them back on the LCD monitor.

JUL 2020 Chapter 90 Police Version Page 90.3

90-00 Description (continued)
The searchlight is installed on a motorized gimbal under the belly. The searchlight power
junction box is located in the right rear under-seat compartment. The searchlight is steerable
in azimuth and elevation and is operated from the left front seat via a remote control. An
optional slaving system allows the searchlight to be slaved to follow the camera. The
searchlight should be stowed horizontally when not in use to minimize chance of damage
during a hard landing.

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

An additional observer-side interior light is operated via a momentary foot switch on the left-
hand forward floor. Power is supplied to the interior light via the “GAGES” breaker in the left
hand circuit breaker panel and is not disconnected by the police equipment master switch.
A 100-watt speaker is located on the aircraft belly near the left rear landing gear strut. The
PA system control panel is located in the avionics stack and allows the pilot or observer to
select PA, radio, yelp, or siren for broadcast through the speaker.
A multi-band FM transceiver may be mounted either next to the LCD monitor or in the main
avionics stack. The FM transceiver band(s) are selectable from the audio control panel(s).
The Lojack installation consists of a receiver installed in the main baggage compartment
behind the interior wall, a display and control unit on the right side of the instrument
console, and four belly-mounted stub antennas. Lojack is used to track stolen vehicles
equipped with Lojack transmitters.
The GPS mapping computer is installed in the main baggage compartment behind the interior
wall and allows an overhead view of the helicopter’s area of operation to be displayed on
the LCD monitor. The computer contains a database of streets, landmarks, and topography
enabling direct navigation to street addresses and other points on the ground. The computer
is accessed using a keyboard below the LCD monitor. An optional inertial monitoring unit
can interface with the computer to keep the camera and/or searchlight trained on a fixed
ground location while the helicopter maneuvers.

Page 90.4 Chapter 90 Police Version JUL 2020

90-10 C023-34 Tailcone Assembly
Refer to Figure 90-1. The C023-34 tailcone assembly has provisions for two upper-mounted
antennas and two lower-mounted antennas and NAV. Refer to § 6-80 for antenna locations.
Refer to § 53-40 for tailcone assembly maintenance procedures.

90-20 C060-3 Interior Light Installation

Refer to Figure 90-1. The C060-3 interior light installation is installed above the observer’s
seat, and has a floor-mounted switch.
A. Schematic
Refer to Figure 90-2 for C060-3 interior light installation wiring schematic.

90-30 C069 Cyclic Control Assembly

Refer to Figure 90-1. On earlier Police helicopters, the C069-9 cyclic control assembly
was modified for clearance with the LCD monitor. The copilot removable grip assembly
(transmit wiring) was omitted and the C058-11 grip weldment was plugged. A second grip
was installed on the cyclic stick.
Refer to § 67-10 for cyclic control and grip assembly maintenance procedures.
A. Schematic
Refer to Figure 90-3 for C058-11 grip assembly wiring schematic.

90-40 C430-2 Five-Point Harness Installation (Optional)

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

90-50 C599 Airspeed Indicator

Police version airspeed limitations (130 knot Vne, KM/H) differ from standard version
helicopters (140 knot Vne, KM/H) due to external equipment. On earlier Police helicopters,
two indicators were available: one with kilometers per hour for primary markings and one
with miles per hour for primary markings. On later Police helicopters, only an indicator with
miles per hour for primary markings is approved.
Refer to § 95-22 for maintenance procedures. Refer to § 90-150 or § 90-155 EFIS
Installation for equipment removal instructions prior to removing instrument face.

JUL 2020 Chapter 90 Police Version Page 90.5

90-60 C813 Transceiver Installation (Optional)
A. Description
The Technisonic TDFM-600/6000/7000 series (C813-2; 5-band) and TDFM-9000
series (C813-4 and C813-5; 6-band) airborne transceivers are wired through the
Technisonic A711L series audio control panel to allow for separate and simultaneous
operation on each band. The C813-2 transceiver (earlier Police helicopters) is located
at the observer’s station. The C813-4 and C813-5 transceivers (separate installations)
are located in the instrument panel for pilot and observer access.
B. Schematic
Refer to Figure 90-4 for C813-2 transceiver installation wiring schematic.
Refer to Figure 90-5 for C813-4 transceiver installation wiring schematic.
Refer to Figure 90-6 for C813-5 transceiver installation wiring schematic.
C. Removal
C813-2 (Technisonic TDFM-600) Transceiver:
1. Refer to Figure 90-1. Turn battery & avionics switches off and pull out (7.5 amp)
circuit breaker at panel.
2. Remove screws securing D413-2 cover to D413-1 box assembly.
3. Disconnect D613-4 harness assembly from C813-2 transceiver.
4. Release slotted turnlock fasteners securing transceiver to box assembly and
remove transceiver.
C813-4 (Technisonic TDFM-9000) Transceiver:
1. Refer to Figure 90-1. Turn battery & avionics switches off and pull out (10 amp)
circuit breaker at panel.
2. Release slotted turnlock fasteners securing C813-4 transceiver to avionics tray
and remove transceiver.
C813-5 (Technisonic TDFM-9000) Transceiver:
1. Refer to Figure 90-1. Turn battery & avionics switches off and pull out (10 amp)
circuit breaker at panel.
2. Remove screws securing G413-14 cover to G070 console assembly and remove
cover.
3. Disconnect G458-1 harness assembly and antenna cables from C813-5 transciever.
4. Release slotted turnlock fasteners and remove transceiver.

Page 90.6 Chapter 90 Police Version JUL 2020

90-60 C813 Transceiver Installation (Optional; continued)
D. Installation
C813-2 (Technisonic TDFM-600) Transceiver:
1. Refer to Figure 90-1. Turn battery & avionics switches off and pull out (10 amp)
circuit breaker at panel.
2. Position C813-2 transceiver in D413-1 box assembly and engage slotted turnlock
fasteners. Verify security.
3. Connect D613-4 harness assembly to transceiver and verify security.
4. Position D413-2 cover on box assembly and install screws; verify security.
4. Push in (7.5 amp) circuit breaker at panel. Turn battery & avionics switches on.
5. Perform appropriate functional checks per Technisonic Industries Limited
Installation and Operating Instructions (supplied with unit). Turn battery &
avionics switches off.
C813-4 (Technisonic TDFM-9000) Transceiver:
1. Refer to Figure 90-1. Turn battery & avionics switches off and pull out (10 amp)
circuit breaker at panel.
2. Position C813-4 transceiver in avionics tray and engage slotted turnlock fasteners.
Verify security.
3. Push in (10 amp) circuit breaker at panel. Turn battery & avionics switches on.
4. Perform appropriate functional checks per Technisonic Industries Limited
Installation and Operating Instructions (supplied with unit). Turn battery &
avionics switches off.
C813-5 (Technisonic TDFM-9000) Transceiver:
1. Refer to Figure 90-1. Turn battery & avionics switches off and pull out (10 amp)
circuit breaker at panel.
2. Position C813-5 transciever in G070 console assembly and engage slotted
turnlock fasteners. Verify security.
3. Connect G458-1 harness assembly and antenna cables to transciever. Verify
security.
4. Install screws securing G413-14 cover to console assembly; verify security.
5. Push in (10 amp) circuit breaker at panel. Turn battery & avionics switches on.
6. Perform appropriate functional checks per Technisonic Industries Limited
Installation and Operating Instructions (supplied with unit). Turn battery &
avionics switches off.

JUL 2020 Chapter 90 Police Version Page 90.7

90-60 C813 Transceiver Installation (Optional; continued)
E. Scheduled Maintenance and Inspections
Refer to Technisonic Industries Limited Installation and Operating Instructions.
F. Special Maintenance and Inspections
1. Turn battery & avionics switches off. Open circuit breaker panel and remove
transceiver per Part C, as required.
2. Inspect condition of and verify no obvious damage to transceiver, avionics tray (if
installed), 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 install transceiver per Part D, as required. Perform
ground checks per last two steps of Part D.

90-70 C823-16 Audio Control Installation

A. Removal
1. Refer to Figure 90-1. Turn battery switch off. Pull-out associated circuit breaker.
2. Release four slot-head fasteners securing C823-16 audio control to radio tray, and
remove audio control.
B. Installation
1. Refer to Figure 90-1. Turn battery switch off & pull-out associated circuit breaker.
2. Position C823-16 audio control into appropriate radio tray support and lock four
slot-head fasteners.
3. Push-in associated circuit breaker & turn battery switch on. Perform post-
installation function checks per the appropriate Northern Airborne Technology
(NAT) Installation and Operation Manual (supplied with unit).
C. Schematic
Refer to Figure 90-7 for C823-16 audio control installation wiring schematic.

Page 90.8 Chapter 90 Police Version JUL 2020

90-80 C849-4 Blower Installation (Optional)
Refer to Figure 90-1. The C849-4 blower installation is optional equipment for the Police
Version.
A. Removal
1. Refer to Figure 90-1. Turn battery switch off & pull-out associated circuit breaker.
2. Remove screws securing securing B050-22 or -23 upper console assembly to
F033-1 lower console assembly and hinge upper console aft. Protect instrument
face with foam support or equivalent.
3. Cut and discard ty-raps as required and disconnect TB1-1.5D blower wiring from
harness wiring at connectors.
4. Pull hose off of blower and tape hose and blower openings to prevent contamination.
5. Remove hardware securing blower to D651-1 bracket, and remove blower.
B. Installation
1. Refer to Figure 90-1. Turn battery switch off & pull-out associated circuit breaker.
2. Without pinching wiring, position TB1-1.5D blower on D651-1 bracket and install
hardware. Verify security.
3. Remove tape and push hose onto blower. Verify security.
4. Connect blower wiring to harness at connectors and install ty-raps as required.
Cinch ty-raps until snug without over-tightening and trim tips flush with heads.
5. Remove support and hinge B050-22 or -23 upper console assembly forward. Install
screws securing upper console to F033-1 lower console assembly.
6. Push-in associated circuit breaker & turn battery switch on. Perform appropriate
post-installation function checks. Turn battery switch off.

JUL 2020 Chapter 90 Police Version Page 90.9

90-90 D301 Ballast Installation

CAUTION
Altering fixed ballast can appreciably affect helicopter center of
gravity (CG).
CAUTION
Maximum allowable empennage ballast is 21.00 lb on Police
Versions. One upper and one lower weight are required.
Available combinations provide total weight of 3, 6, 9, 12, 15,
& 21 lb.

Refer to Chapter 8-00 for weight and balance information.

90-100 F003-19 Seat Removal

A. Description
Police version helicopters have no aft center seat installed. The following equipment
is omitted: F628-4 connector assembly, center F628-6 buckle assembly, F931-1 seat
assembly, A752-3 angle, and associated hardware.

90-110 F014-5 Landing Gear Installation

Refer to Figure 90-1. The F014-5 (extended) landing gear installation provides clearance
for the F081 searchlight installation. F239-5 and -6 forward struts (extended gear) are
approximately 2 inches taller than F239-3 and -4 forward struts (standard gear).
Refer to Chapter 32 for landing gear maintenance procedures, and for extended gear
minimum tail skid height.

90-120 F036-3 Battery Installation

Refer to Figure 90-1. The F036-3 (aft) battery installation was the only approved battery
configuration for earlier Police Version helicopters, for weight and balance purposes.
Additional installation configurations are permissible on later Police Version helicopters.
Refer to § 96-10 for battery maintenance procedures.

Page 90.10 Chapter 90 Police Version JUL 2020

90-130 F051-1 Camera System Installation
A. Gimbal Assembly Removal

NOTE
Removal of nose-mounted camera causes a large shift in CG of
empty helicopter. Calculate weight and balance prior to flight
with camera removed to assure aft CG limit is not exceeded.

1. Refer to Figure 90-1. Turn battery switch off & pull-out associated circuit breaker.
2. Remove screws securing G412-1 fairing to chin. Carefully lower fairing until clear
of gimbal assembly, and remove fairing.
3. Disconnect cables from gimbal assembly.
4. Supporting gimbal assembly, remove fasteners securing D349-3 plate to D349-1
supports, and remove gimbal.
B. Gimbal Assembly Installation

NOTE
Removal of nose-mounted camera causes a large shift in CG of
empty helicopter. Calculate weight and balance prior to flight
with camera removed to assure aft CG limit is not exceeded.

1. Refer to Figure 90-1. Turn battery switch off & pull-out associated circuit breaker.
2. Position gimbal assembly’s D349-3 plate between D349-1 supports and install
fasters. Standard torque nuts per Section 20-32 and torque stripe per Figure 5-1.
Verify security.
3. Connect cables to gimbal assembly.
4. Carefully raise G412-1 fairing around gimbal assembly, position fairing on chin, and
install screws. Verify security.
5. Push-in associated circuit breaker & turn battery switch on. Perform appropriate
post-installation function checks. Turn battery switch off.
C. Controller Assembly Removal
1. Refer to Figure 90-1. Turn battery switch off & pull-out associated circuit breaker.
2. Disconnect D616-1 (FLIR camera) controller assembly plug from G458 harness
receptacle and remove controller.
3. As required, remove screws securing D417-5 box to circuit breaker panel and
remove box.

JUL 2020 Chapter 90 Police Version Page 90.11

90-130 F051-1 Camera System Installation (continued)
D. Controller Assembly Installation
1. Refer to Figure 90-1. Turn battery switch off & pull-out associated circuit breaker.
2. If removed, position D417-5 box on circuit breaker panel and install screws. Verify
security.
3. Connect D616-1 (FLIR camera) controller assembly plug to G458 harness receptacle.
Verify security.
4. Push-in associated circuit breaker & turn battery switch on. Perform appropriate
post-installation function checks. Turn battery switch off.
5. Holster controller assembly and secure with B219-4 strap assembly.
E. Electronics Control Unit Removal
1. Refer to Figure 90-1. Turn battery switch off & pull-out associated circuit breaker.
2. Remove G428-1 wall assembly per § 90-220.
3. Disconnect cable assemblies from 19206-2XX electronics control unit.
4. Remove MS27039C0805 screws securing control unit to D428-16 brackets and
G429-10 support, and remove control unit.
F. Electronics Control Unit Installation
1. Refer to Figure 90-1. Turn battery switch off & pull-out associated circuit breaker.
2. Remove G428-1 wall assembly per § 90-220, if not previously accomplished.
3. Position 19206-2XX electronics control unit on G429-1 support assemblies. Align
control unit, D428-16 brackets, and G429-10 support fastener holes and install
MS27039C0805 screws. Verify security.
4. Connect cable assemblies to control unit. Verify security.
5. Install wall assembly per § 90-220.
6. Push-in associated circuit breaker & turn battery switch on. Perform appropriate
post-installation function checks. Turn battery switch off.
G. Schematic
Refer to Figures 90-8 for F051-1 camera system installation wiring schematic.

90-140 F060 Intercom System Installation

Refer to Figure 90-1. The F060 intercom system installation includes a second floor switch.
Refer to § 90-70 for C823-16 audio control installation maintenance procedures.

Page 90.12 Chapter 90 Police Version JUL 2020

90-150 F075-2 EFIS Installation

90-151 C831-12, -13, & -14 (GTN-XXX Series) GPS/NAV/COM Installation

A. Description
The Garmin GTN 600/700-series GPS for the Police version with Garmin G500H
integrated display system is installed in the pilot-side console location.
B. Maintenance
Refer to § 97-56 for maintenance procedures.

90-152 G060-4 (Garmin G500H) Upper Console Assembly Installation

A. Opening Console
1. Remove Garmin GDU 620 display per § 95-72.
2. Remove C813-4 transceiver per § 90-60.
3. Remove perimeter screws securing instrument face to console.
4. Disconnect instrument pitot-static lines. Plug lines.
5. Remove screws securing console assembly to keel panels and hinge console aft.
B. Securing Console
1. Hinge console assembly forward and install screws securing console to keel
panels.
2. Position instrument face in helicopter, remove plugs, and connect pitot-static
lines.
3. Install perimeter screws securing face to console. Verify security.
4. Install C813-4 transceiver per § 90-60.
5. Install Garmin GDU 620 display per § 95-72.
6. Perform pitot-static system leak check per § 95-10.

JUL 2020 Chapter 90 Police Version Page 90.13

90-155 F075-8 EFIS Installation

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

90-157 F818-11 (G070 Console) GTN 6XX-series GPS/NAV/COM Installation

A. Description
The Garmin GTN 6XX-series GPS/NAV/COM is installed in the G070 upper console
location for the Police Version F075-8 EFIS installation.
B. Maintenance
Refer to § 97-15 for maintenance procedures.

90-158 G070-7 (8-Instrument, High) Upper Console Assembly

A. Removing Upper Console
1. Remove C813-5 transceiver per § 90-60.
2. Remove GTN 650Xi GPS/NAV/COM per § 97-15.
3. Remove perimeter screws securing instrument face to console.
4. Disconnect instrument pitot-static lines. Plug lines.
5. Remove hardware securing console assembly to keel panels and lower console.
Disconnect airframe harnesses from console harnesses and remove console.
B. Installing Upper Console
1. Connect airframe harnesses to console harnesses and position upper console on
lower console and keel panels. Install hardware; verify security.
2. Position instrument face in helicopter, remove plugs, and connect pitot-static
lines.
3. Install perimeter screws securing face to console. Verify security.
4. Install GTN 650Xi GPS/NAV/COM per § 97-15.
5. Install C813-5 transceiver per § 90-60.
6. Perform pitot-static system leak check per § 95-10.

Page 90.14 Chapter 90 Police Version JUL 2020

90-160 F079-1 PA/Siren System Installation
A. Speaker Removal
1. Refer to Figure 90-1. Turn battery switch off & pull-out associated circuit breaker.
2. Cut safety wire securing speaker cone to F644-1 bracket.
3. Unscrew cone and remove cone and speaker horn. Cut and discard remaining
safety wire from inside of cone.
4. Slide back nipples and wire receptacles off of speaker electrical turrets.
5. Cut and discard speaker mounting bolt safety wire and remove bolts. Supporting
speaker, remove two remaining mounting screws and hardware, and remove
speaker.

B. Speaker Installation
1. Refer to Figure 90-1. Turn battery switch off & pull-out associated circuit breaker.
2. Remove cone and speaker horn from speaker. Position speaker with drain hole
down in F644-1 bracket and install mounting hardware. Special torque two bolts
to 60 in.-lb., install 0.032-inch diameter lockwire, and safety bolts together. Verify
speaker security.
3. Slide wire receptacles on speaker electrical turrets. Slide nipples over connections.
4. Install 0.032-inch diameter lockwire inside of cone and prepare safety. Position
speaker horn, drilled hole on top, on speaker and install and tighten cone. Thread
safety through hole and safety cone to bracket. Verify security.

CAUTION
Hearing loss can result if personnel do not wear appropriate
hearing protection when in close proximity to an operating PA/
Siren.

5. Push-in associated circuit breaker & turn battery switch on. Wearing appropriate
hearing protection, perform appropriate post-installation function checks. Turn
battery switch off.
C. Amplifier Removal
1. Refer to Figure 90-1. Turn battery switch off & pull-out associated circuit breaker.
2. Open baggage compartment door. Remove aft left back rest per § 25-22.
3. Disconnect airframe wiring from amplifier at connectors. Remove hardware
securing amplifier to G259-1 bulkhead and remove amplifier.

JUL 2020 Chapter 90 Police Version Page 90.15

90-160 F079-1 PA/Siren System Installation (continued)
D. Amplifier Installation
1. Refer to Figure 90-1. Turn battery switch off & pull-out associated circuit breaker.
2. Open baggage compartment door; remove aft left back rest per § 25-22, if not
previously accomplished.
3. Position amplifer on G259-1 bulkhead and install mounting hardware. Verify
security. Close baggage compartment door.
4. Connect airframe wiring to amplifier at connectors. Verify security. Install aft left
back rest per § 25-22.

CAUTION
Hearing loss can result if personnel do not wear appropriate
hearing protection when in close proximity to an operating PA/
Siren.

5. Push-in associated circuit breaker. Turn battery switch on. Wearing appropriate
hearing protection, perform appropriate post-installation function checks. Turn
battery switch off.
E. Schematic
Refer to Figure 90-9 for F079-1 PA/Siren system installation wiring schematic.

Page 90.16 Chapter 90 Police Version JUL 2020

90-170 F081 Searchlight Installation

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

A. D432-1 or -3 Gimbal Assembly Removal

1. Refer to Figure 90-1. Turn battery switch off & pull-out associated circuit breaker.
2. Disconnect large wiring connector from aft side of 024711-31 searchlight assembly.
3. Hinge aft right seat assembly forward. Disconnect searchlight wires connected to
D432-2 or -4 gearmotor assembly at connectors.
4. Cut and discard ty-raps as required and remove spirap to separate gearmotor and
searchlight harnesses. Pull gearmotor wiring thru hole in belly, toward searchlight.
5. Cut and discard safety wire securing mounting nut to adjacent screw.
6. Have a second person support the searchlight assembly, and prevent it from
rotating. Remove nut, washer, searchlight, and spacer washer.
B. D432-1 or -3 Gimbal Assembly Installation
1. Refer to Figure 90-1. Turn battery switch off & pull-out associated circuit breaker.
2. Install spacer washer (shoulder facing up), 024711-31 searchlight assembly, flat
washer, and nut.
3. Align the searchlight canister with the helicopter fore-to-aft axis. Have a second
person support the searchlight assembly, and prevent it from rotating. Special
torque nut to 20 ft-lb, install 0.032-inch diameter lockwire, and safety nut to
adjacent screw. Verify security.
4. Connect large wiring connector to aft side of searchlight assembly.
5. Hinge aft right seat assembly forward. Route D432-2 or -4 gearmotor assembly
wiring thru hole in belly and connect wiring at connectors.
6. Install spirap. Install one ty-rap near each end of spirap to secure harnesses
together. Cinch ty-raps until snug without over-tightening and trim tips flush with
heads. Hinge seat assembly forward.
7. Push-in associated circuit breaker & turn battery switch on. Perform appropriate
post-installation function checks. Turn battery switch off.
C. Schematic
Refer to Figures 90-10 and 90-11 for F081 searchlight installation wiring schematic.

JUL 2020 Chapter 90 Police Version Page 90.17

90-180 F082-21 Fairing Installation
Refer to § 90-80. The F082-21 fairing installation have (longer) fairing skins for extended
landing gear.
Refer to § 32-40 for fairing assembly maintenance procedures.

90-190 G415-1 DVR Installation (Optional)

A. DVR Removal
1. Refer to Figure 90-1. Turn battery switch off & pull-out associated circuit breaker.
2. Disconnect cables from UDVP-PRO DVR connectors.
3. Remove hardware securing DVR to D856-5 brackets, and remove DVR.
B. DVR Installation
1. Refer to Figure 90-1. Turn battery switch off & pull-out associated circuit breaker.
2. Position UDVP-PRO DVR on D856-5 brackets and install hardware. Verify security.
3. Connect cables to DVR connectors.
4. Push-in associated circuit breaker & turn battery switch on. Perform appropriate
post-installation function checks. Turn battery switch off.
C. Converter Removal
1. Refer to Figure 90-1. Turn battery switch off & pull-out associated circuit breaker.
2. Cut and discard ty-raps, as required, securing XM-DVR PRO converter output
cable and input wiring to harness. Disconnect output cable from UDVP-PRO DVR.
Disconnect input wiring from harness at connectors.
3. Remove F680-3 collective cover assembly. Remove hardware securing converter
to F370-1 panel, and remove converter.
D. Converter Installation
1. Refer to Figure 90-1. Turn battery switch off & pull-out associated circuit breaker.
2. Remove F680-3 collective cover assembly, if not previously accomplished.
3. Position XM-DVR PRO converter on F370-1 panel and install hardware. Verify
security. Install F680-3 collective cover assembly.
4. Connect converter input wiring to harness at connectors. Connect output cable
to DVR. Install ty-raps as required to secure wiring and cable to harness. Cinch
ty-raps until snug without over-tightening and trim tips flush with heads.
5. Push-in associated circuit breaker & turn battery switch on. Perform appropriate
post-installation function checks. Turn battery switch off.
E. Schematic
Refer to Figure 90-12 and 90-13 for G415-1 DVR installation wiring schematic.

Page 90.18 Chapter 90 Police Version JUL 2020

90-200 G416 Monitor Installation
A. Description
The G416-1 monitor installation (earlier helicopters) hinges forward and down for
stowing. The G416-4 and G416-5 monitor installation hinges forward at the right
edge to stow alongside the console.
B. Schematic
Refer to Figure 90-12 for G416-1 monitor installation wiring schematic.
Refer to Figure 90-13 for G416-4 monitor installation wiring schematic.
Refer to Figure 90-14 for G416-5 monitor installation wiring schematic.
C. Removal
G416-1 Monitor Installation
1. Turn battery switch off and pull-out MONITOR (2 amp) circuit breaker at panel.
2. Disconnect cables from V-R1041-RH monitor.
3. Remove hardware securing MS21919WDG8 clamp to monitor.
4. Support monitor. Remove A483-1 knob with associated hardware, and DK-225
knob with associated hardware, securing monitor to D409-8 pivot assembly.
Remove monitor.
5. Remove screws securing D763-3 visor assembly to monitor.
G416-4 Monitor Installation
1. Turn battery switch off and pull-out MONITOR (2 amp) circuit breaker at panel.
2. Disconnect G458 harness assembly cables from DVI 10LDB_RH monitor.
3. Remove screws securing monitor to G417-1 pivot assembly and G417-4 tray
assembly and remove monitor.
G416-5 Monitor Installation
1. Turn battery switch off and pull-out MONITOR (2 amp) circuit breaker at panel.
2. Disconnect G458 harness assembly cables from BHB12HDR15 monitor.
3. Remove screws securing monitor to G417-5 pivot assembly and G417-7 tray
assembly and remove monitor.

JUL 2020 Chapter 90 Police Version Page 90.19

90-200 G416 Monitor Installation (continued)
D. Installation
G416-1 Monitor Installation
1. Install screws securing D763-3 visor assembly to V-R1041-RH monitor. Verify
security.
2. Turn battery switch off and pull-out MONITOR (2 amp) circuit breaker at panel.
Position monitor on D409-8 pivot assembly; install A483-1 knob with associated
hardware, and DK-225 knob with associated hardware, securing monitor to pivot
assembly. Adjust angle as desired. Verify security.
3. Install hardware securing MS21919WDG8 clamp to monitor.
4. Connect cables to monitor.
5. Push in (2 amp) circuit breaker at panel. Turn battery & avionics switches on. Perform
appropriate post-installation function checks. Turn battery & avionics switches off.
G416-4 Monitor Installation
1. Turn battery switch off and pull-out MONITOR (2 amp) circuit breaker at panel.
2. Position DVI 10LDB_RH monitor on G417-1 pivot assembly and G417-4 tray
assembly and install screws. Verify security.
3. Connect G458 harness assembly cables to monitor.
4. Push in (2 amp) circuit breaker at panel. Turn battery & avionics switches on.
Perform appropriate post-installation function checks. Turn battery & avionics
switches off.
G416-5 Monitor Installation
1. Turn battery switch off and pull-out MONITOR (2 amp) circuit breaker at panel.
2. Position BHB12HDR15 monitor on G417-5 pivot assembly and G417-7 tray
assembly and install screws. Verify security.
3. Connect G458 harness assembly cables to monitor.
4. Push in (2 amp) circuit breaker at panel. Turn battery & avionics switches on.
Perform appropriate post-installation function checks. Turn battery & avionics
switches off.
E. Scheduled Maintenance and Inspections
On condition.
F. Special Maintenance and Inspections
Contact Marshall Electronics or Boland Communications Technical Support for
assistance.

Page 90.20 Chapter 90 Police Version JUL 2020

90-210 G423-1 Aux Electrical System Installation
A. Schematic
Refer to § 90-280 for aux electrical system schematics.

90-220 G425-1 Wall Installation

A. Removal
1. Refer to Figure 90-1. Open baggage compartment door. Release quarter-turn slot
and wing head fasteners securing G428-1 wall assembly to G238-1 bulkhead and
G428-2 angles. Carefully remove wall.
B. Installation
1. Refer to Figure 90-1. Open baggage compartment door. Verify no foreign objects
aft of wall mounting points. Verify proper installation and security of equipment.
2. Align G428-1 wall assembly quarter-turn slot and wing head fasteners with
receptacles on G238-1 bulkhead and G428-2 angles, and lock fasteners. Verify
security. Close baggage compartment door.

JUL 2020 Chapter 90 Police Version Page 90.21

90-230 G437-1 Lojack Installation
A. Display Removal
1. Refer to Figure 90-1. Turn battery switch off & pull-out associated circuit breaker.
2. Disconnect cable from 4106-0006-00 display.
3. Remove screws securing D600-3 visor assembly and display to D436-6 support.
Remove visor and display.
B. Display Installation
1. Refer to Figure 90-1. Turn battery switch off & pull-out associated circuit breaker.
2. Connect cable to 4106-0006-00 display.
3. Position D600-3 visor assembly and display on D436-6 support and install screws.
Verify security.
4. Push-in associated circuit breaker & turn battery switch on. Perform appropriate
post-installation function checks. Turn battery switch off.
C. Receiver Removal
1. Refer to Figure 90-1. Turn battery switch off & pull-out associated circuit breaker.
2. Remove G428-1 wall assembly per § 90-220.
3. Remove screws securing two cable backshells to 4107-0003-10 receiver.
Disconnect all cables from receiver.
4. Remove screws securing receiver to G429-3 and G429-4 support assemblies, and
remove receiver.
D. Receiver Installation
1. Refer to Figure 90-1. Turn battery switch off & pull-out associated circuit breaker.
2. Remove G428-1 wall assembly per Section 90-220, if not previously accomplished.
3. Position 4107-0003-10 receiver on G429-3 and G429-4 support assemblies and
install screws. Verify security.
4. Connect all cables to receiver. Install screws securing two cable backshells to
receiver. Verify security.
5. Install G428-1 wall assembly per § 90-220.
6. Push-in associated circuit breaker & turn battery switch on. Perform appropriate
post‑installation function checks. Turn battery switch off.
E. Schematic
Refer to Figure 90-15 for G437-1 Lojack installation wiring schematic.

Page 90.22 Chapter 90 Police Version JUL 2020

90-240 G460 Audio Control Installation
A. Description
Two Technisonic A711L-series audio control panels are installed. The observer’s
audio control panel is installed in the main avionics stack, and the pilot’s panel is
installed in the pilot’s side console. (Earlier police version helicopters had a dual audio
panel located in the avionics stack; refer to § 90-140).
B. Schematic
Refer to Figure 90-17 for G460 audio control installation wiring schematic.
C. Removal
1. Turn battery switch off and pull out ICS (3 amp) circuit breaker at panel.
2. Loosen radio key securing Technisonic A711L-series audio control to avionics tray.
3. Carefully unplug/remove audio control from tray.
D. Installation
1. Turn battery switch off and pull out ICS (3 amp) circuit breaker at panel.
2. Carefully plug-in/install Technisonic A711L-series audio control in appropriate
location in avionics tray.
3. Tighten radio key securing audio control to tray. Verify equipment security.
4. Push in ICS (3 amp) circuit breakers at panel. Turn battery & avionics switches on.
5. Perform appropriate functional checks per Technisonic Industries Limited Installation
and Operating Instructions. Turn battery & avionics switches off.
E. Scheduled Maintenance and Inspections
Refer to Technisonic Industries Limited Installation and Operating Instructions.
F. Special Maintenance and Inspections
1. Turn battery & avionics switches off. Open circuit breaker panel and upper or
pilot’s side console.
2. Inspect condition of and verify no obvious damage to audio control, 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.
3. Secure circuit breaker panel and upper or pilot’s side console. Perform ground
checks per Part D steps 4 and 5.

JUL 2020 Chapter 90 Police Version Page 90.23

90-250 G608 GPS Mapping System Installation
A. Description
The GPS mapping computer is installed in the main baggage compartment behind
the interior wall and allows an overhead view of the helicopter’s area of operation
to be displayed on the LCD monitor. The computer contains a database of streets,
landmarks, and topography enabling direct navigation to street addresses and other
points on the ground. The computer is accessed using a keyboard below the LCD
monitor. An optional inertial monitoring unit can interface with the computer to keep
the camera and/or searchlight trained on a fixed ground location while the helicopter
maneuvers.
B. Schematic
Refer to Figures 90-18 for G608 GPS mapping and MDT installation wiring schematic.
C. Removal
Viewsync3D Computer
1. Turn battery switch off and pull out VIEWSYNC (5 amp) circuit breaker at panel.
2. Remove G428-1 wall assembly per § 90-220.
3. Disconnect cables from Viewsync3D computer.
4. Remove hardware securing computer to isolator mounting tray and remove
computer.
UC-5300/6000 Computer
1. Turn battery switch off and pull out GPS MAP (5 amp) circuit breaker at panel.
2. Remove G428-1 wall assembly per § 90-220.
3. Disconnect cables from UC-5300/6000 computer.
4. Remove hardware securing computer to isolator mounting tray and remove
computer.
IMU Sensor (if installed)
1. Turn battery switch off and pull out GPS MAP (5 amp) circuit breaker at panel.
2. Remove F445-1 and F680-3 cover assemblies and hinge forward left seat forward.
3. Remove hardware securing G702-9 cover assembly to seat assembly.
4. Disconnect cables from IMU Sensor.
5. Remove hardware securing IMU Sensor to G429-15 support assembly and remove
IMU Sensor.

Page 90.24 Chapter 90 Police Version JUL 2020

90-250 G608 GPS Mapping System Installation (continued)
D. Installation
Viewsync3D Computer
1. Turn battery switch off and pull out VIEWSYNC (5 amp) circuit breaker at panel.
2. Position Viewsync3D computer on isolator mounting tray and install hardware.
Verify security.
3. Connect cables to computer.
4. Install G428-1 wall assembly per MM § 90-220.
5. Push in VIEWSYNC (5 amp) circuit breakers at panel. Turn battery & avionics
switches on.
6. Perform appropriate functional checks per Aerocomputers Airborne Systems UC-
5300 Operating Instructions. Turn battery & avionics switches off.
UC-5300/6000 Computer
1. Turn battery switch off and pull out GPS MAP (5 amp) circuit breaker at panel.
2. Position UC-5300/6000 computer on isolator mounting tray and install hardware.
Verify security.
3. Connect cables to computer.
4. Install G428-1 wall assembly per MM § 90-220.
5. Push in GPS MAP (5 amp) circuit breakers at panel. Turn battery & avionics
switches on.
6. Perform appropriate functional checks per Aerocomputers Airborne Systems UC-
5300/6000 Operating Instructions. Turn battery & avionics switches off.
IMU Sensor (if installed)
1. Turn battery switch off and pull out GPS MAP (5 amp) circuit breaker at panel.
2. Position IMU Sensor on G429-15 support assembly and install hardware. Verify
security.
3. Connect cables to IMU Sensor.
4. Install hardware securing G702-9 cover assembly to seat assembly.
5. Install F445-1 and F680-3 cover assemblies and hinge forward left seat aft.
6. Push in GPS MAP (5 amp) circuit breakers at panel. Turn battery & avionics
switches on.
7. Perform appropriate functional checks per Aerocomputers Airborne Systems UC-
5300 Operating Instructions. Turn battery & avionics switches off.

JUL 2020 Chapter 90 Police Version Page 90.25

90-250 G608 GPS Mapping System Installation (continued)
E. Antenna
Refer to § 6-80 for antenna locations & R66 Illustrated Parts Catalog (IPC) Chapter 6.

NOTE
Antenna installation depends on optional equipment installed.

Removal
1. Turn battery switch off and pull out GPS MAP (5 amp) circuit breaker at panel.
2. Remove hardware securing G796-1 duct assembly to cabin and remove duct.
3. Disconnect antenna cable from antenna. Remove screws securing antenna to
cabin and remove antenna.
Installation
1. Turn battery switch off and pull out GPS MAP (5 amp) circuit breaker at panel.
2. Position antenna on cabin and install hardware. Verify security. Connect
antenna cable.
3. Position G796-1 duct assembly on cabin and install hardware. Verify security.
4. Perform ground checks per Part D IMU Sensor steps 6 and 7.
F. Scheduled Maintenance and Inspections
On condition.
G. Special Maintenance and Inspections
Contact Aerocomputers Airborne Systems Technical Support for assistance.

90-260 G685 Aux Strobe Light Installation

Refer to § 33-11 for maintenance procedures.

Page 90.26 Chapter 90 Police Version JUL 2020

FIGURE 90-10 F081-1 SEARCHLIGHT INSTALLATION WIRING SCHEMATIC

JUL 2020 Chapter 90 Police Version Page 90.45

90-280 Wiring Schematics (continued)

FIGURE 90-11 F081-2 AND F081-3 SEARCHLIGHT INSTALLATION WIRING SCHEMATIC

Page 90.56 Chapter 90 Police Version JUL 2020

90-280 Wiring Schematics (continued)

FIGURE 90-17 C460-1 AND C460-2 AUDIO CONTROL

INSTALLATION WIRING SCHEMATIC

JUL 2020 Chapter 90 Police Version Page 90.57

90-280 Wiring Schematics (continued)

FIGURE 90-18 G608 GPS MAPPING AND MDT INSTALLATION WIRING SCHEMATIC

Page 90.58 Chapter 90 Police Version JUL 2020

CHAPTER 92

ENG VERSION
Section Title Page

92-00 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92.1

92-10 A826-18 Transceiver Installation (FM1) . . . . . . . . . . . . . . . . . . . . . . . . . . 92.3
92-20 C023-24 Tailcone Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92.4
92-30 C599-7 Airspeed Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92.4
92-40 C720-1 Support Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92.4
92-50 D097 HD Micro Camera Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92.4
92-51 D097-36 HD Micro Camera Installation (Windshield Bow) . . . . . . . . . . . . 92.5
92-52 D097-37 HD Micro Camera Installation (Aft-center Cabin) . . . . . . . . . . . 92.6
92-53 D097-38 HD Micro Camera Installation (Tail) . . . . . . . . . . . . . . . . . . . . . 92.8
92-54 D097 HD Micro Camera Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92.10
92-60 F003-19 Seat Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92.11
92-70 Landing Gear Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92.11
92-80 F060 Remote Transmit Switch Installations . . . . . . . . . . . . . . . . . . . . . . . 92.11
92-90 F075-1 EFIS Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92.12
92-100 F082-21 Fairing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92.12
92-110 F461-4 Cover Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92.12
92-120 G197-13 Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92.12
92-130 G425-1 Wall Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92.13
92-140 G445-2 Aux Circuit Breaker Panel Installation . . . . . . . . . . . . . . . . . . . . . . 92.13
92-150 G448 Aft Monitors Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92.14
92-151 G448-1 10-inch Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92.15
92-152 G448-1 Five-inch Left Hand Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . 92.16
92-153 G448-2 Five-inch Right Hand Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . 92.17
92-160 G449 Forward Monitors Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92.18
92-170 G454-1 Camera System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92.19
92-171 D050-14 Gimbal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92.19
92-172 E002-2 Laptop Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92.25
92-173 E003-7 Aux Box Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92.26
92-180 G456-1 Microwave System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 92.27
92-181 D558-5 Controller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92.27
92-182 ARC-CM-TX-RX-CR-01 Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92.29
92-183 CMTX7-LITE Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92.30
92-184 PA16-series Pod Antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92.31
92-185 GPS-1270FW Antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92.32

JUL 2020 Chapter 92 ENG Version Page 92.i

CHAPTER 92

ENG VERSION (Continued)

Section Title Page

92-190 Antenna Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92.33

92-191 G457-1 Antenna Installation (Transponder) . . . . . . . . . . . . . . . . . . . . . . 92.33
92-192 G457-2 Antenna Installation (TV Tuner) . . . . . . . . . . . . . . . . . . . . . . . . 92.34
92-193 G457-3 Antenna Installation (Scanner) . . . . . . . . . . . . . . . . . . . . . . . . . 92.35
92-200 G470-1 Aft Console Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92.36
92-210 G487-1 FM Transceivers Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92.36
92-220 G489-1 Scanner Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92.38
92-230 G490-1 Talent Light Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92.39
92-231 D553-1 (Forward Talent) Light Assembly . . . . . . . . . . . . . . . . . . . . . . . 92.39
92-232 ILED-MA (Aft Talent) Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92.40
92-240 G491 TV Receiver Provision Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 92.40
92-241 Distribution Amp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92.41
92-242 Digital TV Receiver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92.42
92-250 G492-1 Audio System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92.43
92-251 Forward Audio Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92.44
92-252 Aft Console Audio Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92.45
92-253 Digital Router . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92.46
92-260 G493-1 Video Components Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 92.47
92-270 G496-1 DVR Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92.48
92-280 Aux Electrical System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92.49
92-285 D301 Ballast Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92.49
92-290 Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92.51

Page 92.ii Chapter 92 ENG Version JUL 2020

CHAPTER 92

ENG VERSION

92-00 Description
The Electronic News Gathering (ENG) version of the R66 helicopter (R66 Turbine Newscopter)
is configured for a typical news crew consisting of a pilot (in standard, right front seat), an
onboard reporter in the left front seat, and a camera operator in the left aft seat.
The ENG version is a four-place helicopter. An equipment console is installed in lieu of the
center aft seat.
The camera operator uses a laptop controller to operate an HD video camera and zoom
lens mounted to a gyro-stabilized gimbal on the helicopter chin. Micro cameras are located
in the cabin for filming an onboard reporter, and another micro camera is mounted to the
horizontal stabilizer sometimes used for weather reporting or to display the aircraft in flight.
A seven-inch monitor and a Geneva digital audio controller are located on each side of the
instrument console. A ten-inch monitor is mounted on an arm assembly in front of the left
aft passenger and controls are located in the equipment console. Each monitor allows for
independent monitoring and transmitting of video from cameras.
R66 ENG is equipped with a microwave system which provides live broadcasting capability.
Other features include a video recorder, TV tuners for monitoring local television broadcasts,
and radios for monitoring AM/FM radio broadcasts and for talking with ground personnel.
ENG equipment has a dedicated circuit breaker panel with a second master switch. Some
ENG equipment is 14-volt equipment (R66 electrical system is 28-volt) requiring a separate
14-volt sub-bus powered by a voltage converter.
Flight with gimbal camera removed is permissible with D050-13 cover assembly installed.
Refer to § 92-171 Part F for maintenance procedures.
Flight with pod antenna removed is permissible with mounting brackets removed and cables
stowed. Refer to § 92-184 Part E for maintenance procedures.

JUL 2020 Chapter 92 ENG Version Page 92.1

FIGURE 92-1 ENG VERSION

Page 92.2 Chapter 92 ENG Version JUL 2020

92-10 A826-18 Transceiver Installation (FM1)
A. Description
The A826-18 (Kenwood TK-7180 series or TK-8180 series) FM transceiver is installed
in the avionics console and includes an antenna, associated wiring, and mounting
hardware. The transceivers are used by the pilot and/or crew to communicate with
ground-based media personnel.
B. Schematic
Refer to Figure 92-3 for A826-18 transceiver installation wiring diagram.
C. Removal
1. Refer to Figure 92-1. Turn battery & avionics switches off and pull out FM1 (10
amp) circuit breaker at panel.
2. Loosen radio key securing A824-18 transceiver to upper console radio tray.
3. Remove transceiver from tray. Disconnect G459 harness assembly from back of
transceiver and remove transceiver.
D. Installation
1. Refer to Figure 92-1. Turn battery & avionics switches off and pull out FM1 (10
amp) circuit breaker at panel.
2. Connect G459 harness assembly to A824-18 transceiver and verify security. Install
transceiver in upper console radio tray.
3. Tighten radio key securing transceiver to tray. Verify equipment security.
4. Push in FM1 (10 amp) circuit breaker at panel. Turn battery & avionics switches on.
5. Perform appropriate functional checks per Kenwood TK-7180/TK-8180 FM
Transceiver Instruction Manual. Turn battery & avionics switches off.
E. Scheduled Inspections
Every 100-hour or annual inspection, inspect A824-18 transceiver for proper installation
(refer to R66 Illustrated Parts Catalog Chapter 92) & proper operation per Part D steps
4 and 5.
F. Special Inspections
1. Refer to Figure 92-1. Turn battery & avionics switches off. Open circuit breaker
panel.
2. As required, remove A824-18 transceiver per Part C. Inspect condition of and
verify no obvious damage to transceiver, 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. Install transceiver per Part D if removed.

JUL 2020 Chapter 92 ENG Version Page 92.3

92-20 C023-24 Tailcone Assembly
A. Description
Refer to Figure 92-1. The C023-24 tailcone assembly has wiring provisions for the
ENG version’s D097-38 HD micro camera (tail).
B. Maintenance Procedures
Refer to § 53-40 for tailcone assembly maintenance procedures.
92-30 C599-7 Airspeed Indicator
A. Description
Refer to Figure 92-1. C599-7 (120 knot VNE, KM/H) airspeed indicator replaces C599‑2
(140 knot VNE, KM/H) airspeed indicator.
B. Maintenance Procedures
Refer to § 95-22 for airspeed indicator maintenance procedures.

92-40 C720-1 Support Installation

A. Removal
Refer to Figure 92-1. Remove hardware securing C719-1 support to C242 skid tube
and remove support.
B. Installation
Install hardware securing C719-1 support to C242 skid tube, special torque bolt per §
20-33, and torque stripe per Figure 5-1.

92-50 HD Micro Camera Installations

A. Description
The micro camera system consists of three small cameras and their control units. The
micro cameras are mounted at the tip of the horizontal stabilizer, on the windshield
bow, and in the center of the cabin. The control units are located in the rear equipment
console. The horizontal stabilizer camera is enclosed in a weatherproof case.
B. Schematic
Refer to Figure 92-4 for D097 HD micro camera installation wiring diagram.

Page 92.4 Chapter 92 ENG Version JUL 2020

92-51 D097-36 HD Micro Camera Installation (Windshield Bow)
A. Removal
1. Refer to Figure 92-1. Turn battery & news equipment switches off, and pull out
MICRO CAMS (2 amp) circuit breaker at panel.
2. Disconnect CV505/345-10FTCBLE cable and G459-2798 wire from CV345-CS/
CSB camera at connectors.
3. Remove D368-2 clamps securing wiring to windshield bow and remove camera.
4. As required, remove screws securing D368-8 mount and D368-10 plate to camera
and remove mount and plate.
B. Installation
1. Refer to Figure 92-1. Turn battery & news equipment switches off, and pull out
MICRO CAMS (2 amp) circuit breaker at panel.
2. If removed, install screws securing D368-10 plate and D368-8 mount to CV345-
CS/CSB camera. Verify security.
3. Install D368-2 clamps every six inches (5 maximum) securing wiring to windshield
bow. Verify security.
4. Connect CV505/345-10FTCBLE cable and G459-2798 wire to camera at
connectors. Verify security.
5. Push in MICRO CAMS circuit breaker (2 amp) at panel. Turn battery & news
equipment switches on.
6. Perform appropriate functional checks per Marshall Electronics CV345 Operation
Manual. Turn battery & news equipment switches off.
C. Scheduled Inspections
Every 100-hour or annual inspection, inspect CV345-CS/CSB micro camera for proper
installation (refer to R66 Illustrated Parts Catalog Chapter 92) & proper operation per
Part B steps 5 and 6.
D. Special Inspections
1. Refer to Figure 92-1. Turn battery & news equipment switches off. Open news
equipment circuit breaker panel.
2. As required, remove CV345-CS/CSB micro camera per Part A. Inspect condition
of and verify no obvious damage to micro camera, mount, 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. Install micro camera per Part B if removed.

JUL 2020 Chapter 92 ENG Version Page 92.5

92-52 D097-37 HD Micro Camera Installation (Aft-center Cabin)
A. Removal
1. Remove ILED-MA (aft talent) light per § 92-232.
2. Refer to Figure 92-1. Turn battery & news equipment switches off, and pull out
MICRO CAMS (2 amp) circuit breaker at panel.
3. Disconnect CV505/345-10FTCBLE cable and G459-756 wire from CV345-CS/
CSB camera at connectors.
4. Unscrew camera from RAM-B-366-201U arm assembly and remove camera.
B. Installation
1. Refer to Figure 92-1. Turn battery & news equipment switches off, and pull out
MICRO CAMS (2 amp) circuit breaker at panel.
2. Screw CV345-CS/CSB camera onto RAM-B-366-201U arm assembly Verify
security.
3. Connect CV505/345-10FTCBLE cable and G459-756 wire to camera at
connectors. Verify security.
4. Install ILED-MA (aft talent) light per § 92-232.
5. Push in MICRO CAMS circuit breaker (2 amp) at panel. Turn battery & news
equipment switches on.
6. Perform appropriate functional checks per Marshall Electronics CV345 Operation
Manual. Turn battery & news equipment switches off.
C. Special Inspections
1. Refer to Figure 92-1. Turn battery & news equipment switches off. Open news
equipment circuit breaker panel.
2. As required, remove CV345-CS/CSB micro camera per Part A. Inspect condition of
and verify no obvious damage to micro camera, RAM-B-366-201U arm assembly,
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. Install micro camera per Part B if removed.

Page 92.6 Chapter 92 ENG Version JUL 2020

Intentionally Blank

JUL 2020 Chapter 92 ENG Version Page 92.7

FIGURE 92-2 ENG VERSION

92-53 D097-38 HD Micro Camera Installation (Tail)

A. Removal
1. Refer to Figure 92-1. Turn battery & news equipment switches off, and pull out
MICRO CAMS (2 amp) circuit breaker at panel.

NOTE

Use caution not to overstretch or sharply-bend HD camera’s

cable assembly; cable is soft and susceptible to damage.

2. Remove grommet from inboard side of horizontal stabilizer at tail gearbox. Pull
C023 wires through hole in stabilizer to access connectors; disconnect CV200-M/
MB camera cable from C023 wires at connectors.
3. Supporting camera, remove screws securing D368-11 clamp to stabilizer and remove
camera and clamp. Carefully remove grommet from outboard side of stabilizer and
pull camera cable through hole in stabilizer. Remove grommet and clamp.
B. Installation
1. Refer to Figure 92-1. Turn battery & news equipment switches off, and pull out
MICRO CAMS (2 amp) circuit breaker at panel.

NOTE

Use caution not to overstretch or sharply-bend HD camera’s

cable assembly; cable is soft and susceptible to damage.

Page 92.8 Chapter 92 ENG Version JUL 2020

92-53 D097-38 HD Micro Camera Installation (Tail; continued)
B. Installation (continued)
2. Install grommet on CV200-M/MB camera cable. Tape camera cable connector to
4.5-ft length of lockwire; route lockwire thru horizontal stabilizer toward gearbox
and thru opposite hole. Pull camera cable thru stabilizer, remove taped lockwire,
and connect C023 wires to cable at connectors. Verify security.
3. Refer to Figure 92-2. Position D368-11 clamp on camera (clamp slot on bottom)
with camera protruding 1.5 inches from clamp as shown. Install screws securing
clamp and camera to horizontal stabilizer. Verify security.
4. Secure inboard and outboard horizontal stabilizer grommets.
5. Push in MICRO CAMS (2 amp) circuit breaker at panel. Turn battery & news
equipment switches on.
6. Perform appropriate functional checks per Marshall Electronics CV200-M/MB
Operation Manual. Turn battery & news equipment switches off.
C. Scheduled Inspections
Every 100-hour or annual inspection, inspect CV200-M/MB micro camera for proper
installation (refer to R66 Illustrated Parts Catalog Chapter 92) & proper operation per
Part B steps 5 and 6.
D. Special Inspections
1. Refer to Figure 92-1. Turn battery & news equipment switches off. Open circuit
breaker panel.
2. As required, remove CV200-M/MB micro camera per Part A. Inspect condition
of and verify no obvious damage to micro camera, horizontal stabilizer tip and
doubler, 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. Install micro camera per Part B if removed.

JUL 2020 Chapter 92 ENG Version Page 92.9

92-54 D097 HD Micro Camera Controller
A. Removal
1. Refer to Figure 92-1. Turn battery & news equipment switches off, and pull out
MICRO CAMS (2 amp) circuit breaker at panel.
2. Remove screws securing G472 face to G471 panels and remove face.
3. Remove screws securing D344 support assembly to G472 face.
4. Cut and discard ty-raps as required and disconnect micro camera cable(s) from
CV505/345-10FTCBLE and/or CV200-M/MB cable controller(s) at connectors.
Detach controller(s) from support assembly (controllers are taped to support).
B. Installation
1. Refer to Figure 92-1. Turn battery & news equipment switches off, and pull out
MICRO CAMS (2 amp) circuit breaker at panel.
2. Connect micro camera cable(s) to CV505/345-10FTCBLE and/or CV200-M/MB
cable controller(s) at connectors. Verify security. Install ty-raps as required.
Cinch ty-raps until snug without overtightening, and trim tips flush with heads.
3. Position controller(s) on D344 support assembly. Install screws securing support
to G472 face. Verify security.
4. Install screws securing face to G471 panels. Verify security.
5. Push in MICRO CAMS circuit breaker (2 amp) at panel. Turn battery & news
equipment switches on.
6. Perform appropriate functional checks per Marshall Electronics CV200-MB/M or
CV345-CS/CSB Operation Manual. Turn battery & news equipment switches off.
C. Scheduled Inspections
Every 100-hour or annual inspection, inspect CV505/345-10FTCBLE and/or
CV200-M/MB cable controllers for proper installation (refer to R66 Illustrated Parts
Catalog Chapter 92) & proper operation per Part B steps 5 and 6.
D. Special Inspections
1. Refer to Figure 92-1. Turn battery & news equipment switches off. Open circuit
breaker panel.
2. As required, remove CV505/345-10FTCBLE and/or CV200-M/MB cable
controller(s) per Part A. Inspect condition of and verify no obvious damage to
cable controllers, 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. Install cable controller(s) per Part B if removed.

Page 92.10 Chapter 92 ENG Version JUL 2020

92-60 F003-19 Seat Removal
Refer to Figure 92-1. ENG version helicopters have no aft center seat installed. The following
equipment is omitted: F628-4 connector assembly, center F628-6 buckle assembly, F931-
1 seat assembly, A752-3 angle, & (2) NAS1352-04-8 screw. Associate hardware is
replaced or omitted; refer to R66 Illustrated Parts Catalog for installation information.

92-70 Landing Gear Assembly

A. Description
Refer to Figure 92-1. The F014-5 extended landing gear raises the forward cross tube
approximately 2 inches higher off the ground, providing additional ground clearance
for optional equipment installations that project below the fuselage.
For ground handling, a second set of wheel installation supports is provided forward
on the landing gear skids. For ground handling using MT950 towcart, install wheels
at forward supports and use cart at aft cross tube as indicated on cart instructions
(online at www.robinsonheli.com). For ground handling without towcart, wheels may
be installed at all four support locations.
B. Maintenance Procedures
Refer to Chapter 32 for landing gear assembly maintenance procedures (identical to
standard gear maintenance procedures unless otherwise specified). Forward wheel
support maintenance procedures are located in § 92-40.

92-80 F060 Remote Transmit Switch Installations

A. Description
Refer to Figure 92-1. A handheld remote switch is installed at the co-pilot seat,
allowing the occupant to transmit on the radio selected without touching the flight
controls, or when the co-pilot flight controls are removed.
The switch plugs into a socket on the base of the seat.
B. Schematic
Refer to Figure 98-24 for F060 intercom system installation wiring diagram.

JUL 2020 Chapter 92 ENG Version Page 92.11

92-90 F075-1 EFIS Installation
A. Description
Refer to Figure 92-1. The R66 ENG version is equipped with the Garmin G500H
Electronic Flight Instrument System (EFIS).
B. Maintenance Procedures
Refer to §§ 95-70 & 97-10 for Garmin G500H EFIS maintenance procedures.

92-100 F082-21 Fairing Installation

A. Description
Refer to Figure 92-1. Extended landing gear F082-21 strut fairings are longer than but
are otherwise identical to standard strut fairings. F082-21 fairing installation replaces
F082-1 fairing installation.
B. Maintenance Procedures
Refer to § 32-40 fairing assemblies for maintenance procedures.

92-110 F461-4 Cover Assembly

Refer to Figure 92-1. Refer to R66 Illustrated Parts Catalog Chapter 6 for access and
inspection panel locations. F461-4 cover assembly replaces F461-1 cover assembly.

92-120 G197-13 Window

A. Description
Refer to Figure 92-1. The G197-13 window illuminates the ENG version instrument
console for night lighting. G197-13 window replaces G197-9 window.
B. Maintenance Procedures
Refer to § 33-21 for panel light maintenance procedures. Adjust window laterally as
required to ensure even light spread on console.

Page 92.12 Chapter 92 ENG Version JUL 2020

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

92-140 G445-2 Aux Circuit Breaker Panel Installation

A. Description
ENG equipment has a dedicated circuit breaker panel with a second news master
switch, allowing the pilot to easily remove power for the majority of ENG equipment
simultaneously.
B. Schematic
Refer to Figure 92-5 for G445-2 aux circuit breaker panel installation wiring diagram.
C. Access
1. Turn battery & news equipment switches off.
2. Remove screws securing G445-2 aux circuit breaker panel to ledge. Carefully lift
panel for access.
3. Verify circuit breaker security and inspect wiring condition. Position G445-2 aux
circuit breaker panel on ledge and install screws. Verify security.
D. Scheduled Inspections
Every 100-hour or annual inspection, access G445-2 aux circuit breaker panel interior
per Part C and inspect panel per standard circuit breaker panel inspection in § 5-45.
E. Special Inspections
Access G445-2 aux circuit breaker panel interior per Part C and inspect panel per
standard circuit breaker panel inspection in § 5-45.

JUL 2020 Chapter 92 ENG Version Page 92.13

92-150 G448 Aft Monitors Installation
A. Description
The aft monitor installation consists of one large main LCD monitor mounted to the
cross tube between the front seatbacks and either one or two smaller LCD monitors
mounted near the longitudinal tube running above the rear center equipment console.
The large, main LCD monitor is mounted on a pivoting arm. The pivoting arm allows
the monitor to be rotated between the stowed position inboard and operating position
directly in front of the camera operator. A spring-loaded pin beneath the pivot locks
the monitor in the stowed position. Pulling the pin releases the monitor for use. The
Velcro tether attached to the monitor should be wrapped around the seat back cross
tube to hold the monitor in the operating position. Detaching the tether will cause
the monitor to return to the stowed position. Verify monitor locks in position after
detaching tether.

NOTE
Monitor must be stowed below 500 ft AGL. If not stowed, the
monitor is a potential source of head injury in an accident.

The main rear LCD monitor may be switched between three input signals. Input A
displays nose camera, micro camera, or video recorder images as selected by the
video switcher. Input B bypasses the video switcher and displays nose-camera images
directly. The accessory input bypasses the video switcher and displays annotated
nose-camera images.
One or two smaller auxiliary monitors are installed near the longitudinal tube above
the rear equipment console and display TV broadcasts as selected by the TV tuner(s).
B. Schematic
Refer to Figure 92-6 for G448 aft monitors installation wiring diagram.

Page 92.14 Chapter 92 ENG Version JUL 2020

92-151 G448-1 10-inch Monitor
A. Removal
1. Refer to Figure 92-1. Turn battery & news equipment switches off and pull out
10” MON (2 amp) circuit breaker at panel.
2. Disconnect G459 harness assembly from HD10CINEROB monitor at connectors.
Supporting monitor, remove screws securing monitor to G477-1 arm assembly
and remove monitor.
B. Installation
1. Refer to Figure 92-1. Turn battery & news equipment switches off and pull out
10” MON (2 amp) circuit breaker at panel.
2. Install screws securing HD10CINEROB monitor to G477-1 arm assembly. Verify
security.
3. Connect G459 harness assembly to monitor; verify security.
4. Push in 10” MON (2 amp) circuit breaker at panel. Turn battery & news equipment
switches on.
5. Perform appropriate functional checks per Transvideo operator’s guide. Turn
battery & news equipment switches off.
C. Scheduled Inspections
Every 100-hour or annual inspection, inspect HD10CINEROB monitor for proper
installation (refer to R66 Illustrated Parts Catalog Chapter 92) & proper operation per
Part B steps 4 and 5.
D. Special Inspections
1. Refer to Figure 92-1. Turn battery & news equipment switches off. Open circuit
breaker panel.
2. As required, remove CHD10CINEROB monitor per Part A. Inspect condition of
and verify no obvious damage to monitor, 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. Install monitor per Part B if removed.

JUL 2020 Chapter 92 ENG Version Page 92.15

92-152 G448-1 Five-inch Left Hand Monitor
A. Removal
1. Refer to Figure 92-1. Turn battery & news equipment switches off and pull out
5” MONS (2 amp) circuit breaker at panel.
2. Disconnect G459 harness assembly from VFM-056W monitor. Supporting
monitor, remove hardware securing monitor to G474-5 bracket and remove
monitor.
B. Installation
1. Refer to Figure 92-1. Turn battery & news equipment switches off and pull out
5” MONS (2 amp) circuit breaker at panel.
2. Install hardware securing VFM-056W monitor to G474-5 bracket. Verify security.
3. Connect G459 harness assembly to monitor; verify security.
4. Push in 5” MONS (2 amp) circuit breaker at panel. Turn battery & news equipment
switches on.
5. Perform appropriate functional checks per TVLogic VRM-056W Operation Manual.
Turn battery & news equipment switches off.
C. Scheduled Inspections
Every 100-hour or annual inspection, inspect VFM-056W monitor for proper
installation (refer to R66 Illustrated Parts Catalog Chapter 92) & proper operation per
Part B steps 4 and 5.
D. Special Inspections
1. Refer to Figure 92-1. Turn battery & news equipment switches off. Open circuit
breaker panel.
2. As required, remove VFM-056W monitor per Part A. Inspect condition of and
verify no obvious damage to monitor, G474-5 bracket, 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. Install monitor per Part B if removed.

Page 92.16 Chapter 92 ENG Version JUL 2020

92-153 G448-2 Five-inch Right Hand Monitor
A. Removal
1. Refer to Figure 92-1. Turn battery & news equipment switches off and pull out
5” MONS (2 amp) circuit breaker at panel.
2. Disconnect G459 harness assembly from VFM-056W monitor. Supporting
monitor, loosen B630-14 mount handle to release mount ball and remove monitor
with ball attached. Unscrew and remove ball as required.
B. Installation
1. Refer to Figure 92-1. Turn battery & news equipment switches off and pull out
5” MONS (2 amp) circuit breaker at panel.
2. Screw B630-14 mount ball in bottom of monitor if removed. Position VFM-056W
monitor and attached ball in mount and tighten handle. Verify security.
3. Connect G459 harness assembly to monitor; verify security.
4. Push in 5” MONS (2 amp) circuit breaker at panel. Turn battery & news equipment
switches on.
5. Perform appropriate functional checks per TVLogic VRM-056W Operation Manual.
Turn battery & news equipment switches off.
C. Scheduled Inspections
Every 100-hour or annual inspection, inspect VFM-056W monitor for proper
installation (refer to R66 Illustrated Parts Catalog Chapter 92) & proper operation per
Part B steps 4 and 5.
D. Special Inspections
1. Refer to Figure 92-1. Turn battery & news equipment switches off. Open circuit
breaker panel.
2. As required, remove VFM-056W monitor per Part A. Inspect condition of and
verify no obvious damage to monitor, B630-14 mount, 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. Install monitor per Part B if removed.

JUL 2020 Chapter 92 ENG Version Page 92.17

92-160 G449 Forward Monitors Installation
A. Description
The forward monitor installation consists of two small LCD monitors mounted to the
left and right of the instrument console. The right monitor displays nose camera,
micro camera, or video tape recorder images as selected by the video switcher. The
left monitor displays TV broadcasts as selected by the TV tuner.
B. Schematic
Refer to Figure 92-7 for G449 forward monitors installation wiring diagram.
C. Removal
1. Refer to Figure 92-1. Turn battery & news equipment switches off and pull out 7”
MONS (2 amp) circuit breaker at panel.
2. Disconnect G459 harness assembly from BVB07 monitor(s). Supporting monitor(s),
remove screws securing monitor(s) to G474 bracket assembly and remove monitor(s).
D. Installation
1. Refer to Figure 92-1. Turn battery & news equipment switches off and pull out 7”
MON (2 amp) circuit breaker at panel.
2. Install screws securing BVB07 monitor(s) to G474 bracket assembly. Verify
security.
3. Connect G459 harness assembly to monitor; verify security.
4. Push in 7” MON (2 amp) circuit breaker at panel. Turn battery & news equipment
switches on.
5. Perform appropriate functional checks per Boland Communications BVB07 User
Manual. Turn battery & news equipment switches off.
E. Scheduled Inspections
Every 100-hour or annual inspection, inspect BVB07 monitor(s) for proper installation
(refer to R66 Illustrated Parts Catalog Chapter 92) & proper operation per Part D steps
4 and 5.
F. Special Inspections
1. Refer to Figure 92-1. Turn battery & news equipment switches off. Open circuit
breaker panel.
2. As required, remove BVB07 monitor(s) per Part C. Inspect condition of and verify
no obvious damage to monitor(s), G474 bracket assemblies, 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. Install monitor(s) per Part D if removed.

Page 92.18 Chapter 92 ENG Version JUL 2020

92-170 G454-1 Camera System Installation
A. Description
The nose-mounted camera system consists of a gyro-stabilized, gimbal-mounted video
camera in the chin and a power junction box in the main baggage compartment. A
fairing between the camera ball and chin minimizes the aerodynamic effects of the
camera. The camera is operated from the left rear seat via a laptop controller.
When not in use, the laptop controller may be stowed and secured in the recess at the
aft end of the rear equipment console.
Flight with gimbal assembly removed is permissible with D050-13 cover assembly
installed. Refer to § 92-171 Part F for maintenance procedures.
B. Schematic
Refer to Figure 92-8 for G454-1 camera system installation wiring diagram.

92-171 D050-14 Gimbal Installation

A. Removal
1. Refer to Figure 92-1. Turn battery & news equipment switches off and pull out
GIMBAL CAMERA (10 amp) circuit breaker at panel.
2. Remove screws securing G427 fairings to chin and remove fairings.
3. Disconnect E195-2 and E204-6 cable assemblies from E801-1 gimbal assembly.
4. Have a second person support gimbal assembly. Remove screws securing D374-
3 spacer and gimbal assembly to D385-4 mount assembly and remove spacer
and gimbal.
5. Configure helicopter for flight with gimbal assembly removed per Part F as required.
B. Installation
1. Refer to Figure 92-1. Turn battery & news equipment switches off and pull out
GIMBAL CAMERA (10 amp) circuit breaker at panel.
2. Configure helicopter for flight with gimbal assembly installed per Part F as required.
3. Have a second person support E801-1 gimbal assembly. Install hardware securing
D374-3 spacer and gimbal assembly to D385-4 mount assembly. Verify security.
4. Connect E195-2 and E204-6 cable assemblies to gimbal assembly. Verify security.
5. Install screws securing G427 fairings to chin. Verify security.
6. Push in GIMBAL CAMERA (10 amp) circuit breaker at panel. Turn battery & news
equipment switches on.
7. Perform appropriate function checks per Part C.

JUL 2020 Chapter 92 ENG Version Page 92.19

92-171 D050-14 Gimbal Installation (continued)
C. Function Checks
1. Power switch: (Locking Toggle)
‘Off’ LED is illuminated when system power is off. Moving the locking switch up
powers up the camera, laptop controller, and gimbal.
Wait 60 seconds after power is switched to on. The wait period ensures that gimbal
finishes its initialization sequence. Keep system on for the remainder of the function test.
2. Pan/Tilt Mode Switch: (Momentary Toggle)
Changes modes by moving switch in the direction of the desired mode. Mode
selected is illuminated.
A mode: Inertial Mode.
Gimbal Pan and Tilt are controlled via joystick X and Y motions.
B mode: Not used.
C mode: Position Mode.
Gimbal position is referenced to user specified positions via Pan/Tilt knobs.
3. Roll Mode Switch: (Momentary Toggle)
Changes modes by moving switch in direction of desired mode. Mode selected
is illuminated.
A mode: Inertial Mode.
Gimbal Roll is controlled via joystick rotational motions about Z axis and ROLL
TRIM knob.
B mode: Position Mode.
Gimbal position is controlled via ROLL POSITION knob.
4. Panel Lights Dimmer Knob
Adjust the illumination level of the panel.
5. Roll Position Knob:
Controls Roll position while ROLL Mode is in “B”.
Inactive when ROLL Mode is in “A”.
6. Tilt Position Knob (Mode C) / Fine AZ Drift (Mode A):
Controls Tilt Position while PAN/TILT Mode is in “C”.
Provides fine pan drift control when PAN/TILT Mode is in “A”.
7. Pan Position Knob
Controls Pan Position while PAN/TILT Mode is in “C”.
Inactive when PAN/TILT Mode is in “A”.
8. Roll Trim Knob:
Controls Roll Position while Roll Mode is in “A”.
9. Tilt Drift Knob:
Controls Tilt Drift while PAN/TILT Mode is in “A”.
Inactive when PAN/TILT Mode is in “C”.

Page 92.20 Chapter 92 ENG Version JUL 2020

92-171 D050-14 Gimbal Installation (continued)
C. Function Checks (continued)
10. Coarse Pan (AZ) Drift Knob:
Controls Pan Drift while PAN/TILT Mode is in “A”.
Inactive when PAN/TILT Mode is in “C”.
11. OPT EXT Lens Switch: (Two-position toggle)
Controls position of lens extender. Position selected is illuminated.
2x: Lens extender inserted
1x: Lens extender extracted
12. Roll Polarity Switch:
Controls polarity of Roll joystick and Roll Trim Command. Position selected is
illuminated. Bottom two positions are not used.
“+”: Joystick moves CW; Roll Axis moves CCW.
“—“: Joystick moves CW; Roll Axis moves CW.
13. DIG EXT Switch: (Two-position toggle)
Controls the digital zoom function. (Feature not active in some cameras)
2x: Activate digital zoom
1x: Deactivate digital zoom
14. Zoom Rate Knob:
Controls magnitude of the zoom rocker switch.
CCW: Decrease zoom rocker response
CW: Increase zoom rocker response
15. Joystick Polarity Knob: (Four position)
Controls polarity of joystick command. Position selected is illuminated.
++: Positive Tilt / Positive Pan
+—: Positive Tilt / Negative Pan
—+: Negative Tilt / Positive Pan
——: Negative Tilt / Negative Pan
16. Joystick Rate Mode Switch: (Two-position toggle)
Controls Joystick Rate Mode. Mode selected is illuminated.
Man: Manual Mode – Rate is controlled using Joystick Rate knob only
Auto: Automatic Mode – Rate is proportionally scaled to field of view

JUL 2020 Chapter 92 ENG Version Page 92.21

92-171 D050-14 Gimbal Installation (continued)
C. Function Checks (continued)
17. Joystick Rate Knob:
Controls Joystick Rate Scaling based on Joystick Rate Mode Switch.
Manual Mode:
CCW: Decrease Joystick Rate
CW: Increase Joystick Rate
Automatic Mode:
Zoom in picture to maximum (narrowest field of view) and set desired joystick
rate using Joystick Rate Knob. As the zoom is reduced (increased field of
view), the joystick rate will be increased automatically to compensate for the
increased field of view.
18. Focus Knob:
Controls camera focus (CW – Infinity, CCW – Near).
19. Focus Helper Button: (Momentary Toggle)
Activates and Deactivates Transvideo Monitor “Focus Helper” function in the
monitor. Only available in some models. Corresponding LED light on switch test
box (WA5) should light up when activated.
20. Zoom Rocker Switch:
Controls Camera Zoom (T – Zoom in, W – Zoom Wide).
21. Ikegami RM-11 Camera Controller:
Test the following items:
Mode:
BARS: Display color bar on screen.
CAL: Display gray scale.
Gain:
up toggle (image appears brighter in each incremental toggle)
down toggle (image appears dimmer in each decrement toggle)
AWB and ABB:
On screen display will indicate activation of the selected adjustment.
Camera shutter:
On screen display will indicate selected value.
Iris:
CW open (brighter). CCW close (dimmer).
22. Joystick Snap Zoom Button:
Allows the operator to immediately zoom in picture to maximum.
Depressed (Fully zoomed in). Not depressed (Zoom rocker setting).
23. Lower Joystick Button:
Not used.

Page 92.22 Chapter 92 ENG Version JUL 2020

92-171 D050-14 Gimbal Installation (continued)
C. Function Checks (continued)
24. Joystick:
When Pan / Tilt mode is in “A”, X and Y axes Joystick movements control Pan
and Tilt Gimbal movements respectively. Inactive when Pan / Tilt mode is in “C”.
When Roll Mode is in “A”, Joystick rotation in Z axis controls Roll position.
Inactive when ROLL Mode is in “B”.
25. Camera Menu Button: (Momentary and Rotary)
Click the Button to access camera menu. Rotate button to navigate through
items in the menu. Click button to confirm selection.
26. Neutral Density (ND) Filter Position Knob: (Four positions)
Controls which ND filter is used.
1: Clear
2: 1/8 ND (dark)
3: 1/16 ND (darker)
4: 1/64 ND (darkest)
27. Electronic Color Correction (ECC) Filter: (Two-position toggle)
Toggles between two ECC filters.
Top: 5600K (Warm orange shade color)
Bottom: 3200K (Cold blue shade color)
28. Remote Video Switcher Toggle: (Momentary toggle)
Switches output of main video switcher between Gimbal camera and Micro camera.
Corresponding LED light on switch test box (WA5) should light up when activated.
29. VTR Start / Stop Toggle: (Two-position toggle)
Toggle to start and stop recording of the video recorder. Operates on selected
video recorders only. Corresponding LED light on switch test box (WA5) should
light up when activated.
30. Transmit (XMIT) Switch: (Momentary and Latched toggle)
Toggle switch outward and hold switch to transmit via selected radio. Toggle
switch inward to continuously transmit via selected radio. Corresponding LED
light on switch test box (WA5) should light up when activated.
31. Intercom (INTCM) Switch: (Momentary and Latched toggle)
Toggle switch outward and hold switch to communicate via intercom. Toggle
switch inward to continuously communicate via intercom. Corresponding LED
light on switch test box (WA5) should light up when activated.

JUL 2020 Chapter 92 ENG Version Page 92.23

92-171 D050-14 Gimbal Installation (continued)
D. Scheduled Inspections
Every 100-hour or annual inspection, inspect E801-1 gimbal assembly for proper
installation (refer to R66 Illustrated Parts Catalog Chapter 92) & proper operation per
Part B steps 5 and 6.
E. Special Inspections
1. Refer to Figure 92-1. Turn battery & news equipment switches off. Open circuit
breaker panel.
2. As required, remove E801-1 gimbal assembly per Part A. Inspect condition of and
verify no obvious damage to gimbal, G427 fairings, 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. Install gimbal per Part B if removed.
F. Configurations for Flight
1. Configuration for Flight with Gimbal Camera Removed
a. Remove E801-1 gimbal assembly per Part A.
b. Install clean, dry plastic bags individually over exposed E195-2 and E204-6
cable assembly connectors to prevent moisture or debris from contacting
connector sockets/pins; secure with ty-raps. Stow and secure cables with
ty-raps to surrounding structure. Verify security.
c. Verify cable assembly clearance to tail rotor pedal controls thru full range of travel.
d. Install screws securing D050-13 cover to chin. Verify security.
e. Revise Weight and Balance Record in R66 Pilot’s Operating Handbook (POH)
Section 6 to incorporate the following data:
Subtract:
Item Weight Long. Arm Long. Moment Lat. Arm Lat. Moment
ENG Gimbal 56.4 lb 6.2 in. 349.7 in.-lb 0 in. 0 in.-lb

2. Configuration for Flight with Gimbal Camera Installed

a. Remove screws securing D050-13 cover to chin and remove cover.
b. Remove and discard ty-raps and plastic bags securing E195-2 and E204-6
cable assemblies to surrounding structure.
c. Install E801-1 gimbal assembly per Part B.
d. Revise Weight and Balance Record in R66 Pilot’s Operating Handbook (POH)
Section 6 to incorporate the following data:
Add:
Item Weight Long. Arm Long. Moment Lat. Arm Lat. Moment
ENG Gimbal 56.4 lb 6.2 in. 349.7 in.-lb 0 in. 0 in.-lb

Page 92.24 Chapter 92 ENG Version JUL 2020

92-172 E002-2 Laptop Assembly
A. Removal
1. Refer to Figure 92-1. Turn battery & news equipment switches off and pull out
GIMBAL CAMERA (10 amp) circuit breaker at panel.
2. Disconnect G459 harness assembly from E002-2 laptop assembly and remove
laptop.
B. Installation
1. Refer to Figure 92-1. Turn battery & news equipment switches off and pull out
GIMBAL CAMERA (10 amp) circuit breaker at panel.
2. Connect G459 harness assembly to E002-2 laptop assembly.
3. Push in GIMBAL CAMERA (10 amp) circuit breaker at panel. Turn battery & news
equipment switches on.
4. Perform appropriate function checks per § 92-171 Part C.
C. Scheduled Inspections
Every 100-hour or annual inspection, inspect E002-2 laptop assembly for proper
installation (refer to R66 Illustrated Parts Catalog Chapter 92) & proper operation per
Part B steps 3 and 4.
D. Special Inspections
1. Refer to Figure 92-1. Turn battery & news equipment switches off. Open circuit
breaker panel.
2. As required, remove E002-2 laptop assembly per Part A. Inspect condition of
and verify no obvious damage to laptop, 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. Install laptop per Part B if removed.

JUL 2020 Chapter 92 ENG Version Page 92.25

92-173 E003-7 Aux Box Assembly
A. Removal
1. Refer to Figure 92-1. Turn battery & news equipment switches off and pull out
GIMBAL CAMERA (10 amp) circuit breaker at panel.
2. Remove baggage compartment wall per § 92-130.
3. Disconnect G459 harness assembly and E195-2, E199-3, and E204-6 cable
assemblies from E003-7 auxiliary box assembly.
4. Remove screws securing D429 brackets to D429-1 support assemblies and
remove aux box.
5. As required, remove screws securing D429 brackets to aux box and remove
brackets.
B. Installation
1. Refer to Figure 92-1. Turn battery & news equipment switches off and pull out
GIMBAL CAMERA (10 amp) circuit breaker at panel.
2. As required, install screws securing D429 brackets to E003-7 aux box assembly.
Verify security.
3. Install screws securing brackets to D429-1 support assemblies. Verify security.
4. Connect G459 harness assembly and E195-2, E199-3, and E204-6 cable
assemblies to aux box. Verify security.
5. Install baggage compartment wall per § 92-130.
6. Push in GIMBAL CAMERA (10 amp) circuit breaker at panel. Turn battery & news
equipment switches on.
7. Perform appropriate function checks per § 92-171 Part C.
C. Scheduled Inspections
Every 100-hour or annual inspection, inspect E003-7 aux box assembly for proper
installation (refer to R66 Illustrated Parts Catalog Chapter 92) & proper operation per
Part B steps 6 and 7.
D. Special Inspections
1. Refer to Figure 92-1. Turn battery & news equipment switches off. Open circuit
breaker panel.
2. As required, remove E003-7 aux box assembly per Part A. Inspect condition of
and verify no obvious damage to aux box, 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. Install aux box per Part A if removed.

Page 92.26 Chapter 92 ENG Version JUL 2020

92-180 G456-1 Microwave System Installation
A. Description
The microwave transmitting system consists of a microwave transmitter, power
amplifier, control panels, and a directional antenna pod.
The microwave transmitter is located in the main baggage compartment. The control
panel for the transmitter is located in the rear equipment console.
The directional antenna pod is located beneath the aircraft belly at approximately the
center of the cabin, and the power amplifier is mounted on top of it. The directional
antenna pod contains a GPS tracking system which keeps the antenna aimed at a
ground-based receive site. The antenna has its own control panel located in the rear
equipment panel.
Flight with pod antenna removed is permissible with mounting brackets removed and
cables stowed. Refer to § 92-184 Part E for maintenance procedures.
B. Schematic
Refer to Figure 92-9 for G456-1 microwave system installation wiring diagram.

92-181 D588-5 Controller Assembly

A. Removal
1. Refer to Figure 92-1. Turn battery & news equipment switches off, and pull out
MWAVE XMIT (5 amp) circuit breaker at panel.
2. Disconnect G459 harness assembly from D588-5 controller assembly.
3. Remove screws securing G472 face to G471 panels.
4. Remove screws securing controller to G472 face and remove controller.
B. Installation
1. Refer to Figure 92-1. Turn battery & news equipment switches off, and pull out
MWAVE XMIT (5 amp) circuit breaker at panel.
2. Install screws securing D588-5 controller assembly to G472 face. Verify security.
3. Install screws securing G472 face to G471 panels. Verify security.
4. Connect G459 harness assembly to controller. Verify security.
5. Push in MWAVE XMIT (5 amp) circuit breaker at panel. Turn battery & news
equipment switches on.
6. Perform appropriate post-installation function checks. Turn battery switch off.

JUL 2020 Chapter 92 ENG Version Page 92.27

92-181 D588-5 Controller Assembly (continued)
C. Scheduled Inspections
Every 100-hour or annual inspection, inspect D588-5 controller assembly for proper
installation (refer to R66 Illustrated Parts Catalog Chapter 92) & proper operation per
Part B steps 5 and 6.
D. Special Inspections
1. Refer to Figure 92-1. Turn battery & news equipment switches off. Open circuit
breaker panel.
2. As required, remove D588-5 controller assembly per Part A. Inspect condition of
and verify no obvious damage to controller, 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. Install controller per Part A if removed.

Page 92.28 Chapter 92 ENG Version JUL 2020

92-182 ARC-CM-TX-RX-CR-01 Controller
A. Removal
1. Refer to Figure 92-1. Turn battery & news equipment switches off, and pull out
MWAVE XMIT (5 amp) circuit breaker at panel.
2. Remove hardware securing ARC-CM-TX-RX-CR-01 controller to G472 face.
3. Lift controller from console; disconnect G459 harness assembly from controller.
B. Installation
1. Refer to Figure 92-1. Turn battery & news equipment switches off, and pull out
MWAVE XMIT (5 amp) circuit breaker at panel.
2. Connect G459 harness assembly to ARC-CM-TX-RX-CR-01 controller. Verify
security.
3. Position controller in aft console and install hardware securing controller to G472
face. Verify security.
4. Push in MWAVE XMIT (5 amp) circuit breaker at panel. Turn battery & news
equipment switches on.
5. Perform appropriate post-installation function checks. Turn battery switch off.
C. Scheduled Inspections
Every 100-hour or annual inspection, inspect ARC-CM-TX-RX-CR-01 controller
for proper installation (refer to R66 Illustrated Parts Catalog Chapter 92) & proper
operation per Part B steps 4 and 5.
D. Special Inspections
1. Refer to Figure 92-1. Turn battery & news equipment switches off. Open circuit
breaker panel.
2. As required, remove ARC-CM-TX-RX-CR-01 controller per Part A. Inspect
condition of and verify no obvious damage to controller, 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. Install controller per Part A if removed.

JUL 2020 Chapter 92 ENG Version Page 92.29

92-183 CMTX7-LITE Transmitter
A. Removal
1. Refer to Figure 92-1. Turn battery & news equipment switches off, and pull out
MWAVE XMIT (5 amp) circuit breaker at panel.
2. Remove baggage compartment wall per § 92-130.
3. Disconnect G459 harness assembly from CMTX7-LITE transmitter.
4. Remove screws securing N-4-BK clamps to D429-12 angles.
5. Remove screws securing D429-12 angles to D429-16 support assembly and
remove transmitter.
6. As required, remove screws securing D429-12 angles to transmitter & remove angles.
B. Installation
1. Refer to Figure 92-1. Turn battery & news equipment switches off, and pull out
MWAVE XMIT (5 amp) circuit breaker at panel.
2. As required, install screws securing D429-12 angles to CMTX7-LITE transmitter.
Verify security.
3. Install screws securing angles to D429-16 support assembly. Verify security.
4. Install screws securing N-4-BK clamps to angles. Verify security.
5. Connect G459 harness assembly to transmitter. Verify security.
6. Install baggage compartment wall per § 92-130.
7. Push in MWAVE XMIT (5 amp) circuit breaker at panel. Turn battery & news
equipment switches on.
8. Perform appropriate post-installation function checks. Turn battery switch off.
C. Scheduled Inspections
Every 100-hour or annual inspection, inspect CMTX7-LITE transmitter for proper
installation (refer to R66 Illustrated Parts Catalog Chapter 92) & proper operation per
Part B steps 7 and 8.
D. Special Inspections
1. Refer to Figure 92-1. Turn battery & news equipment switches off. Open circuit
breaker panel.
2. As required, remove CMTX7-LITE transmitter per Part A. Inspect condition of
and verify no obvious damage to transmitter, 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. Install transmitter per Part A if removed.

Page 92.30 Chapter 92 ENG Version JUL 2020

92-184 PA16-series Pod Antenna
A. Removal
1. Refer to Figure 92-1. Turn battery & news equipment switches off, and pull out
MWAVE XMIT (5 amp) circuit breaker at panel.
2. Disconnect G459 harness assembly from PA16-series pod antenna and D618-1
amp assembly.
3. Have a second person support pod antenna. Remove screws and washers
securing pod antenna to D586 brackets, and remove pod antenna.
4. As required, remove screws securing amp assembly to pod antenna, and remove
amp and R5683 thermal pads.
5. Configure helicopter for flight with pod antenna removed per Part E as required.
B. Installation
1. Refer to Figure 92-1. Turn battery & news equipment switches off, and pull out
MWAVE XMIT (5 amp) circuit breaker at panel.
2. Configure helicopter for flight with pod antenna installed per Part E as required.
3. If removed, position R5683 thermal pads and D618-1 amp assembly on PA16-
series pod antenna and install screws. Verify security.
4. Have a second person support pod antenna. Install screws and washers securing
pod antenna to D586 brackets. Verify security.
5. Connect G459 harness assembly to pod antenna and amp assembly. Verify security.
6. Push in MWAVE XMIT (5 amp) circuit breaker at panel. Turn battery & news
equipment switches on.
7. Perform appropriate post-installation function checks. Turn battery switch off.
C. Scheduled Inspections
Every 100-hour or annual inspection, inspect PA16-series pod antenna for proper
installation (refer to R66 Illustrated Parts Catalog Chapter 92) & proper operation per
Part B steps 5 and 6.
D. Special Inspections
1. Refer to Figure 92-1. Turn battery & news equipment switches off. Open circuit
breaker panel.
2. As required, remove PA16-series pod antenna per Part A. Inspect condition of
and verify no obvious damage to antenna, D586 brackets, 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. Install antenna per Part A if removed.

JUL 2020 Chapter 92 ENG Version Page 92.31

92-184 PA16-series Pod Antenna (continued)
E. Configurations for Flight
1. Configuration for Flight with Pod Antenna Removed
a. Remove PA16-series pod antenna per Part A.
b. Remove hardware securing D586 brackets to F794-2 panel and remove
brackets.
c. Install clean, dry plastic bags individually over exposed cable assembly
connectors to prevent moisture or debris from contacting connector sockets/
pins; secure with ty-raps. Install clean, dry plastic bag over bagged cables/
connectors; secure with ty-raps. Verify security.
d. Revise Weight and Balance Record in R66 Pilot’s Operating Handbook (POH)
Section 6 to incorporate the following data:
Subtract:
Weight Long. Arm Long. Moment Lat. Arm Lat. Moment
18.1 lb 80.7 in. 1460.7 in.-lb 0 in. 0 in.-lb

2. Configuration for Flight with Pod Antenna Installed

a. Remove and discard ty-raps and plastic bags securing cable assemblies
together and ty-raps and bags protecting connectors.
b. Install hardware securing D586 brackets to F794-2 panel. Verify security.
c. Install PA16-series pod antenna per Part B.
d. Revise Weight and Balance Record in R66 Pilot’s Operating Handbook (POH)
Section 6 to incorporate the following data:
Add:
Weight Long. Arm Long. Moment Lat. Arm Lat. Moment
18.1 lb 80.7 in. 1460.7 in.-lb 0 in. 0 in.-lb

Page 92.31A Chapter 92 ENG Version JUL 2020

Intentionally Blank

JUL 2020 Chapter 92 ENG Version Page 92.31B

92-185 GPS-1270FW Antenna
A. Removal
1. Remove tailcone cowling per § 53-23.
2. Refer to Figure 92-1. Remove hardware securing GPS-1270FW antenna to F706-
1 cowling assembly and remove antenna. Discard o-ring.
B. Installation
1. Refer to Figure 92-1. Turn battery & news equipment switches off and pull out
MWAVE XMIT (5 amp) circuit breaker at panel.
2. Install new o-ring and install hardware securing GPS-1270FW antenna to F706-1
cowling assembly. Verify security.
3. Install tailcone cowling per § 53-23.
4. Push in MWAVE XMIT (5 amp) circuit breaker at panel. Turn battery & news
equipment switches on.
5. Perform appropriate post-installation function checks. Turn battery switch off.
C. Scheduled Inspections
Every 100-hour or annual inspection, inspect GPS-1270FW antenna for proper
installation (refer to R66 Illustrated Parts Catalog Chapter 92) & proper operation per
Part B steps 4 and 5.
D. Special Inspections
1. Refer to Figure 92-1. Turn battery & news equipment switches off. Open circuit
breaker panel.
2. As required, remove GPS-1270FW antenna per Part A. Inspect condition of
and verify no obvious damage to antenna, circuit breaker, and wiring. Verify no
loose, chafed, or broken wires or terminals. Verify no evidence of arcing. Verify
equipment security.
3. Secure circuit breaker panel. Install antenna per Part A if removed.

Page 92.32 Chapter 92 ENG Version JUL 2020

92-190 Antenna Installations

92-191 G457-1 Antenna Installation (Transponder)

A. Schematic
Refer to Figure 98-15 for C804-22 transponder installation wiring diagram.
B. Removal
1. Refer to Figure 92-1. Turn battery & avionics switches off and pull out XPDR (3
amp) circuit breaker at panel.
2. Disconnect G457-2817 cable from engine cowling near right side access door.
Remove engine cowling per § 53-21.
3. Using plastic scraper, remove B270-1 sealant from around CI 105-16 transponder
antenna at where it attaches to aft cowling.
4. Disconnect antenna cable from antenna at connectors. Remove hardware
securing B322-12 doubler and antenna to cowling and remove antenna.
C. Installation
1. Refer to Figure 92-1. Turn battery & avionics switches off and pull out XPDR (3
amp) circuit breaker at panel.
2. Remove paint & primer from between cabin skin and B322-12 plate, and between
cabin skin and CI 105-16 transponder antenna to ensure electrical ground.
3. Install hardware securing B322-12 doubler and transponder antenna to mounting
plate to aft cowling. Verify security.
4. Apply small bead of B270-1 sealant (0.1 inch max in height) around antenna
(exterior only) where it attaches to aft cowling.
5. Connect antenna cable to antenna at connectors; verify security.
6. Install engine cowling per § 53-21.
7. Push in XPDR (3 amp) circuit breaker at panel. Turn battery & avionics switches on.
8. Perform appropriate functional checks per Garmin GTX 345 Pilot’s Guide. Turn
battery & avionics switches off.
D. Scheduled Inspections
Every 100-hour or annual inspection, inspect CI 105-16 transponder antenna for
proper installation (refer to R66 Illustrated Parts Catalog Chapter 92) & proper
operation per Part C steps 7 and 8.

JUL 2020 Chapter 92 ENG Version Page 92.33

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

92-192 G457-2 Antenna Installation (TV Tuner)

A. Schematic
Refer to Figure 92-13 for G491 TV receiver provision installation electrical schematic.
B. Removal
1. Refer to Figure 92-1. Turn battery & news equipment switches off and pull out
TV TUNER (2 amp) circuit breaker at panel.
2. Using plastic scraper, remove B270-1 sealant from around CI 273 TV tuner
antenna where it attaches to cabin skin.
3. Remove screws securing B322-11 plate to cabin skin and remove plate with
antenna attached. Disconnect antenna cable from antenna at connectors.
4. Disassemble antenna from plate as required.
C. Installation
1. Refer to Figure 92-1. Turn battery & news equipment switches off and pull out
TV TUNER (2 amp) circuit breaker at panel.
2. Remove paint & primer from between cabin skin and B322-11 plate to ensure
electrical ground.
3. Assemble CI 273 TV tuner antenna on B322-11 plate as required. Verify security.
4. Connect antenna cable to antenna at connectors. Install screws securing plate
to cabin skin. Verify security.
5. Apply small bead of B270-1 sealant around antenna (exterior only) where it
attaches to cabin skin.
6. Push in TV TUNER (2 amp) circuit breaker at panel. Turn battery & news equipment
switches on.
7. Perform appropriate functional checks per TV tuner manufacturer’s instructions.
Turn battery & news equipment switches off.

Page 92.34 Chapter 92 ENG Version JUL 2020

92-192 G457-2 Antenna Installation (TV Tuner; continued)
D. Scheduled Inspections
Every 100-hour or annual inspection, inspect CI 273 TV tuner antenna for proper
installation (refer to R66 Illustrated Parts Catalog Chapter 92) & proper operation per
Part C steps 6 and 7.
E. Special Inspections
1. Refer to Figure 92-1. Turn battery & news equipment switches off. Open circuit
breaker panel.
2. As required, remove CI 273 TV tuner antenna per Part A. Inspect condition of
and verify no obvious damage to antenna, circuit breaker, and wiring. Verify no
loose, chafed, or broken wires or terminals. Verify no evidence of arcing. Verify
equipment security.
3. Secure circuit breaker panel. Install antenna per Part A if removed.

92-193 G457-3 Antenna Installation (Scanner)

A. Schematic
Refer to Figure 92-11 for G489 scanner installation wiring diagram.
B. Removal
1. Refer to Figure 92-1. Turn battery & news equipment switches off and pull out
SCANNER (2 amp) circuit breaker at panel.
2. Remove G13000 audio system router per § 92-253.
3. Disconnect antenna cable from CI 285 antenna at connectors.
4. Supporting antenna and B322-14 plate, remove screws securing antenna and
plate to cabin skin and remove antenna and plate.
C. Installation
1. Refer to Figure 92-1. Turn battery & news equipment switches off and pull out
SCANNER (2 amp) circuit breaker at panel.
2. Remove paint & primer from between cabin skin and CI 285 antenna to ensure
electrical ground.
3. Supporting antenna and B322-14 plate, install screws securing antenna and plate
to cabin skin. Verify security.
4. Connect antenna cable to antenna at connectors.
5. Install G13000 audio system router per § 92-253.

JUL 2020 Chapter 92 ENG Version Page 92.35

92-193 G457-3 Antenna Installation (Scanner; continued)
C. Installation (continued)
6. Apply small bead of B270-1 sealant (0.1 inch max in height) around antenna
(exterior only) where it attaches to cabin skin.
7. Push in SCANNER (2 amp) circuit breaker at panel. Turn battery & news equipment
switches on.
8. Perform appropriate functional checks per Uniden Scanners User’s Guide. Turn
battery & news equipment switches off.
D. Scheduled Inspections
Every 100-hour or annual inspection, inspect CI 285 antenna for proper installation
(refer to R66 Illustrated Parts Catalog Chapter 92) & proper operation per Part C
steps 7 and 8.
E. Special Inspections
1. Refer to Figure 92-1. Turn battery & news equipment switches off. Open circuit
breaker panel.
2. As required, remove CI 285 antenna per Part A. Inspect condition of and verify no
obvious damage to antenna, circuit breaker, and wiring. Verify no loose, chafed,
or broken wires or terminals. Verify no evidence of arcing. Verify equipment
security.
3. Secure circuit breaker panel. Install antenna per Part A if removed.

92-200 G470-1 Aft Console Installation

The G470-1 aft console installation is a sheet metal console installed in place of the F931-1
(middle) aft seat assembly, reducing maximum number of occupants to 4. The aft console
contains equipment and controls used by the camera operator.

92-210 G487-1 FM Transceivers Installation

A. Description
FM transceiver #1 is mounted in the lower instrument panel, and FM transceivers #2
and #3 are mounted in the rear equipment console. All 3 transceivers are selectable
from any of the three main audio control panels.
B. Schematic
Refer to Figure 92-10 for G487-1 FM transceivers installation wiring diagram.

Page 92.36 Chapter 92 ENG Version JUL 2020

92-210 G487-1 FM Transceivers Installation (continued)
C. Removal
1. Refer to Figure 92-1. Turn battery & news equipment switches off and pull out
FM2 (10 amp) and FM3 (10 amp) circuit breakers at panel.
2. Remove screws securing G472 face to G471 panels.
3. Disconnect G459 harness assembly from A824 transceiver(s).
4. Supporting transceiver(s), remove hardware securing B344-25 angle assemblies to
face and transceiver(s). Remove angles and transceiver(s).
D. Installation
1. Refer to Figure 92-1. Turn battery & news equipment switches off and pull out
FM2 (10 amp) and FM3 (10 amp) circuit breakers at panel.
2. Supporting A824 transceiver(s), install hardware securing B344-25 angle assemblies
to face and transceiver(s). Verify security.
3. Install screws securing G472 face to G471 panels.
4. Connect G459 harness assembly to transceiver(s).
5. Push in FM2 (10 amp) and FM3 (10 amp) circuit breakers at panel. Turn battery &
news equipment switches on.
6. Perform appropriate functional checks per Kenwood TK-7180/TK-8180 VHF FM /
UHF FM Transceiver Instruction Manual. Turn battery & new equipment switches off.
E. Scheduled Inspections
Every 100-hour or annual inspection, inspect A824 transceiver(s) for proper installation
(refer to R66 Illustrated Parts Catalog Chapter 92) & proper operation per Part D steps
5 and 6.
F. Special Inspections
1. Refer to Figure 92-1. Turn battery & news equipment switches off. Open circuit
breaker panel.
2. As required, remove A824 transceiver(s) per Part A. Inspect condition of and
verify no obvious damage to transceiver(s), 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. Install transceiver(s) per Part A if removed.

JUL 2020 Chapter 92 ENG Version Page 92.37

92-220 G489-1 Scanner Installation
A. Description
A multi-band scanner may be installed in place of the AM/FM receiver and is selectable
from any of the three main audio control panels.
B. Schematic
Refer to Figure 92-11 for G489 scanner installation wiring diagram.
C. Removal
1. Refer to Figure 92-1. Turn battery & news equipment switches off and pull out
SCANNER (2 amp) circuit breaker at panel.
2. Remove screws securing G472 face to G471 panels.
3. Disconnect G459 harness assembly from scanner.
4. Supporting BCD996XT scanner, remove hardware securing D344-19 angle
assemblies to face and scanner. Remove angles and scanner.
D. Installation
1. Refer to Figure 92-1. Turn battery & news equipment switches off and pull out
SCANNER (2 amp) circuit breaker at panel.
2. Supporting BCD996XT scanner, install hardware securing D344-19 angle assemblies
to face and scanner. Verify security.
3. Connect G459 harness assembly to scanner. Verify security.
4. Install screws securing G472 face to G471 panels.
5. Push in SCANNER (2 amp) circuit breaker at panel. Turn battery & news equipment
switches on.
6. Perform appropriate functional checks per Uniden Scanners User’s Guide. Turn
battery & new equipment switches off.
E. Scheduled Inspections
Every 100-hour or annual inspection, inspect BCD996XT scanner for proper installation
(refer to R66 Illustrated Parts Catalog Chapter 92) & proper operation per Part D steps
5 and 6.
F. Special Inspections
1. Refer to Figure 92-1. Turn battery & news equipment switches off. Open circuit
breaker panel.
2. As required, remove BCD996XT scanner per Part A. Inspect condition of and verify
no obvious damage to scanner, 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. Install scanner per Part A if removed.

Page 92.38 Chapter 92 ENG Version JUL 2020

92-230 G490-1 Talent Light Installation
A. Description
The forward talent light is mounted on the left side of the instrument console and is
used to illuminate the left front seat occupant (typically a reporter) during broadcasts
in low-light conditions. Beam elevation is adjustable via a friction mount. The aft
talent light is mounted on top of the center-cabin camera and is used to illuminate rear
seat areas as desired. The forward light is controlled by a toggle switch on the rear
equipment console, and the aft light is controlled by a switch on the light itself.
B. Schematic
Refer to Figure 92-12 for G490-1 talent light installation wiring diagram.

92-231 D553-1 (Forward Talent) Light Assembly

A. Lamp Replacement
1. Refer to Figure 92-1. Turn battery & news equipment switches off and pull out
TALENT LTS (3 amp) circuit breaker at panel.
2. Supporting D553-1 light assembly, remove hardware securing light assembly to
D566-10 bracket.
3. Holding light assembly vertically, unscrew D553-3 housing from D566-9 cap and
remove housing and D566-5 lens.
4. Unplug L517A lamp from H8841 holder. Replace lamp as required and reassemble
(frosted side of D566-5 lens toward lamp). Verify security.
5. Push in TALENT LTS (3 amp) circuit breaker at panel. Turn battery & news
equipment switches on. Verify talent light switches on and off using switch.
B. Scheduled Inspections
Every 100-hour or annual inspection, inspect D553-1 light assembly for proper
installation (refer to R66 Illustrated Parts Catalog Chapter 92) & proper operation per
Part A step 5.

JUL 2020 Chapter 92 ENG Version Page 92.39

92-232 ILED-MA (Aft Talent) Light
A. Removal
1. Refer to Figure 92-1. Turn battery & news equipment switches off and pull out
TALENT LTS (3 amp) circuit breaker at panel.
2. Unplug mini USB cable from ILED-MA light.
3. Using backup wrench on lower 91819A110 nut, loosen upper 91819A110 nut
securing light to 90322A645 stud; unscrew light off of stud.
B. Installation
1. Refer to Figure 92-1. Turn battery & news equipment switches off and pull out
TALENT LTS (3 amp) circuit breaker at panel.
2. Using backup wrench on lower 91819A110 nut, screw ILED-MA light onto
90322A645 stud; tighten upper 91819A110 nut securing light to stud. Verify
security.
3. Plug in mini USB cable to light.
4. Push in TALENT LTS (3 amp) circuit breaker at panel. Turn battery & news
equipment switches on. Verify talent light switches on and off using switch.
C. Scheduled Inspections
Every 100-hour or annual inspection, inspect ILED-MA light for proper installation (refer
to R66 Illustrated Parts Catalog Chapter 92) & proper operation per Part B step 4.

92-240 G491 TV Receiver Provision Installation

A. Description
Refer to Figure 92-1. The TV tuner is mounted in the rear equipment console and is
used to select television broadcasts to be displayed on the monitors. A second tuner
is optional.
B. Schematic
Refer to Figure 92-13 for G491 TV receiver provision installation wiring diagram.

Page 92.40 Chapter 92 ENG Version JUL 2020

92-241 Distribution Amp
A. Removal
1. Refer to Figure 92-1. Turn battery & news equipment switches off and pull out
TV TUNER (2 amp) circuit breaker at panel.
2. Remove screws securing G472 face to G471 panels.
3. Supporting 11-911-102 distribution amp(s), remove screws securing amp(s) to
aft console assembly. Disconnect G459 harness assembly from amp(s).
B. Installation
1. Refer to Figure 92-1. Turn battery & news equipment switches off and pull out
TV TUNER (2 amp) circuit breaker at panel.
2. Connect G459 harness assembly to 11-911-102 distribution amp(s). Verify
security.
3. Install screws securing amp(s) to aft console assembly. Verify security.
4. Install screws securing G472 face to G471 panels.
5. Push in TV TUNER (2 amp) circuit breaker at panel. Turn battery & news equipment
switches on.
6. Perform appropriate functional checks per TV receiver manufacturer’s instructions
(manufacturer’s may vary due to regional requirements). Turn battery & new
equipment switches off.
C. Scheduled Inspections
Every 100-hour or annual inspection, inspect 11-911-102 distribution amp(s) for
proper installation (refer to R66 Illustrated Parts Catalog Chapter 92) & proper
operation per Part B steps 5 and 6.
D. Special Inspections
1. Refer to Figure 92-1. Turn battery & news equipment switches off. Open circuit
breaker panel.
2. As required, remove 11-911-102 distribution amp(s) per Part A. Inspect condition
of and verify no obvious damage to distribution amp(s), 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. Install distribution amp(s) per Part A if removed.

JUL 2020 Chapter 92 ENG Version Page 92.41

92-242 Digital TV Receiver
A. Removal
1. Refer to Figure 92-1. Turn battery & news equipment switches off and pull out
TV TUNER (2 amp) circuit breaker at panel.
2. Remove screws securing G472 face to G471 panels.
3. Disconnect G459 harness assembly from CTDVBT-288X digital TV receiver(s).
4. Remove screws securing receiver(s) to and remove receiver(s).
B. Installation
1. Refer to Figure 92-1. Turn battery & news equipment switches off and pull out
TV TUNER (2 amp) circuit breaker at panel.
2. Install screws securing CTDVBT-288X digital TV receiver(s) to F463-1 cover
assembly. Verify security.
3. Connect G459 harness assembly to receiver(s). Verify security.
4. Install screws securing G472 face to G471 panels. Verify security.
5. Push in TV TUNER (2 amp) circuit breaker at panel. Turn battery & news equipment
switches on.
6. Perform appropriate functional checks per TV receiver manufacturer’s instructions
(manufacturer’s may vary due to regional requirements). Turn battery & new
equipment switches off.
C. Scheduled Inspections
Every 100-hour or annual inspection, inspect CTDVBT-288X digital TV receiver(s)
for proper installation (refer to R66 Illustrated Parts Catalog Chapter 92) & proper
operation per Part B steps 5 and 6.
D. Special Inspections
1. Refer to Figure 92-1. Turn battery & news equipment switches off. Open circuit
breaker panel.
2. As required, remove CTDVBT-288X digital TV receiver(s) per Part A. Inspect
condition of and verify no obvious damage to receiver(s), 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. Install receiver(s) per Part A if removed.

Page 92.42 Chapter 92 ENG Version JUL 2020

92-250 G492-1 Audio System Installation
A. Description
The audio system consists of four audio control panels and an audio junction box. The
audio junction box is located beneath the right rear seat. Power is supplied via a 5-amp
circuit breaker in the main circuit breaker panel on the left hand side of the aircraft.
Power to the audio system is not disconnected by the news equipment master switch.
The pilot’s audio panel is located on the accessory bar in front of the pilot’s seat. Push
buttons are used to select a primary (transmit and monitor) audio component. Green
LEDs indicate which audio component is currently selected as primary. Additional
components may be monitored by selecting their toggle switches up. Sliders control
volume level for each component being monitored.
Intercom control is at the far right of the audio panel. Toggle switch down isolates
the pilot from the intercom. With the toggle switch up, the ICS slider controls volume,
and the VOX slider (adjacent to the left) controls voice-activation threshold. VOX
slider full down is maximum threshold (keyed intercom). Pushing the ICS push-button
(illuminating the green LED) provides hot mic regardless of VOX slider position.
The first detent of the pilot’s trigger switch is the intercom key. The second detent
transmits on the #1 VHF communications radio regardless of audio panel configuration.
The audio panel transmit thumb button transmits on the panel-selected audio
component.
A toggle switch to the left of the pilot’s audio panel may be used to bypass the audio
system and connect the pilot directly to Com 1. This mode is automatically engaged
in the event of an audio system power failure. (The transmit indicator on the radio
display can be used to verify transmission.)
The left front seat audio panel operates in the same manner as the pilot’s audio panel
but is not connected to the bypass toggle switch. The first detent of the copilot’s
trigger switch is the intercom key, and the second detent transmits on the panel-
selected audio component. A handheld transmit switch has been added for use when
the left cyclic grip is removed.
The left front seat audio panel also controls the audio configuration for the right rear
seat.
The left rear seat audio panel is connected to the left rear seat headset jack. The laptop
camera controller contains intercom and transmit switches for the camera operator.
The microwave audio panel controls which signals are sent to the microwave transmitter
and video recorder. Selecting the toggle switch up for a component sends its signal
to the transmitter. Push buttons are not functional on this panel.

B. Schematic
Refer to Figure 92-14 for G492-1 audio system installation wiring diagram.

JUL 2020 Chapter 92 ENG Version Page 92.43

92-251 Forward Audio Panels
A. Removal
1. Remove forward monitor(s) per § 92-160.
2. Refer to Figure 92-1. Turn battery & news equipment switches off, and pull out
AUDIO PANEL (5 amp) circuit breaker at panel.
3. Remove hardware securing G11431-00102-1 audio panel(s) to G474 bracket
assembly.
4. Disconnect G459 harness assembly from audio panel(s) and remove panel(s).
B. Installation
1. Refer to Figure 92-1. Turn battery & news equipment switches off, and pull out
7” MONS (2 amp) and AUDIO PANEL (5 amp) circuit breakers at panel.
2. Connect G459 harness assembly to G11431-00102-1 audio panel(s). Verify
security.
3. Install hardware securing audio panel(s) to G474 bracket assembly. Verify
security.
4. Install forward (monitor(s) per § 92-160.
5. Push in 7” MONS (2 amp) and AUDIO PANEL (5 amp) circuit breakers at panel.
6. Perform appropriate functional checks per Geneva Aviation user guide. Turn
battery & news equipment switches off.
C. Scheduled Inspections
Every 100-hour or annual inspection, inspect G11431-00102-1 audio panel(s)
for proper installation (refer to R66 Illustrated Parts Catalog Chapter 92) & proper
operation per Part B steps 5 and 6.
D. Special Inspections
1. Refer to Figure 92-1. Turn battery & news equipment switches off. Open circuit
breaker panel.
2. As required, remove G11431-00102-1 audio panel(s) per Part A. Inspect condition
of and verify no obvious damage to audio panel(s), G474 bracket assemblies, 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. Install audio panel(s) per Part A if removed.

Page 92.44 Chapter 92 ENG Version JUL 2020

92-252 Aft Console Audio Panels
A. Removal
1. Refer to Figure 92-1. Turn battery & news equipment switches off, and pull out
AUDIO PANEL (5 amp) circuit breaker at panel.
2. Remove face screws securing G11431-00102 audio panel(s) to D344-4 angle
assemblies and lift audio panel from console.
3. Disconnect G459 harness assembly from audio panel(s) and remove panel(s).
4. As required, remove hardware securing D557-4 cover assemblies from audio
panels and remove covers.
B. Installation
1. Refer to Figure 92-1. Turn battery & news equipment switches off, and pull out
AUDIO PANEL (5 amp) circuit breaker at panel.
2. If removed, install hardware securing D557-4 cover assemblies to G11431-
00102-1 audio panel(s) and install covers.
3. Connect G459 harness assembly to audio panel(s). Verify security.
4. Position audio panel(s) in console and install face screws securing audio panel(s)
to D344-4 angle assemblies. Verify security.
5. Push in AUDIO PANEL (5 amp) circuit breaker at panel.
6. Perform appropriate functional checks per Geneva Aviation user guide. Turn
battery & news equipment switches off.
C. Scheduled Inspections
Every 100-hour or annual inspection, inspect G11431-00102-1 audio panel(s)
for proper installation (refer to R66 Illustrated Parts Catalog Chapter 92) & proper
operation per Part B steps 5 and 6.
D. Special Inspections
1. Refer to Figure 92-1. Turn battery & news equipment switches off. Open circuit
breaker panel.
2. As required, remove G11431-00102-1 audio panel(s) per Part A. Inspect condition
of and verify no obvious damage to audio panel(s), 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. Install audio panel(s) per Part A if removed.

JUL 2020 Chapter 92 ENG Version Page 92.45

92-253 Digital Router
A. Removal
1. Refer to Figure 92-1. Turn battery & news equipment switches off, and pull out
AUDIO PANEL (5 amp) circuit breaker at panel.
2. Lift aft right seat forward. Remove or loosen screws securing G459 harness
assembly to G13000 router.
3. Remove screws and C130-51 spacers securing router to F387-1 (belly) skin and
remove router.
B. Installation
1. Refer to Figure 92-1. Turn battery & news equipment switches off, and pull out
AUDIO PANEL (5 amp) circuit breaker at panel.
2. Lift aft right seat forward. Install screws and C130-51 spacers securing G13000
router to F387-1 (belly skin). Verify security.
3. Install or tighten screws securing G459 harness assembly to router. Verify
security.
4. Push in AUDIO PANEL (5 amp) circuit breaker at panel.
5. Perform appropriate functional checks per Geneva Aviation user guide. Turn
battery & news equipment switches off.
C. Scheduled Inspections
Every 100-hour or annual inspection, inspect G13000 router for proper installation
(refer to R66 Illustrated Parts Catalog Chapter 92) & proper operation per Part B
steps 4 and 5.
D. Special Inspections
1. Refer to Figure 92-1. Turn battery & news equipment switches off. Open circuit
breaker panel.
2. As required, remove G13000 router per Part A. Inspect condition of and verify no
obvious damage to router, 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. Install router per Part A if removed.

Page 92.46 Chapter 92 ENG Version JUL 2020

92-260 G493-1 Video Components Installation
A. Description
The video switcher is located in the rear equipment console and is used to select the
video signal source (nose camera, video recorder playback, or micro cameras). The
signal is then routed to the monitors, microwave transmitter, and video recorder.
B. Schematic
Refer to Figure 92-15 for G493-1 video components wiring diagram.
C. Removal
1. Refer to Figure 92-1. Turn battery & news equipment switches off and pull out
VID SW (2 amp) circuit breaker at panel.
2. Remove screws securing G472 face to G471 panels and remove face.
3. Supporting component(s), remove screws securing BENXT430X video router or
RH-AB video switch to G470-1 console assembly, as required.
4. Supporting component(s), disconnect G459 harness assembly from video router or
video switch as required and remove component.
D. Installation
1. Refer to Figure 92-1. Turn battery & news equipment switches off and pull out
VID SW (2 amp) circuit breaker at panel.
2. Connect G459 harness assembly to BENXT430X video router or RH-AB video
switch, as required.
3. Install screws securing video router or video switch to G470-1 console assembly,
as required. Verify security.
4. Install screws securing G472 face to G471 panels. Verify security.
5. Push in VID SW (2 amp) circuit breaker at panel. Turn battery & news equipment
switches on.
6. Perform appropriate functional checks per Ensemble Designs BrightEye NXT Routers
430 Guide. Turn battery & news equipment switches off.
E. Scheduled Inspections
Every 100-hour or annual inspection, inspect BENXT430X video router and RH-AB
video switch for proper installation (refer to R66 Illustrated Parts Catalog Chapter
92) & proper operation per Part D steps 5 and 6.

JUL 2020 Chapter 92 ENG Version Page 92.47

92-260 G493-1 Video Components Installation (continued)
F. Special Inspections
1. Refer to Figure 92-1. Turn battery & news equipment switches off. Open circuit
breaker panel.
2. As required, remove BENXT430X video router and RH-AB video switch per Part A.
Inspect condition of and verify no obvious damage to video router, video switch,
circuit breaker, and wiring. Verify no loose, chafed, or broken wires or terminals.
Verify no evidence of arcing. Verify equipment security.
3. Secure circuit breaker panel. Install video router and video switch per Part A if
removed.

92-270 G496-1 DVR Installation

A. Description
The video recorder is located on the cross tube between the front seatbacks and has
a built-in monitor and controls.
B. Schematic
Refer to Figure 92-16 for G496-1 DVR installation wiring diagram.
C. Removal
1. Refer to Figure 92-1. Turn battery & news equipment switches off and pull out
DVR (2 amp) circuit breaker at panel.
2. Disconnect G459 harness assembly from ODYSSEY7Q or ODYSSEY7QPLUS
monitor/recorder.
3. Supporting monitor/recorder, remove hardware securing monitor/recorder to G474-
3 bar and remove monitor/recorder.
D. Installation
1. Refer to Figure 92-1. Turn battery & news equipment switches off and pull out
DVR (2 amp) circuit breaker at panel.
2. Install hardware securing ODYSSEY7Q or ODYSSEY7QPLUS monitor/recorder to
G474-3 bar. Verify security.
3. Connect G459 harness assembly to monitor/recorder. Verify security.
4. Push in DVR (2 amp) circuit breaker at panel. Turn battery & news equipment
switches on.
5. Perform appropriate functional checks per Convergent Design Odyssey 7Q+ User
Manual. Turn battery & news equipment switches off.

Page 92.48 Chapter 92 ENG Version JUL 2020

92-270 G496-1 DVR Installation (continued)
E. Scheduled Inspections
Every 100-hour or annual inspection, inspect ODYSSEY7Q or ODYSSEY7QPLUS
monitor/recorder for proper installation (refer to R66 Illustrated Parts Catalog Chapter
92) & proper operation per Part D steps 4 and 5.
F. Special Inspections
1. Refer to Figure 92-1. Turn battery & news equipment switches off. Open circuit
breaker panel.
2. As required, remove ODYSSEY7Q or ODYSSEY7QPLUS monitor/recorder per Part
A. Inspect condition of and verify no obvious damage to monitor/recorder, 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. Install monitor/recorder per Part A if removed.

92-280 Aux Electrical System Installation

An additional circuit breaker panel on the ledge just forward of the pilot’s seat contains
all circuit breakers for ENG equipment. The forward row of circuit breakers is a 28-volt
bus and the aft row is a 14-volt bus. A 28 to 14-volt converter powers the 14-volt bus.
The news equipment master switch on the left side of the panel controls power to all ENG
equipment.

NOTE

ENG circuit breaker panel will not be powered by news equipment

master switch unless avionics switch is also on.

92-285 D301 Ballast Installation

CAUTION
Altering fixed ballast can appreciably affect helicopter center of
gravity (CG).
CAUTION
Maximum allowable empennage ballast is 21.00 lb on E.N.G
Versions. One upper and one lower weight are required.
Available combinations provide total weight of 3, 6, 9, 12, 15,
& 21 lb.

Refer to Chapter 8-00 for weight and balance information.

JUL 2020 Chapter 92 ENG Version Page 92.49

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Page 92.50 Chapter 92 ENG Version JUL 2020

92-290 Wiring Diagrams

FIGURE 92-3 A826-18 TRANSCEIVER INSTALLATION (FM1) WIRING DIAGRAM

JUL 2020 Chapter 92 ENG Version Page 92.51

92-290 Wiring Diagrams (continued)

FIGURE 92-4 D097 HD MICRO CAMERA INSTALLATION WIRING DIAGRAM

Page 92.52 Chapter 92 ENG Version JUL 2020

92-290 Wiring Diagrams (continued)

FIGURE 92-5 G445-2 AUX CIRCUIT BREAKER PANEL INSTALLATION WIRING DIAGRAM

JUL 2020 Chapter 92 ENG Version Page 92.53

92-290 Wiring Diagrams (continued)

FIGURE 92-6 G448 AFT MONITORS INSTALLATION WIRING DIAGRAM

Page 92.54 Chapter 92 ENG Version JUL 2020

92-290 Wiring Diagrams (continued)

FIGURE 92-7 G449 FORWARD MONITORS INSTALLATION WIRING DIAGRAM

JUL 2020 Chapter 92 ENG Version Page 92.55

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Page 92.56 Chapter 92 ENG Version JUL 2020

92-280 Wiring Diagrams (continued)

FIGURE 92-8 G454-1 CAMERA SYSTEM INSTALLATION WIRING DIAGRAM

JUL 2020 Chapter 92 ENG Version Page 92.57

Intentionally Blank

Page 92.58 Chapter 92 ENG Version JUL 2020

92-290 Wiring Diagrams (continued)

FIGURE 92-9 G456-1 MICROWAVE SYSTEM INSTALLATION WIRING DIAGRAM

JUL 2020 Chapter 92 ENG Version Page 92.59

92-290 Wiring Diagrams (continued)

FIGURE 92-10 G487-1 FM TRANSCEIVERS INSTALLATION WIRING DIAGRAM

Page 92.60 Chapter 92 ENG Version JUL 2020

92-290 Wiring Diagrams (continued)

FIGURE 92-11 G489 SCANNER INSTALLATION WIRING DIAGRAM

JUL 2020 Chapter 92 ENG Version Page 92.61

92-290 Wiring Diagrams (continued)

FIGURE 92-12 G490-1 TALENT LIGHT INSTALLATION WIRING DIAGRAM

Page 92.62 Chapter 92 ENG Version JUL 2020

92-290 Wiring Diagrams (continued)

FIGURE 92-13 G491 TV RECEIVER PROVISION INSTALLATION WIRING DIAGRAM

JUL 2020 Chapter 92 ENG Version Page 92.63

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Page 92.64 Chapter 92 ENG Version JUL 2020

92-280 Wiring Diagrams (continued)

FIGURE 92-14 G492-1 AUDIO SYSTEM INSTALLATION WIRING DIAGRAM

JUL 2020 Chapter 92 ENG Version Page 92.65

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Page 92.66 Chapter 92 ENG Version JUL 2020

92-290 Wiring Diagrams (continued)

FIGURE 92-15 G493-1 VIDEO COMPONENTS INSTALLATION WIRING DIAGRAM

JUL 2020 Chapter 92 ENG Version Page 92.67

92-290 Wiring Diagrams (continued)

FIGURE 92-16 G496-1 DVR INSTALLATION WIRING DIAGRAM

Page 92.68 Chapter 92 ENG Version JUL 2020

CHAPTER 95

INSTRUMENT SYSTEM
Section Title Page

95-00 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95.1

95-10 Pitot-Static System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95.3
95-20 Primary Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95.5
95-21 Vertical Speed Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95.6
95-22 Airspeed Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95.7
95-23 Engine (N2) and Rotor Dual Tachometer . . . . . . . . . . . . . . . . . . . . . . . . 95.8
95-24 Altimeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95.11
95-25 Torquemeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95.12
95-26 Magnetic Compass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95.13
95-30 Engine Gages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95.14
95-31 N1 Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95.14
95-32 Measured Gas (Turbine) Temperature (MGT) Gage . . . . . . . . . . . . . . . . . 95.15
95-33 Engine Oil Pressure Gage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95.16
95-34 Engine Oil Temperature Gage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95.16
95-35 Fuel Quantity Gage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95.17
95-40 Additional Standard Indicating Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . 95.18
95-41 Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95.18
95-42 Ammeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95.19
95-43 Outside Air Temperature (OAT) Gage/Voltmeter . . . . . . . . . . . . . . . . . . . 95.20
95-44 Hourmeters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95.21
95-50 Console Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95.22
95-60 Instrument Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95.22
95-70 Electronic Flight Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95.25
95-71 Garmin Display Unit (GDU) 1060 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95.25
95-72 Garmin Display Unit (GDU) 620 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95.27
95-73 Aspen EFD500H & EFD1000H Display(s) Installation . . . . . . . . . . . . . . . . 95.28

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Page 95.ii Chapter 95 Instrument System JUL 2020

CHAPTER 95

INSTRUMENT SYSTEM

95-00 Description

Standard primary instruments include an airspeed indicator, engine (N2) and rotor dual
tachometer, altimeter, torquemeter, and magnetic compass. Engine gages include an N1
tachometer, measured gas (turbine) temperature, oil pressure, oil temperature, and fuel
quantity. Also standard are a clock, an ammeter, a digital outside air temperature gage/
voltmeter, and an hourmeter. An additional hourmeter is located outboard of the pilot’s seat.
Both hourmeters require main gearbox oil pressure to activate. The outboard hourmeter is
collective activated and may be used to determine time in service.
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 sources are located on each side of the cabin, aft of the rear doors.
Water can be drained from pitot-static lines by removing the plastic drain plugs which are
accessible through the aft inspection panel on the underside of the cabin. Draining lines
should be required only if the airspeed indicator or altimeter appears erratic.
Pitot and static sources should be inspected frequently for bugs or other obstructions.

APR 2017 Chapter 95 Instrument System Page 95.1

FIGURE 95-1 PITOT - STATIC SYSTEM INSTALLATION

Page 95.2 Chapter 95 Instrument System APR 2017

95-10 Pitot-Static System

A. Pitot System Leak Test

CAUTION
Do not apply suction to pitot system or pressure to static system.

1. Open mast fairing per § 53-22.

2. Refer to Figures 95-1 and 95-2. Seal drain hole in elbow aft of pitot tube with
pressure sensitive tape. 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. Release force on plunger; plunger will remain in place
without need to pinch flexible tubing.
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.

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 Figures 95-1 and 95-2. Set altimeter to location elevation.

2. Temporarily seal left or right side static opening with pressure sensitive tape. Cover
remaining static port with a suction cup attached to a medical syringe.
3. SLOWLY apply suction to static port by withdrawing syringe plunger until altimeter
indicates 500 feet greater than location elevation. Release force on plunger, wait
one minute, and note any change in altimeter indication.
4. Change of less than 100 feet indication in one minute is acceptable. SLOWLY
remove suction from static port. Locate and repair leak(s) if altimeter indication
changes 100 or more feet in one minute. Retest after any repairs.
5. Remove test equipment.

APR 2017 Chapter 95 Instrument System Page 95.3

FIGURE 95-2 PITOT - STATIC SYSTEM INSTALLATION

Page 95.4 Chapter 95 Instrument System APR 2017

FIGURE 95-3 PITOT - STATIC SYSTEM SCHEMATIC

95-20 Primary Instruments

95-21 Vertical Speed Indicator

A. Description
The vertical speed indicator indicates rate of ascent or descent. Check vertical speed
indicator for a zero-rate needle indication when rotorcraft is in a stationary hover.

B. Schematic
Refer to Figure 95-3 for pitot-static system schematic.

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.

APR 2017 Chapter 95 Instrument System Page 95.5

95-21 Vertical Speed Indicator (continued)

D. Installation

CAUTION
Protect instrumentation using foam padding or equivalent.
Handle instruments like eggs.

1. Turn battery switch off and pull out applicable circuit breaker(s).
2. Remove caps and plugs and connect pitot/static lines. Verify security.
3. 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 § 95-10.
7. Perform appropriate function checks per § 5-40.

E. Scheduled Maintenance and Inspections

Refer to § 5-45 100-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 § 95-10.
2. Perform appropriate function checks per § 5-40. 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.

Page 95.6 Chapter 95 Instrument System APR 2017

95-22 Airspeed Indicator

A. Description
The airspeed indicator displays airspeed in knots and either miles or kilometers per
hour. The airspeed indicator operates properly in forward flight only; backward or
lateral flight will not indicate correct airspeed.

B. Schematic
Refer to Figure 95-3 for pitot-static system schematic.

C. Removal
Remove airspeed indicator per § 95-21 Part C.

D. Installation
Install airspeed indicator per § 95-21 Part D.

E. Scheduled Maintenance and Inspections

Refer to § 5-45 100-Hour/Annual Inspection.

F. Special Maintenance and Inspections

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 § 95-10.
e. Perform appropriate function checks per § 5-40. 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 § 95-10.
f. Perform appropriate function checks per § 5-40. If indicator still displays erratic
indication, remove indicator per Part C, and return to RHC for inspection.
g. Install airworthy indicator per Part D.

APR 2019 Chapter 95 Instrument System Page 95.7

95-23 Engine (N2) and Rotor Dual Tachometer

A. Description

CAUTION
Installation of electrical devices can affect accuracy and
reliability of electronic tachometers.

An electronic engine (N2) and rotor dual tachometer is standard. Engine tachometer
signal is provided by a transducer on the engine gearbox. Rotor tachometer signal is
provided by magnets on the main gearbox tail rotor driveline yoke. Each tachometer
is on a separate circuit with its own circuit breaker.
The tachometer bus receives power from the avionics bus or through the battery
relay bypass circuit as long as the main rotor gearbox has oil pressure. Therefore, the
tachometers will receive power through the bypass circuit whenever the rotors are
turning even if the avionics bus is not powered. The bypass circuit is disconnected
from the tachometer bus when the annunciator test button is depressed. Pressing
the test button while the helicopter is running will confirm that the tachometers are
receiving power from the avionics bus.

NOTE
Do not use magnetized tools.
CAUTION
Protect instrumentation using foam padding or equivalent.
Handle instruments like eggs.

B. Removal
1. Turn battery switch off and pull out TACHS N2 (2 amp) and R (2 amp) circuit
breakers on circuit breaker panel.
2. Remove perimeter screws securing instrument face to console and pull face aft.
3. Remove screws securing console harness connector to F792-1 dual tachometer
and unplug connector.
4. Supporting instrument, remove screws securing tachometer to face, and remove
tachometer.

Page 95.8 Chapter 95 Instrument System APR 2019

95-23 Engine (N2) and Rotor Dual Tachometer (continued)

C. Installation
1. Turn battery switch off and pull out TACHS N2 (2 amp) and R (2 amp) circuit
breakers on circuit breaker panel.
2. Install screws securing F792-1 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. Accuracy Check and Needle Synchronization

CAUTION
Inadvertent engine overspeed can occur if accuracy check is
not performed.

1. Perform PTG rigging check per § 76-22.

2. Install magnetic pickup (or photocell) portion of calibrated main rotor balancing
equipment per § 18-11.
3. Push in TACHS N2 (2 amp) and R (2 amp) circuit breakers on circuit breaker panel.
Turn battery switch on, open throttle, and “beep” actuator to minimum (RPM)
setting. Close throttle and turn battery switch off.
4. a. Start engine and run-up helicopter per R66 Pilot’s Operating Handbook (POH)
Section 4, establish stable idle, and record dual tachometer’s % N2 indication.
Also record RPM displayed on balancer.
b. Multiply dual tachometer’s % N2 indication (use 0.69 for 69%, 0.70 for 70%,
etc.) by 408 RPM. Verify calculated RPM is within ± 8 RPM displayed on
balancer.
c. If calculated RPM is more than ± 8 RPM displayed on balancer, shut down
helicopter per POH Section 4. Do not proceed further; contact RHC Technical
Support.
5. Monitor RPM displayed on balancer and increase throttle to full open. Immediately
close throttle and shut down helicopter per POH Section 4 if balancer indication
exceeds 412 RPM.
6. Monitor RPM displayed on balancer and “beep” actuator until dual tachometer
indicates 100% N2. Verify RPM displayed on balancer is 408 ± 4 RPM; do not
exceed 412 RPM.

APR 2019 Chapter 95 Instrument System Page 95.9

95-23 Engine (N2) and Rotor Dual Tachometer (continued)
D. Accuracy Check and Needle Synchronization (continued)
7. Verify dual tachometer’s % NR indication is within 1% of % N2 indication. If
required, adjust % NR by turning screw on back of tachometer. Turning screw
clockwise increases % NR and turning screw counterclockwise decrease % NR;
one-half turn equals approximately 1% change. Adjusting screw is accessed by
removing instrument face perimeter screws and pulling face aft.
8. Shut down helicopter per R66 POH Section 4.
9. Install perimeter screws securing face to console. Verify security.

E. Scheduled Maintenance and Inspections

Refer to § 5-45 100-Hour/Annual Inspection.
Refer to § 4-22 for recommended replacement time between overhauls.

F. Special Maintenance and Inspections

1. Perform accuracy check and needle synchronization 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.

Page 95.10 Chapter 95 Instrument System APR 2019

95-24 Altimeter

A. Description
The sensitive altimeter provides altitude information relative to mean sea level when
the barometric pressure correction scale is properly set. Check altimeter calibration
by setting correction scale to the current altimeter setting and checking the altimeter
reading against field elevation; they must agree within 70 feet.

B. Schematic
Refer to Figure 95-3 for pitot-static system schematic.

C. Removal
Remove altimeter per § 95-21 Part C.

D. Installation
Install altimeter per § 95-21 Part D.

E. Scheduled Maintenance and Inspections

Refer to § 5-45 100-Hour/Annual Inspection.

F. Special Maintenance and Inspections

1. If altimeter displays no indication:
a. Inspect static lines for obstructions and remove obstructions if found.
b. Perform pitot-static system checks as required per § 95-10.
c. Perform appropriate function checks per § 5-40. 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.
b. Perform pitot-static system checks as required per § 95-10.
c. Perform appropriate function checks per § 5-40. If altimeter still displays erratic
indication, remove altimeter per Part C, and return to RHC for inspection.
d. Install airworthy altimeter per Part D.

APR 2017 Chapter 95 Instrument System Page 95.11

95-25 Torquemeter

A. Description
The electronic torquemeter indicates percent torque. The torque sensor is an oil
pressure transducer mounted on the front of the engine’s accessory gearbox.

B. Schematic
Refer to Figure 98-1 for electrical schematic.

C. Removal
Remove torquemeter per § 95-21 Part C.

D. Installation
Install torquemeter per § 95-21 Part D.

E. Scheduled Maintenance and Inspections

Refer to § 5-45 100-Hour/Annual Inspection.

F. Special Maintenance and Inspections

1. Inspect wiring for loose, chafed, frayed, or broken wires. Verify no damaged
connectors. Verify wiring neatness, proper routing and installation, and security.
2. Perform appropriate function checks per § 5-40. If accuracy of torquemeter is
suspected, remove torquemeter per Part C, and check calibration per Figure 95-3A.
3. Install airworthy torquemeter per Part D.

PIN FUNCTION % TORQUE* SIGNAL (VDC)*

1 SPARE 0 0.480
2 GND 20 0.914
3 CASE GND 40 1.347
4 SHIELD 60 1.781
5 SPARE 80 2.214
6 +POWER 83 2.279
7 +POWER 100 2.648
8 SIGNAL LO 120 3.081
9 SIGNAL HI
* Accuracy is ± 0.5% at 20% and 100%;
± 2% elsewhere.

FIGURE 95-3A TORQUEMETER CALIBRATION CHECK

Page 95.12 Chapter 95 Instrument System APR 2017

95-26 Magnetic Compass
A. Description
An internally illuminated, wet-type compass is attached to the center bow between
the windshields above the instrument panel.

B. Schematic
Refer to Figure 98-1 for electrical schematic.

C. Removal
1. Remove hardware securing B339-2 mount to windshield bow.
2. Remove hardware securing B148-5 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 B148-5 compass assembly’s light bar
wires to airframe harness. Verify security. Activate heat shrinks.
2. Install hardware securing compass to B339-2 mount. Verify security.
3. Install hardware securing mount to windshield bow. Verify security.
4. 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.

E. Scheduled Maintenance and Inspections

Refer to § 5-45 100-Hour/Annual Inspection.

F. Special Maintenance and Inspections

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.

APR 2017 Chapter 95 Instrument System Page 95.13

95-30 Engine Gages

95-31 N1 Tachometer

A. Description
The electronic N1 tachometer indicates percent RPM of the engine’s gas producer
section. The N1 sensor is a sealed variable-reluctance, permanent-magnet device
mounted atop the engine’s accessory gearbox adjacent to the hoisting lug.

B. Schematic
Refer to Figure 98-1 for electrical schematic.

C. Removal
1. Turn battery switch off and pull out applicable circuit breaker(s).
2. Remove screws securing upper console to lower console and tilt upper console
aft.
3. Loosen screws securing console wiring connector to G144-6 instrument cluster
and disconnect wiring.
4. Remove screws securing instrument cluster to G051 shell assembly’s face plate
and remove instrument cluster.

D. Installation
1. Turn battery switch off and pull out applicable circuit breaker(s).
2. Remove screws securing upper console to lower console and tilt upper console
aft.
3. Position G144-6 instrument cluster on G051 shell assembly’s face plate and
install screws. Verify security.
4. Connect console wiring connector to G144-6 instrument cluster tighten connector
screws. Verify security.
5. Tilt console forward and install screws securing upper console to lower console.
Verify security.
6. Perform appropriate function checks per § 5-40.

E. Scheduled Maintenance and Inspections

Refer to § 5-45 100-Hour/Annual Inspection.

Page 95.14 Chapter 95 Instrument System APR 2017

95-31 N1 Tachometer (continued)

F. Special Maintenance and Inspections

1. Inspect wiring for loose, chafed, frayed, or broken wires. Verify no damaged
connectors. Verify wiring neatness, proper routing and installation, and security.
2. Perform appropriate function checks per § 5-40. If accuracy of engine gage is
suspected, remove G144-6 instrument cluster per Part C, and return to RHC for
inspection.
3. Install airworthy instrument cluster per Part D.

95-32 Measured Gas (Turbine) Temperature (MGT) Gage

A. Description
The measured gas temperature (MGT) gage connects to the engine’s thermocouple
harness via different size connectors to ensure correct polarity. Refer to RR300 Series
Operation and Maintenance Manual (OMM) for periodic calibration requirements.

B. Schematic
Refer to Figure 98-1 for electrical schematic.

C. Removal
Remove G144-6 instrument cluster per § 95-31 Part C.

D. Installation
Install G144-6 instrument cluster per § 95-31 Part D.

E. Scheduled Maintenance and Inspections

Refer to § 5-45 100-Hour/Annual Inspection.

F. Special Maintenance and Inspections

Perform special maintenance and inspections per § 95-31 Part F.

APR 2017 Chapter 95 Instrument System Page 95.15

95-33 Engine Oil Pressure Gage

A. Description
The engine oil pressure gage is electronic. The oil pressure sensor is a transducer
mounted on the lower front of the engine’s accessory gearbox.

B. Schematic
Refer to Figure 98-1 for electrical schematic.

C. Removal
Remove G144-6 instrument cluster per § 95-31 Part C.

D. Installation
Install G144-6 instrument cluster per § 95-31 Part D.

E. Scheduled Maintenance and Inspections

Refer to § 5-45 100-Hour/Annual Inspection.

F. Special Maintenance and Inspections

Perform special maintenance and inspections per § 95-31 Part F.

95-34 Engine Oil Temperature Gage

A. Description
The engine oil temperature gage is electronic. The oil temperature sensor is a
transducer mounted on the inboard wall of the oil tank.

B. Schematic
Refer to Figure 98-1 for electrical schematic.

C. Removal
Remove G144-6 instrument cluster per § 95-31 Part C.

D. Installation
Install G144-6 instrument cluster per § 95-31 Part D.

E. Scheduled Maintenance and Inspections

Refer to § 5-45 100-Hour/Annual Inspection.

F. Special Maintenance and Inspections

Perform special maintenance and inspections per § 95-31 Part F.

Page 95.16 Chapter 95 Instrument System APR 2017

95-35 Fuel Quantity Gage

A. Description
The electric fuel quantity gage indicates relative fuel quantity. The variable resistance
sender is mounted near the fuel cap.

B. Schematic
Refer to Figure 98-1 for electrical schematic.

C. Removal
Remove G144-6 instrument cluster per § 95-31 Part C.

D. Installation
Install G144-6 instrument cluster per § 95-31 Part D.

E. Scheduled Maintenance and Inspections

Refer to § 5-45 100-Hour/Annual Inspection.

F. Special Maintenance and Inspections

Perform special maintenance and inspections per § 95-31 Part F.

APR 2017 Chapter 95 Instrument System Page 95.17

95-40 Additional Standard Indicating Equipment

95-41 Clock

A. Description
A manually set electric analog clock is standard equipment; a digital clock is optional.

B. Schematic
Refer to Figure 98-1 for electrical schematic.

C. Removal
1. Remove perimeter screws securing face to console and pull face aft, or remove
screws securing upper console to lower console and tilt upper console aft, as
applicable.
2. Remove screws securing clock to face.
3. Disconnect console wiring from clock wiring at connectors, and remove clock.

D. Installation
1. Connect console wiring to clock wiring at connectors. Verify security.
2. Install screws securing clock to face. Verify security.
3. Install perimeter screws securing face to console and verify security, or tilt console
forward and install screws securing upper console to lower console and verify
security, as required.

E. Scheduled Maintenance and Inspections

Refer to § 5-45 100-Hour/Annual Inspection.

F. Special Maintenance and Inspections

1. Check AGC-3 (3 amp) fuse at firewall for evidence of melting and replace fuse 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 clock is still inoperative, remove clock per Part C, and install airworthy clock per
Part D.

Page 95.18 Chapter 95 Instrument System APR 2017

95-42 Ammeter

A. Description
The ammeter indicates electrical system loads. System load is measured across the
A780-71 cable (shunt; cable is calibrated, do not alter cable) located between the
starter/generator and relay on right side of engine compartment.

B. Schematic
Refer to Figure 98-1 for electrical schematic.

C. Removal
1. Remove perimeter screws securing face to console and pull face aft, or remove
screws securing upper console to lower console and tilt upper console aft, as
applicable.
2. Remove screws securing ammeter to face.
3. Disconnect console wiring from ammeter wiring at connectors, and remove
ammeter.

D. Installation
1. Connect console wiring to ammeter wiring at connectors. Verify security.
2. Install screws securing ammeter to face. Verify security.
3. Install perimeter screws securing face to console and verify security, or tilt console
forward and install screws securing upper console to lower console and verify
security, as required.

E. Scheduled Maintenance and Inspections

Refer to § 5-45 100-Hour/Annual Inspection.

F. Special Maintenance and Inspections

1. Check continuity across two 3-amp fuses in B304-16 fuse assembly (in airframe
harness on right side of engine compartment) 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.

APR 2017 Chapter 95 Instrument System Page 95.19

95-43 Outside Air Temperature (OAT) Gage/Voltmeter

A. Description

NOTE
No cutting or splicing of OAT probe wires is permitted.

The outside air temperature gage is connected via a calibrated, twisted pair wiring
harness to a stainless steel probe protruding from the chin.

B. Schematic
Refer to Figure 98-1 for electrical schematic.

C. Removal
1. Remove perimeter screws securing face to console and pull face aft, or remove
screws securing upper console to lower console and tilt upper console aft, as
applicable.
2. Remove screws securing OAT gage to face.
3. Disconnect console wiring from OAT gage wiring at connectors, and remove
gage.

D. Installation
1. Connect console wiring to OAT gage wiring at connectors. Verify security.
2. Install screws securing OAT gage to face. Verify security.
3. Install perimeter screws securing face to console and verify security, or tilt console
forward and install screws securing upper console to lower console and verify
security, as required.

E. Scheduled Maintenance and Inspections

Refer to § 5-45 100-Hour/Annual Inspection.

F. Special Maintenance and Inspections

1. Inspect wiring for loose, chafed, frayed, or broken wires. Verify no damaged
connectors. Verify wiring neatness, proper routing and installation, and security.
2. If OAT gage is still inoperative, remove OAT gage per Part C, and install airworthy
OAT gage per Part D.

Page 95.20 Chapter 95 Instrument System APR 2017

95-44 Hourmeters
A. Description
Two hourmeters are standard. One hourmeter is mounted above the ammeter and
is activated by main gearbox oil pressure. Another hourmeter on the horizontal
panel outboard of the pilot’s seat is activated by a combination of main gearbox oil
pressure and a raised collective and is approved for recording time in service.
B. Schematic
Refer to Figure 98-1 for electrical schematic.
C. Removal
Collective-Activated Hourmeter
1. Remove screws securing hourmeter, faceplate, and carpet to F353-2 panel.
2. Disconnect airframe wiring from hourmeter wiring at connectors, and remove
hourmeter.
Console Hourmeter
1. Remove screws securing hourmeter to F640 face assembly, remove screws
securing face to lower console, and supporting hourmeter, remove face.
2. Disconnect airframe wiring from hourmeter, and remove hourmeter.
D. Installation
Collective-Activated Hourmeter
1. Connect airframe wiring to hourmeter wiring at connectors. Verify security.
2. Install screws securing hourmeter, faceplate, and carpet to F353-2 panel. Verify
security.
Console Hourmeter
1. Connect airframe wiring to hourmeter (F859-2053 to positive terminal). Verify
security.
2. Install screws securing F640 face assembly to lower console. Install screws
securing hourmeter to face. Verify security.
E. Scheduled Maintenance and Inspections
On condition.
F. Special Maintenance and Inspections
1. Inspect wiring for loose, chafed, frayed, or broken wires. Verify no damaged
connectors. Verify wiring neatness, proper routing and installation, and security.
2. If hourmeter is still inoperative, remove hourmeter per Part C, and install airworthy
hourmeter per Part D. Make appropriate maintenance record entries.

JUL 2020 Chapter 95 Instrument System Page 95.21

95-50 Console Assemblies

NOTE
Refer to R66 Pilot's Operating Handbook Section 7 for views of
typical instrument panels, and the Optional Avionics Supplement
for views of panels with electronic flight displays.

A. Opening Console
Upper instrument panels that do not include Electronic Flight Displays (EFDs) or other
avionics may be "opened" by removing screws securing console assembly to forward
keel panels and hinging console aft. Secure console by hinging forward and installing
screws. If an EFD or any other avionics are installed in the upper instrument panel,
remove console per Part B.
B. Removing Console
1. Remove EFD if installed per § 95-70.
2. Remove avionics if installed and located in upper instrument console per Chapter 97.
3. Remove HeliSAS control panel if installed and located in upper instrument console
(not required if control panel is located at top of avionics stack).
4. Remove perimeter screws securing instrument face to console.
5. Disconnect instrument pitot-static lines. Plug lines.
6. Remove screws securing console assembly to forward keel panels and lower panel.
Remove console and disconnect console harness from airframe harness.
C. Installing Console
1. Connect console assembly harness to airframe harness and install screws securing
console to forward keel panels and lower panel.
2. Position instrument face in helicopter, remove plugs, and connect pitot-static lines.
3. Install perimeter screws securing face to console. Verify security.
4. Install HeliSAS control panel, if removed.
5. Install avionics per Chapter 97, if removed.
6. Install EFD per § 95-70, if removed.
7. Perform pitot-static system leak check per § 95-10.

95-60 Instrument Markings

See R66 Pilot’s Operating Handbook (POH) Section 2 for instrument markings.

Page 95.22 Chapter 95 Instrument System JUL 2020

Intentionally Blank

APR 2019 Chapter 95 Instrument System Page 95.23

FIGURE 95-4 GARMIN G500H UPPER CONSOLE WITH GDU 1060

FIGURE 95-5 GARMIN G500H UPPER CONSOLE PITOT-STATIC SCHEMATIC

Page 95.24 Chapter 95 Instrument System APR 2019

95-70 Electronic Flight Displays

95-71 Garmin Display Unit (GDU) 1060

NOTE
Refer to Garmin G500H Instructions for Continued Airworthiness.

A. Description
The GDU 1060 integrates with the Garmin G500H Electronic Flight Instrument
System (EFIS). Similar to the GDU 620, the GDU 1060 electronically displays primary
flight instrumentation via a primary flight display (PFD) and moving map, weather,
traffic, terrain and other functionality via a multifunction display (MFD), but includes
touch-screen technology on one large 10.6 inch display. A larger instrument panel
accommodates the larger display.
Refer to § 97-10 for Garmin G500H EFIS system components.
B. Schematics
Refer to Figure 98-9 for GDU 1060 installation electrical schematic.
Refer to Figures 95-3 & 95-5 for Garmin G500H upper console pitot-static schematic.
C. Removal
1. Turn battery & avionics switches off and pull out EFIS circuit breaker (5 amp) on
circuit breaker panel.
2. Remove screws securing GDU to console face.
3. Pull out and support display, unplug console harness connectors, and remove display.
D. Installation
1. Turn battery & avionics switches off and pull out EFIS circuit breaker (5 amp) on
circuit breaker panel.
2. Visually inspect console harness connectors and verify no bent or damaged pins.
Support display and plug in console harness connectors.
3. Place GDU in console, then install and tighten screws. Verify security.
4. Push in EFIS circuit breaker on circuit breaker panel. Turn battery & avionics
switches on.
5. Perform appropriate functional checks per Garmin G500H Instructions for
Continued Airworthiness. Turn battery & avionics switches off.

APR 2019 Chapter 95 Instrument System Page 95.25

FIGURE 95-6 GARMIN G500H UPPER CONSOLE WITH GDU 620

95-71 Garmin Display Unit (GDU) 1060 (continued)

E. Scheduled Maintenance and Inspections
Refer to Garmin G500H Instructions for Continued Airworthiness.

Page 95.26 Chapter 95 Instrument System APR 2019

95-71 Garmin Display Unit (GDU) 1060 (continued)
F. Special Maintenance and Inspections
1. Remove GDU per § 95-71 Part C.
2. Open circuit breaker panel and upper console.
3. Inspect condition of and verify no obvious damage to GDU, copper bus bars,
circuit breaker, and wiring. Verify no loose, chafed, or broken wires or terminals.
Verify no evidence of arcing. Verify installed equipment security.
4. Secure circuit breaker panel and upper console.
5. Install GDU per § 95-71 Part D.

95-72 Garmin Display Unit (GDU) 620 Installation

NOTE
Refer to Garmin G500H Instructions for Continued Airworthiness.

A. Description
The GDU 620 integrates with the Garmin G500H Electronic Flight Instrument System
(EFIS). The GDU 620 electronically displays primary flight instrumentation via a
primary flight display (PFD) and moving map, weather, traffic, terrain and other
functionality via a multifunction display (MFD) on dual 6.5 inch displays.
Refer to § 97-10 for Garmin G500H EFIS system components.
B. Schematics
Refer to Figure 98-10 for GDU 620 installation electrical schematic.
Refer to Figures 95-3 & 95-5 for Garmin G500H upper console pitot-static schematic.
C. Removal
Remove GDU per § 95-71 Part C.
D. Installation
Install GDU per § 95-71 Part D.
E. Scheduled Maintenance and Inspections
Refer to Garmin G500H Instructions for Continued Airworthiness.
F. Special Maintenance and Inspections
Refer to § 95-71 Part F.

APR 2019 Chapter 95 Instrument System Page 95.27

FIGURE 95-7 EIGHT-INSTRUMENT CONSOLE WITH ASPEN PFD

FIGURE 95-8 EIGHT-INSTRUMENT CONSOLE WITH ASPEN PFD PITOT-STATIC SCHEMATIC

Page 95.28 Chapter 95 Instrument System APR 2019

95-73 Aspen EFD500H & EFD1000H Display(s) Installation
A. Description
R66 options include a single screen Aspen PFD, or a dual-screen Aspen PFD and MFD.
The Aspen PFD (Primary Flight Display) is an LCD unit with displays for attitude,
altitude, airspeed, heading, and optional NAV (HSI/CDI). 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). Primary GPS position data is provided by GTN-
series GPS. Heading and outside air temperature data is received from the Aspen
remote sensor module (RSM). The RSM provides backup GPS position data if primary
GPS fails.
The Aspen MFD (Multifunction Display) is an LCD unit with displays for moving
map navigation data, terrain, and traffic. Terrain and traffic may also be overlaid on
moving map. GPS position data is provided by Garmin GTN-series GPS for moving
map and terrain displays. Aspen MFD also includes an internal terrain database.
TIS-A traffic data may be received from Garmin GTX330 transponder for moving
map display.

FIGURE 95-9 SIX-INSTRUMENT CONSOLE WITH ASPEN PFD PITOT-STATIC SCHEMATIC

APR 2019 Chapter 95 Instrument System Page 95.29

FIGURE 95-10 EIGHT-INSTRUMENT CONSOLE WITH ASPEN PFD AND MFD

FIGURE 95-11 EIGHT-INSTRUMENT CONSOLE WITH ASPEN PFD AND MFD PITOT-STATIC SCHEMATIC

Page 95.30 Chapter 95 Instrument System APR 2019

95-73 Aspen EFD500H & EFD1000H Display(s) Installation (continued)
B. Schematics
Refer to Figure 98-19 for Aspen EFD500H Display Installation electrical schematic,
and Figure 98-18 for Aspen EFD1000H Display Installation electrical schematic.
Refer to Figures 95-3, 95-8, and 95-9 for Aspen PFD pitot-static schematic, and
Figures 95-3 and 95-11 for Aspen MFD pitot-static schematic.
C. Removal
1. Turn battery switch off and pull-out EFIS circuit breaker (7.5 amp) on circuit
breaker panel.
2. Gently depress blue tab(s) at top of Aspen PFD/MFD to release display(s) from
mounting bracket(s).
3. PFD only: 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(s) to display(s), unplug
connector(s), and remove display(s).
D. Installation
1. Turn battery switch off and pull-out EFIS circuit breaker (7.5 amp) on circuit
breaker panel.
2. Plug airframe wiring harness connector(s) into Aspen PFD/MFD display(s) and
tighten screws. Verify security.
3. PFD only: Remove temporary fitting caps and connect pitot and static lines to
display using quick-disconnect couplers.
4. Insert display(s) into mounting bracket(s) until blue tab(s) snap(s) into place.
Verify security.
5. Push-in EFIS circuit breaker (7.5 amp) on circuit breaker panel. Turn battery &
avionics switches on.
6. Perform appropriate functional checks per Aspen EFD1000H PFD / EFD500H
MFD Pilot's Guide. Turn battery and avionics switches off.
7. Perform pitot-static leak check.

APR 2019 Chapter 95 Instrument System Page 95.31

95-73 Aspen EFD500H & EFD1000H Display(s) Installation (continued)
E. Remote Sensor Module (RSM) Antenna

NOTE
Do not use magnetized tools.
Removal
1. Turn battery switch off and pull-out EFIS circuit breaker (7.5 amp) on circuit
breaker panel.
2. Refer to § 6-80 for antenna locations. Using plastic scraper, remove B270-1
sealant from around EFIS antenna at corners where it attaches to tailcone.
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
1. Turn battery switch off and pull-out EFIS circuit breaker (7.5 amp) on circuit
breaker panel.
2. Remove paint & 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 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 § 97-60 for avionics software information.

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.

Page 95.32 Chapter 95 Instrument System APR 2019

CHAPTER 96

ELECTRICAL SYSTEM
Section Title Page

96-00 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96.1

96-10 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96.3
96-11 Lead-Acid Battery Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96.3
96-12 Lithium-Ion Battery Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96.7
96-20 External Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96.9
96-30 Starter and Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96.9
96-40 Lighting System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96.10
96-50 Annunciator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96.10
96-60 Low Rotor RPM Warning Unit Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 96.12
96-70 Audio System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96.12
96-80 Engine Monitoring Unit (EMU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96.13
96-90 Emergency Locator Transmitter (ELT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96.14
96-100 Electrical Load Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96.15
96-110 Audio Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96.18

JUL 2020 Chapter 96 Electrical System Page 96.i

Intentionally Blank

Page 96.ii Chapter 96 Electrical System JUL 2020

CHAPTER 96

ELECTRICAL SYSTEM

96-00 Description

CAUTION
The installation of electrical devices can affect the accuracy
and reliability of the electronic tachometer.

A 28-volt DC electrical system is standard. Primary system components are a sealed

lead-acid battery, a starter-generator, and a generator control unit. The battery is located
beneath the left front seat or in a compartment in the left side of the baggage compartment.
The circuit breaker panel is on the ledge just forward of the left front 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 connects the battery to the electrical
system. A wire protected by a fuse near the battery bypasses the battery relay to allow
the tachometers and clock to receive battery power with the battery switch OFF.
The avionics switch controls power to avionics. This allows avionics to be switched
OFF via a single switch. Having sensitive electrical equipment off when the generator is
switched ON protects against voltage spikes.
An ammeter indicates total generator output. A digital voltmeter which reads main bus
voltage at the circuit breaker panel is incorporated as part of the OAT indicator. Normal
indication is 27.3 to 28.7 volts with the generator ON.
A generator control unit (GCU) controls starter-generator function. Below 58 percent N1
RPM, the GCU is in start mode regardless of generator switch position. Above 58 percent,
the GCU automatically switches to generate mode. The generator switch should normally
be off for starting to prevent applying generator load to the engine before reaching idle RPM.

APR 2019 Chapter 96 Electrical System Page 96.1

FIGURE 96-1A B237-7 (LEAD-ACID) BATTERY INSTALLATION

Page 96.2 Chapter 96 Electrical System APR 2019

96-10 Battery

96-11 Lead-Acid Battery Installations

NOTE
Refer to Concorde Battery Corporation's Owner/Operator's
Manual, and Instruction for Continued Airworthiness for battery
maintenance procedures.
CAUTION
B237-7 battery (19 AH) weighs 42 lb and B237-8 battery (25
AH) weighs 52 lb including electrolyte. Carefully remove/install
battery using handle provided to prevent injury.
CAUTION
Use insulated tools when performing maintenance near battery.
When removing or installing G131-2 and G131-4 plate, use
caution not to contact battery terminals with tools.
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

1. Turn battery switch off. Open baggage compartment door. Remove auxiliary
fuel tank per § 28-51, if installed.
2. Refer to Figure 96‑1A & 96-1B. Remove G248-8 cover assembly.
3. Remove hardware securing negative (ground) cable to battery negative terminal
(B237-7 battery) or G131-5 terminal assembly (B237-8 battery).
4. Remove hardware securing positive cable to battery positive terminal. Carefully
remove battery. Remove G131-5 terminal assembly (B237-8 battery), as required.
B. Installing and Connecting Battery
1. Turn battery switch off. Open baggage compartment door. Refer to Figure
96‑1A & 96-1B.
a. If B237-7 battery was removed and B237-8 battery is being installed:
Remove G131-4 plate and install G131-2 plate as shown; verify security. If
not previously installed, verify battery terminal is clean and install G131‑5
terminal assembly; special torque bolt per battery decal. Carefully install
B237-8 battery.

APR 2019 Chapter 96 Electrical System Page 96.3

FIGURE 96-1B B237-8 (LEAD-ACID) BATTERY INSTALLATION

Page 96.4 Chapter 96 Electrical System APR 2019

96-11 Lead-Acid Battery Installations (continued)
B. Installing and Connecting Battery (continued)
1. b. If B237-8 battery was removed and B237-7 battery is being installed:
Remove G131-2 plate and install G131-4 plate as shown; verify security.
Carefully install B237-7 battery.
c. If battery being installed is same part number as battery removed: Verify
installation and security of parts. Carefully install battery.
2. Verify G131-2 or G131-4 plate just contacts top of battery (holes are slotted).
Adjust as required; verify security.
3. Verify negative (ground) cable is attached to airframe and routed as shown.
Adjust as required.
4. Verify battery terminal is clean and install positive cable on battery positive
terminal. Special torque bolt per battery decal and torque stripe per Figure 5-1.
Slide insulating nipple over attached terminal.
5. Verify battery terminal is clean and install negative (ground) cable on battery
negative terminal (B237-7 battery) or G131-5 terminal assembly (B237-8 battery),
routing negative (ground) cable as shown. Special torque bolt per battery decal
and torque stripe per Figure 5-1.
6. Install G248-8 cover assembly; verify security. Install auxiliary fuel tank per §
28-51, as required. Close baggage compartment door.
7. a. If B237-7 battery was removed and B237-8 battery was installed: Revise
Weight and Balance Record in R66 Pilot’s Operating Handbook (POH) Section
6 to incorporate the following data:
Subtract:
Item Weight Long. Arm Long. Moment Lat. Arm Lat. Moment
B237-7 Battery 42.00 lb 96.88 in. 4068.96 in.-lb -20.87 in. -876.54 in.-lb
Add:
Item Weight Long. Arm Long. Moment Lat. Arm Lat. Moment
B237-8 Battery 52.00 lb 96.88 in. 5037.76 in.-lb -21.73 in. -1129.96 in.-lb

b. If B237-8 battery was removed and B237-7 battery was installed: Revise
Weight and Balance Record in R66 Pilot’s Operating Handbook (POH) Section
6 to incorporate the following data:
Subtract:
Item Weight Long. Arm Long. Moment Lat. Arm Lat. Moment
B237-8 Battery 52.00 lb 96.88 in. 5037.76 in.-lb -21.73 in. -1129.96 in.-lb
Add:
Item Weight Long. Arm Long. Moment Lat. Arm Lat. Moment
B237-7 Battery 42.00 lb 96.88 in. 4068.96 in.-lb -20.87 in. -876.54 in.-lb

APR 2019 Chapter 96 Electrical System Page 96.4A

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Page 96.4B Chapter 96 Electrical System APR 2019

Intentionally Blank

JUL 2020 Chapter 96 Electrical System Page 96.5

FIGURE 96-2 LITHIUM-ION BATTERY INSTALLATION

Page 96.6 Chapter 96 Electrical System JUL 2020

96-12 Lithium-Ion Battery Installation
A. Description
The True Blue Power (a division of Mid-Continent Instrument Company) TB17 Lithium-
ion battery is a 24-volt, 17 amp-hour battery, and weighs 15.6 lb.
In addition to significant weight savings (the R66 standard lead-acid battery weighs
42 lb), lithium batteries feature improved starter performance as well as cooler starts.
A dedicated vent line ensures proper venting of toxic or flammable gases in the
unlikely event of a battery internal failure.
A 7-pin “comm” connector sends signals to the console indicator lights. In cold
weather, a heater light may illuminate when the battery is switched on, indicating that
the lithium battery’s internal battery is automatically warming the battery cells to an
optimal starting temperature. It is recommended that the heater light is extinguished
prior to attempting an engine start.
The battery’s internal circuitry is self-monitoring and will switch itself off when it
reaches a certain low state of charge (SOC). In that event, two commercial, non-
rechargeable, 9-volt batteries mounted under the co-pilot’s seat will supply backup
power to the EMU and MGT gage. Though not critical for flight safety, power to
these units ensures the recording of a gas temperature exceedence were one to
occur during engine start.

NOTE
Refer to True Blue Power Installation Manual and Operating
Instructions 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.

B. Disconnecting and Removing Battery

1. Remove auxiliary fuel tank per § 28-51, if installed.
2. Turn battery switch off. Open baggage compartment door.
3. Remove hardware securing G248-8 cover assembly and remove cover.
4. Loosen clamp securing vent hose to battery and pull hose off of battery.
5. Disconnect airframe wiring plug from battery’s comm connector.
6. Remove hardware securing negative (ground) cable to battery negative terminal.
7. Slide nipple away from battery positive terminal and remove hardware securing
positive cable to battery positive terminal. Carefully remove battery.

JUL 2020 Chapter 96 Electrical System Page 96.7

96-12 Lithium-Ion Battery Installation (continued)
C. Installing and Connecting Battery
1. Remove auxiliary fuel tank per § 28-51, if installed.
2. Perform pre-installation inspection and completely charge battery per True Blue
Power Installation Manual and Operating Instructions. If battery is new, also
perform visual inspection, charging, capacity check, and return to service per
True Blue Power Installation Manual and Operating Instructions.
3. Turn battery switch off. Open baggage compartment door.
4. Refer to Figure 96-2. Verify security, proper orientation, and installation of
G131‑9 plate. Carefully install battery.
5. Verify G131-9 plate just contacts top of battery (holes are slotted). Adjust as
required.
6. Verify battery terminal surfaces are clean to ensure electrical conductivity. Install
positive cable on battery positive terminal and install battery hardware. Special
torque terminal bolt as noted on battery label, and torque stripe per Figure 5-1.
Slide nipple over terminal.
7. Install negative (ground) cable to battery negative terminal and install battery
hardware. Special torque terminal bolt as noted on battery label, and torque
stripe per Figure 5-1.
8. Install G248-8 cover assembly and install hardware. Verify security. Close and
latch baggage compartment door.

D. Scheduled Maintenance and Inspections

Every 6 Months: If battery is unused for more than 6 months, either installed in
helicopter or in storage, completely charge battery per True Blue Power Installation
Manual and Operating Instructions.
Every Annual Inspection: Replace two, non-rechargeable, 9-volt batteries mounted
under the co-pilot’s seat every annual inspection.
Every 24 Months: Perform visual inspection, charging, capacity check, and return to
service per True Blue Power Installation Manual and Operating Instructions every 24
months from date of aircraft delivery or subsequent new battery installation.

Page 96.8 Chapter 96 Electrical System JUL 2020

96-12 Lithium-Ion Battery Installation (continued)
E. Special Maintenance and Inspections
No other battery maintenance other than routine maintenance specified by True Blue
Power is permitted.
Operators are encouraged to review important safety information regarding handling,
shipping, storage instructions, estimated unit life, and disposal instructions provided
in True Blue Power Installation Manual and Operating Instructions.
Note: In accordance with industry and regulatory standards, the TB17 Lithium-ion
battery will be shipped with a state of charge (SOC) not to exceed 30% of rated
capacity.

96-20 External Power

A 28-volt MS3506-compatible external power receptacle is located inside the right engine
cowl door. When the battery is switched ON, the external power relay and the battery
relay both close, connecting external power to the aircraft electrical system and battery
The external power relay will not close if reverse polarity is provided to the receptacle.
A separate wire from the external power receptacle to the battery bypasses the external
power and battery relays. This wire allows battery charging via the external receptacle
with the battery switch OFF. A 10-amp circuit breaker at the receptacle opens if current
exceeds normal charging levels, and a diode provides polarity protection.

96-30 Starter and Ignition System

A single starter-generator is used for engine starting and electrical power generation. A
generator control unit (GCU) controls starter-generator function. During a start, the GCU
latches the starter on until N1 reaches 58 percent RPM. Therefore, the pilot is not required to
hold the start button down throughout the start sequence. Above 58 percent N1 RPM, the GCU
automatically switches out of start mode, but the generator switch should not be switched ON
until idle RPM stabilizes to prevent the generator load from bringing the RPM down.
When the igniter key switch is in the enable position, depressing the start button causes a
normal start sequence with the starter latching on and the igniter firing. Above 58 percent
N1 RPM, the igniter will fire while the start button is depressed.
When the igniter switch is OFF, the engine can be motored by the starter by depressing the
start button without the starter latching or the igniter firing. This is useful for performing
a compressor wash or rinse. If the igniter is switched OFF during a start, the starter will
disengage. If the igniter is switched OFF while the engine is running, the engine will
continue to run; however, this is not recommended.

NOTE
Start button is active when battery switch is ON, even if igniter
switch is OFF. Rotor brake may be left engaged after shutdown
to disable start button.

APR 2017 Chapter 96 Electrical System Page 96.9

96-40 Lighting System
A red anti-collision light is installed on the tailcone and is controlled by the strobe switch on
the instrument console. Position lights are installed on each side of the cabin and in the tail
and are controlled by the nav lights switch. A light at the top of the windshield and post
lights illuminate the instrument panel. Panel 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 with high and low settings.
The map light may be used for emergency lighting of the instrument panel. An additional
cabin light with an adjacent switch is located just aft of the map light. The map and cabin
lights are not connected to the dimmer circuit.
Two long-life, high intensity discharge (HID) landing lights are installed in the nose. One
wide-angle and one narrow-beam light are used to increase lighted area. The landing light
switch is located on the cyclic center post.

NOTE
Continuous operation of landing and position lights in flight is
recommended to promote collision avoidance.

An optional flashing light may be mounted on the tailcone in addition to the standard anti-
collision light. The optional light is controlled by an additional position on the strobe switch
and may be turned on or off anytime at pilot discretion.

96-50 Annunciator Panel

The annunciator panel consists of illuminated segments located at the top of the main
instrument panel. If a caution or warning condition occurs, the appropriate segment(s)
illuminate indicating the nature of the problem.
The CHIP segments are illuminated by magnetic chip devices in each gearbox which collect
metallic particles in order to complete an electric circuit. The engine gearbox has two
magnetic chip detectors, either of which can illuminate the ENGINE CHIP segment.
The MR TEMP/PRESS segment is illuminated by either the temperature switch or oil pressure
switch at the main gearbox. The ENGINE FIRE segment is illuminated by a temperature
switch in the engine compartment. The ENGINE OIL segment is activated by a pressure
switch which is independent of the oil pressure sender. The ANTI-ICE segment illuminates
via a pressure switch in the engine anti-ice air line. The GEN segment illuminates when the
generator is disconnected from the main electrical bus.
The LOW FUEL segment is illuminated by a float switch in the tank which is independent
of the fuel quantity sender. The FUEL FILTER segment illuminates when a pressure switch
detects excessive pressure drop across the fuel filter. The LOW RPM segment is illuminated
by a sensor measuring driveline speed at the aft end of the main gearbox. A horn sounds
simultaneously with illumination of the LOW RPM segment when rotor speed is below 95%
RPM. The horn is disabled when the collective is fully down.

Page 96.10 Chapter 96 Electrical System APR 2017

96-50 Annunciator Panel (continued)
A. Description
The COWL DOOR segment is illuminated when the fuel filler cowl door, the right
engine cowl door (which accesses the external power receptacle), or the baggage
door is not closed. The AIR FILTER segment illuminates when pressure drop across
the filter opens bypass doors, allowing unfiltered air to the engine. The EMU (Engine
Monitoring Unit) segment indicates the EMU status with either steady, flashing, or no
illumination. The EMU segment will illuminate only when the test button is depressed.
A push-to-test button on the instrument panel should cause all segments on the
annunciator panel, as well as the ROTOR BRAKE light, to illuminate when depressed.
The LOW FUEL segment takes approximately two seconds before it illuminates due
to a time delay in the circuit (time delay prevents sloshing fuel from giving a false
indication.) The EMU segment takes approximately ten seconds to perform a self-test
after the battery is switched ON before it will illuminate. The test button may be used
on the ground or in flight to verify all circuits are functioning.

B. Troubleshooting
1. Turn battery switch off. Access EMU behind right, aft seatback assembly.
2. Disconnect EMU from airframe electrical harness.
3. Using an insulated jumper, connect airframe wire -2044 (pin 13 on airframe
connector to EMU) to a convenient airframe ground.
4. Turn battery switch on. Depress push-to-test switch adjacent to annunciator panel
and observe EMU annunciator segment response:
a. If EMU annunciator segment illuminates: Turn battery switch off and disconnect
jumper. Replace EMU per § 71-43.
b. If EMU annunciator segment remains extinguished: Turn battery switch off
and disconnect jumper. Proceed to step 5.
5. Turn battery switch on. Depress push-to-test switch and verify system voltage at
wire -2044 (pin 13 on EMU airframe connector). Turn battery switch off. If there is
no system voltage at wire -2044, disconnect F695-4 tester assembly from airframe
electrical harness. Using an insulated jumper, connect airframe wire -2062 (pin 38 on
airframe connector to F695-4/F694-1 circuit board) to a convenient airframe ground.
6. Turn battery switch on. Depress push-to-test switch adjacent to annunciator panel
and observe EMU annunciator segment response:
a. If EMU annunciator segment illuminates: Turn battery switch off and disconnect
jumper. Replace F695-4 tester.
b. If EMU annunciator segment remains extinguished: Turn battery switch off
and disconnect jumper. Proceed to step 7.

APR 2017 Chapter 96 Electrical System Page 96.11

96-50 Annunciator Panel (continued)
B. Troubleshooting (continued)
7. Either an open circuit exists along wire -2062 between F695-1 tester and G198-1
annunciator, or G198-1 annunciator panel is faulty. Troubleshoot beginning with
Console Connector 1 (“C1”), pin 34 and verifying security of pins on both halves
of connector. If no fault is found in connector, verify continuity of wire -2062
at all connections. If no fault is detected in wire -2062 circuit, replace G198-1
annunciator panel.

96-60 Low Rotor RPM Warning Unit Adjustment

The low rotor RPM warning unit is located inside the upper console, mounted to the left
vertical panel. Two magnets attached to the main gearbox tail rotor driveline output yoke
provide an RPM signal for the warning unit’s gearbox-mounted Hall-effect senders. When
the collective is at least 0.2 to 0.4 inch (measured at grip) above the full down position and
rotor RPM is 95% or less, the warning unit illuminates the Low RPM annunciator segment
and sounds two warning horns. Fully lowering the collective will silence both horns, but
will not extinguish the annunciator segment. The Low RPM annunciator segment and both
horns must remain off above 95% rotor RPM.
To make an adjustment, remove the plastic plug (from a 3/8-inch diameter hole) in the left-
vertical panel exterior. Adjust screw on back of warning unit (2 turns equals approximately
1% change).

96-70 Audio System

A five-place audio system is standard. An audio control panel allows control of communication
radios, intercom, and stereo-capable auxiliary audio (e.g. music) input.
The system has four modes of operation. In normal mode, all occupants hear incoming and
outgoing radio communications, intercom, and auxiliary audio. The pilot and copilot can
both transmit on the selected radio.
In crew mode, the pilot and copilot are isolated from rear seat occupants. The crew does
not hear rear seat intercom or auxiliary audio and rear seat occupants do not hear crew
intercom or radio communications.
In pilot isolate mode, the pilot is isolated from all other occupants. The copilot is grouped
with the rear seat occupants for intercom and auxiliary audio.
In emergency mode, the pilot transmits and receives on the number one radio only (regardless
of audio panel switch position). All other audio is disabled.
The first three modes are selectable via the audio control panel. Emergency mode occurs
if power to the panel is lost. In addition to the mode control, the audio panel has controls
for squelch, volume, and selection of transmit and receive radios. A detail description of
these controls can be found in the audio system operation manual.

Page 96.12 Chapter 96 Electrical System APR 2017

96-70 Audio System (continued)
Headset jacks are located in the ceiling near each seat. Pilot and copilot intercom and
transmit are controlled via trigger switches on the cyclic grips. The trigger has two
detents; the first detent activates the intercom and the second detent transmits. Additional
intercom buttons are located on the forward side of the rear seats and on the left forward
floor. Intercom may also be set to be voice activated. Auxiliary audio may be plugged in
to a jack on the forward face of the circuit breaker panel. In normal mode, auxiliary audio
is automatically muted during radio communication.

96-80 Engine Monitoring Unit (EMU)

Refer to Section 71-43 for EMU maintenance procedures.
The Engine Monitoring Unit (EMU) is a digital recording device mounted behind the
right rear seatback panel. The EMU continuously monitors N1, N2, engine torque, and
MGT. EMU status is indicated by the EMU segment on the annunciator panel. The EMU
segment will only illuminate while the annunciator panel test button is depressed. The
EMU requires approximately ten seconds to initialize after the aircraft battery is switched
ON. Once initialization is complete, steady illumination of the annunciator means normal
EMU operation. A slowly flashing indication (once every two seconds) is given if the EMU
detects a fault in its senders or circuitry. A fast flashing indication (four times per second)
is given if the EMU has detected an exceedance. A fault or exceedance indication should
be investigated and reset by a qualified mechanic prior to further flight.
The EMU records exceedances of Rolls-Royce engine limits, not airframe operating limits
as given in Section 2. The EMU will record an exceedance if any of the following are
exceeded:

MGT during start: 999°C, or 927°C for 1 second, or 810°C for 10 seconds.
MGT engine running: 843°C, or 782°C for 6 seconds, or 706°C for 5 minutes.
N1: 106%, or 105% for 15 seconds.
N2: 110%, or 105% for 15 seconds.
78% to 88% for 60 seconds over 38% torque.
Torque: 122% for 15 seconds, or 104% for 5 minutes.

The EMU also records a start cycle when N1 exceeds 30% and MGT is at least 343°C.
The EMU is intended to be used only as a maintenance aid. It is the pilot's responsibility
to report any observed exceedances and the operator's responsibility to maintain a record
of engine starts and time in service.

APR 2017 Chapter 96 Electrical System Page 96.13

96-90 Emergency Locator Transmitter (ELT)
Refer to Section 25-61 for ELT programming instructions and maintenance procedures.
The Emergency Locator Transmitter (ELT) installation consists of a transmitter with internal
battery pack, an external antenna, and a remote switch/annunciator. The transmitter is
mounted to the upper steel tube frame and is accessible through the spring loaded air
intake door in the right-side cowl. The remote switch/annunciator is located left of the
cyclic stick.
The ELT is operated by a switch on the transmitter and by the remote switch. The
transmitter switch has been set in the 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 be in the ARMED position for flight. With both switches
set to armed, 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 momentary RESET & TEST position of the
remote switch to stop transmission and reset the unit. The red indicator will extinguish
when unit is reset.
For more detailed instructions on ELT operation, maintenance, and required tests, refer to
manufacturer's instructions supplied with the unit.

Page 96.14 Chapter 96 Electrical System APR 2017

96-100 Electrical Load Analysis

CONTINUOUS INTERMITTENT CONTINUOUS INTERMITTENT

COMPONENT QTY
AMPS EACH AMPS EACH TOTAL TOTAL

MAIN BUS
WARNING LT PANEL 1 0.006 0.320 0.006 0.320
ROTOR BRAKE LT 1 --- 0.044 0.000 0.044
MAPLIGHT 1 0.020 0.020 0.020 0.020
INTERIOR DOME LT 1 0.020 0.020 0.020 0.020
OAT GAGE 1 0.150 0.150 0.150 0.150
ENGINE TORQUEMETER 1 0.050 0.050 0.050 0.050
INSTRUMENT CLUSTER 1 0.375 0.375 0.375 0.375
MOP SENDER 1 0.025 0.025 0.025 0.025
TORQ SENDER 1 0.025 0.025 0.025 0.025
LOW RPM UNIT W/HORN 1 0.045 0.160 0.045 0.160
AA12S-600 AUDIO PANEL 1 1.000 1.000 1.000 1.000
N2 GOVERNOR SYSTEM 1 0.000 0.0871
N2 GOV ACTUATOR @ 12V 1 --- 0.150 0.000 0.0871
N2 GOV RELAY @ 12V 1 --- 0.010
ANTI-ICE SOLENOID 1 0.670 0.670 0.670 0.670
HEATED PITOT 1 4.000 4.000 4.000 4.000
ENGINE HOUR METER 2 0.015 0.015 0.030 0.030
HYD CONTROL SOLENOID 1 --- 0.800 0.000 0.800
ENGINE MONITORING UNIT 1 0.180 0.180 0.180 0.180
AVIONICS RELAY 1 --- 0.060 0.000 0.060
LOW FUEL RELAY 1 --- 0.010 0.000 0.010
WARNING LIGHT TEST CB 1 --- 0.020 0.000 0.020
TACH PWR TEST RELAY 1 --- 0.060 0.000 0.060
BOSE HEADSET 5 0.025 0.500 0.125 2.500
AUX POWER PLUG 1 2.000 2.000 2.000 2.000

SUBTOTAL (MAIN BUS) 8.721 12.606

APR 2017 Chapter 96 Electrical System Page 96.15

96-100 Electrical Load Analysis (continued)

CONTINUOUS INTERMITTENT CONTINUOUS INTERMITTENT

COMPONENT QTY
AMPS EACH AMPS EACH TOTAL TOTAL

LIGHTS BUS
LANDING LT BALLAST 2 1.6003 5.2503 3.200 10.500
LANDING LT RELAY 1 0.060 0.060 0.060 0.060
CIRCUIT BREAKER LTS 1 0.0013 0.0013 0.001 0.001
INSTRUMENT LT 1 0.5005 0.5005 0.5005 0.5005
POST LTS 2 0.0401 0.0401 0.080 0.080
INTERNAL AVIONICS LTS 6 0.1001 0.1001 0.600 0.600
VERT CARD COMPASS LT 1 0.0503 0.0503 0.050 0.050
POSITION LT RH (GREEN) 1 0.250 0.250 0.250 0.250
POSITION LT LH (RED) 1 0.250 0.250 0.250 0.250
POSITION LT TAIL (WHT) 1 0.300 0.300 0.300 0.300
STROBE LIGHT 1 0.670 3.000 0.670 3.000

SUBTOTAL (LIGHTS BUS) 5.961 15.591

CONTINUOUS INTERMITTENT CONTINUOUS INTERMITTENT

COMPONENT QTY
AMPS EACH AMPS EACH TOTAL TOTAL

AVIONICS BUS
KY196A COM 1 1.000 5.000 1.000 5.0002
GNC 420W GPS/COM 1 1.215 4.200 1.215 1.2152
GNS 530AW GPS/COM/NAV 1 1.415 4.400 1.415 1.4152
GTX 330 XPDR 1 1.640 9.090 1.640 9.090
BLIND ENCODER 1 0.600 0.600 0.600 0.600
AM/FM/CD RCVR 1 1.500 1.500 1.500 1.500
KR87 ADF RCVR 1 0.429 0.429 0.429 0.429
KR22 MARKER BEACON 1 0.040 0.500 0.040 0.500
AVIONIC BLOWER 1 0.180 0.180 0.180 0.180
PILOT AV BLOWER 1 0.100 0.100 0.100 0.100
ELT4 1 --- --- --- ---
HSI (PICT NAV SYSTEM) 1 1.730 1.730 1.730 1.730
ATTITUDE HORIZON 1 0.270 0.700 0.270 0.700
TURN COORDINATOR 1 0.350 0.350 0.350 0.350
RADAR ALTIMETER 1 0.727 0.727 0.727 0.727

SUBTOTAL (AVIONICS BUS) 11.196 23.536

Page 96.16 Chapter 96 Electrical System APR 2017

96-100 Electrical Load Analysis (continued)

CONTINUOUS INTERMITTENT CONTINUOUS INTERMITTENT

COMPONENT QTY
AMPS EACH AMPS EACH TOTAL TOTAL

TACH BUS
N2 TACH (INCL REG) 1 0.0221 0.0221
0.0221 0.0221
N2 TACH @ 13.75V 1 0.035 0.035
ROTOR TACH (INCL REG) 1 0.0221 0.0221
0.0221 0.0221
ROTOR TACH @13.75V 1 0.035 0.035

SUBTOTAL (TACH BUS) 0.044 0.044

CONTINUOUS INTERMITTENT CONTINUOUS INTERMITTENT

COMPONENT QTY
AMPS EACH AMPS EACH TOTAL TOTAL

OTHER EQUIPMENT
TACH RELAY 1 0.060 0.060 0.060 0.060
CLOCK (DIGITAL) 1 0.003 0.003 0.003 0.003
BATTERY RELAY 1 0.250 6.000 0.250 6.000
START/GEN RELAY 1 0.250 6.000 0.250 6.000
GEN LT RELAY 1 0.010 0.010 0.010 0.010
GEN CONTROL UNIT 1 0.2004 2.0005 0.200 2.000
IGNITION EXCITER 1 --- 1.500 0.000 1.500
EXTERNAL PWR RELAY2 1 0.250 6.000 --- ---
BAGGAGE COMPARTMENT 1 0.020 0.020
--- ---
LT2
SIGHT GLASS LED2 2 0.020 0.020 --- ---
LATCHING START RELAY3 1 0.060 0.060 --- ---
STARTER-GENERATOR3 1 --- 231.06 --- ---

SUBTOTAL (OTHER) 0.773 15.573

TOTAL (MAIN + LIGHTS + AVIONICS + TACH + OTHER) 26.70 67.357

STARTER-GENERATOR MARGIN (160-AMP MAX) +133.30 +92.657

JUL 2020 Chapter 96 Electrical System Page 96.17

96-110 Audio Alerts
All R66 helicopters have a low-RPM horn which sounds when rotor RPM is below 95%.
The horn is muted when the collective is fully down. On earlier aircraft, the horn is provided
by speakers in the side of the instrument console. On later aircraft, a tone generator in the
audio system provides the horn through crew headsets.
Later aircraft also have audio alerts in the headsets for high rotor RPM and high engine
torque/MGT. For high RPM, a warble tone (high/low tone) indicates rotor RPM above
105%. For high engine torque/MGT, a beeping tone indicates torque above 100% or
MGT above 782°C (5-minute limits). High torque is indicated by four beeps per second,
increasing to 12 beeps per second if torque exceeds 108%. High MGT is indicated by 12
beeps per second. The beep tone will also come on during start if MGT exceeds 860°C,
indicating an abnormally hot start.
Test buttons on the instrument panel permit pre-flight or in-flight tests of the high RPM and
high torque/MGT tones. For high torque/MGT, depressing the test button give four beeps
per second for two seconds followed by 12 beeps per second.
Additional audio alerts may my be provided in the headsets depending on optional equipment
installed, such as terrain warnings, traffic warnings, and autopilot modes.

Page 96.18 Chapter 96 Electrical System JUL 2020

CHAPTER 97

AVIONICS
Section Title Page

97-10 Garmin G500H Electronic Flight Instrument System (EFIS) Installation . . . . . . 97.1
97-11 LRU Installation – Garmin Display Unit (GDU) . . . . . . . . . . . . . . . . . . . . . 97.1
97-12 LRU Installation – GDC 74H Air Data Computer . . . . . . . . . . . . . . . . . . . 97.1
97-13 LRU Installation – GRS 77H AHRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97.3
97-14 LRU Installation – GMU 44 Magnetometer . . . . . . . . . . . . . . . . . . . . . . . 97.4
97-15 GPS Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97.6
97-20 Radar Altimeter Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97.9
97-30 Garmin GTX 33 Transponder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 97.12
97-40 Garmin GDL 69A XM Receiver Installation . . . . . . . . . . . . . . . . . . . . . . . . . 97.15
97-50 Avionics for R66 S/N 293, 520, 522 & Subsequent . . . . . . . . . . . . . . . . . . 97.17
97-51 Cyclic Grip Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97.17
97-52 Aspen EFD Electronic Flight Instrument System (EFIS) Installations . . . . . . 97.17
97-53 Garmin GTR 225B COM Radio Installation . . . . . . . . . . . . . . . . . . . . . . . 97.18
97-54 Garmin GDL 88 ADS-B In Receiver Installation . . . . . . . . . . . . . . . . . . . . 97.20
97-55 Garmin GTX 330 ES Transponder Installation . . . . . . . . . . . . . . . . . . . . . 97.22
97-56 Garmin GTN 600/700-series GPS Installation . . . . . . . . . . . . . . . . . . . . . 97.24
97-57 Electrical System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97.27
97-58 Intercom System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97.27
97-60 Avionics Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97.29

APR 2019 Chapter 97 Avionics Page 97.i

Intentionally Blank

Page 97.ii Chapter 97 Avionics APR 2019

CHAPTER 97

AVIONICS

97-10 Garmin G500H Electronic Flight Instrument System (EFIS) Installation

The Garmin G500H is an integrated avionics display system that provides flight instrument,
moving-map navigation, and additional situational awareness information to the flight crew
via the Garmin Display Unit (GDU).

NOTE
Refer to Garmin G500H Instructions for Continued Airworthiness.

97-11 LRU Installation – Garmin Display Unit (GDU)

Refer to § 95-70 for GDU maintenance procedures.

97-12 LRU Installation – GDC 74H Air Data Computer

A. Description
The GDC 74H Air Data Computer (ADC) compiles information from the pitot-static
system and an Outside Air Temperature (OAT) sensor. The GDC 74H computer
provides pressure altitude, airspeed, vertical speed, and OAT information to the
G500H EFIS system. The GDC 74H computer communicates with the GDU display
and GRS 77H AHRS using an ARINC 429 digital interface.
B. Schematic
Refer to Figure 98-10 for GDC 74H Air Data Computer Installation electrical schematic.
C. Removal
1. Turn battery & avionics switches off and pull out EFIS (5 amp) circuit breaker on
circuit breaker panel.
2. Hinge left seat forward and remove F748-1 cover assembly.
3. Disconnect airframe harness from GDC 74H air data computer at connectors.
4. Disconnect pitot and static tube fittings from computer and plug fittings.
5. Remove screws securing computer to F950-2 support assembly. Carefully
remove computer from under left seat.

APR 2019 Chapter 97 Avionics Page 97.1

97-12 LRU Installation – GDC 74H Air Data Computer (continued)
D. Installation
1. Turn battery & avionics switches off and pull out EFIS (5 amp) circuit breaker on
circuit breaker panel.
2. Place GDC 74H air data computer on F950-2 support assembly and install screws.
Verify security.
3. Remove plugs from fittings and connect pitot and static tube fittings to computer.
Verify security. Perform pitot and static system leak checks per § 95-10.
4. Connect airframe harness to computer at connectors.
5. Push in EFIS circuit breaker (5 amp) on circuit breaker panel. Turn battery &
avionics switches on.
6. Perform appropriate functional checks per Garmin G500H Instructions for
Continued Airworthiness. Turn battery & avionics switches off.
7. Install F748-1 cover assembly and hinge left seat back.
E. Scheduled Maintenance and Inspections
Refer to Garmin G500H EFIS Maintenance Manual, Section 5 Periodic Maintenance.

F. Special Maintenance and Inspections

1. Turn battery & avionics switches off. Open circuit breaker panel, hinge left seat
forward, and remove F748-1 cover assembly.
2. Inspect condition of and verify no obvious damage to Garmin GDC 74H Air Data
Computer, pitot-static tubes, 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. Perform ground checks per Part D steps 5 thru 7.

Page 97.2 Chapter 97 Avionics APR 2019

97-13 LRU Installation – GRS 77H AHRS
A. Description
The Garmin GRS 77H Attitude and Heading Reference System (AHRS) provides
aircraft attitude information to the G500H EFIS system. The GRS 77H interfaces
with both the GDC 74H Air Data Computer and the GMU 44 magnetometer. The
GRS 77H also utilizes GPS data forwarded from the GDU 620. Actual attitude and
heading information is sent to the GDU 620 using an ARINC 429 digital interface.
B. Schematic
Refer to Figure 98-11 for GRS 77H AHRS Installation electrical schematic.
C. Removal
1. Turn battery & avionics switches off and pull out EFIS (5 amp) circuit breaker on
circuit breaker panel.
2. Hinge left seat forward and remove F950-3 cover assembly.
3. Disconnect airframe harness from GRS 77H AHRS at connectors.
4. Loosen thumbscrews securing AHRS to F950-1 support assembly. Carefully
remove AHRS from under left seat.
D. Installation
1. Turn battery & avionics switches off and pull out EFIS (5 amp) circuit breaker on
circuit breaker panel.
2. Place GRS 77H AHRS on F950-1 support assembly and tighten thumbscrews.
Verify security.
3. Connect airframe harness to GRS 77H AHRS at connectors.
4. Push in EFIS circuit breaker (5 amp) on circuit breaker panel. Turn battery &
avionics switches on.
5. Perform appropriate functional checks per Garmin G500H Instructions for
Continued Airworthiness. Turn battery & avionics switches off.
6. Install F950-3 cover assembly and hinge left seat back.

APR 2019 Chapter 97 Avionics Page 97.3

97-13 LRU Installation – GRS 77H AHRS (continued)
E. Scheduled Maintenance and Inspections
Refer to Garmin G500H EFIS Maintenance Manual, Section 5 Periodic Maintenance.

F. Special Maintenance and Inspections

1. Turn battery & avionics switches off. Open circuit breaker panel, hinge left seat
forward, and remove F950-3 cover assembly.
2. Inspect condition of and verify no obvious damage to Garmin GRS 77H AHRS,
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. Perform ground checks per Part D steps 4 thru 6.

97-14 LRU Installation – GMU 44 Magnetometer

A. Description
The GMU 44 magnetometer senses the earth’s magnetic field. Data is sent to the
GRS 77H AHRS for processing to determine aircraft magnetic heading. This unit
receives power directly from the GRS 77H and communicates with the GRS 77H
using an RS-485 digital interface.
B. Schematic
Refer to Figure 98-11 for GRS 77H AHRS Installation electrical schematic.
C. Removal
1. Turn battery & avionics switches off and pull out EFIS (5 amp) circuit breaker on
circuit breaker panel.
2. Remove tailcone cowling per § 53-23.
3. Supporting GMU 44 magnetometer, remove hardware securing magnetometer to
F950-4 bracket.
4. Remove MS21919WDG12 clamp and disconnect magnetometer harness from
F951-1 harness assembly at connectors. Remove magnetometer.

Page 97.4 Chapter 97 Avionics APR 2019

97-14 LRU Installation – GMU 44 Magnetometer
D. Installation
1. Turn battery & avionics switches off and pull out EFIS (5 amp) circuit breaker on
circuit breaker panel.
2. Position MS21919WDG12 clamp on GMU 44 magnetometer connector.
3. Install hardware securing magnetometer to F950-4 bracket. Verify security.
4. Connect F951-1 harness assembly to magnetometer harness at connectors.
5. Push in EFIS circuit breaker (5 amp) on circuit breaker panel. Turn battery &
avionics switches on.
6. Perform appropriate functional checks per Garmin G500H Instructions for
Continued Airworthiness. Turn battery & avionics switches off.
7. Install tailcone cowling per § 53-23.
E. Scheduled Maintenance and Inspections
Refer to Garmin G500H EFIS Maintenance Manual, Section 5 Periodic Maintenance.

F. Special Maintenance and Inspections

1. Turn battery & avionics switches off. Open circuit breaker panel and remove
tailcone cowling per § 53-23.
2. Inspect condition of and verify no obvious damage to Garmin GMU 44
magnetometer, 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. Perform ground checks per Part D steps 5 thru 7.

APR 2019 Chapter 97 Avionics Page 97.5

97-15 GPS Installation

NOTE
Refer to Garmin GTN 600/700 series Maintenance Manual and
Instructions for Continued Airworthiness.

A. Description
The G500H system requires connection to at least one WAAS-enabled GPS receiver.
Garmin's Wide Area Augmentation System (WAAS) utilizes ground reference stations
that monitor GPS satellite data and issue correction messages which are broadcast
via satellite to WAAS-enabled GPS receivers, improving accuracy, integrity, and
availability.
One GTN 700-series, or one or two GTN 600-series, GPS(s) may be installed in the
G060 upper console.
Also refer to § 97-56 for Garmin GTN 600/700-series GPS Installation.
B. Schematic
Refer to Figure 98-12 for GTN 600/700-series GPS Installation electrical schematic.
C. Removal
1. Turn battery & avionics switches off and pull out GPS 1 (5 amp) and GPS 2 (5
amp) circuit breakers as required on circuit breaker panel.
2. Loosen radio key securing GTN 600/700-series GPS(s) to tray in upper console.
3. Carefully unplug/remove GPS(s) from tray.
D. Installation
1. Turn battery & avionics switches off and pull out GPS 1 (5 amp) and GPS 2 (5
amp) circuit breakers as required on circuit breaker panel.
2. Carefully plug-in/install GTN 600/700-series GPS(s) in appropriate location in tray
in upper console.
3. Tighten radio key securing GPS(s) to tray. Verify equipment security.
4. Push in GPS 1 (5 amp) and GPS 2 (5 amp) circuit breakers as required on circuit
breaker panel. Turn battery & avionics switches on.
5. Perform appropriate functional checks per Garmin GTN 600/700 series Pilot's
Guide. Turn battery & avionics switches off.

Page 97.6 Chapter 97 Avionics APR 2019

97-15 GPS Installation (continued)
E. Antenna
Refer to § 6-80 for antenna locations and R66 Illustrated Parts Catalog (IPC) Chapter 6.

NOTE
Antenna installation depends on number of COM installations
and additional equipment installed.

Removal
1. Turn battery & avionics switches off and pull out GPS 1 (5 amp) and GPS 2
(5 amp) circuit breakers as required on circuit breaker panel.
2. Using plastic scraper, remove B270-1 sealant from around GPS antenna at
corners where it attaches to tailcone.
3. Disconnect antenna cable from antenna. As required, remove B270-13
sealant from fastener holes. Remove hardware securing antenna (and B322-
10 spacers for NAV) to tailcone (or chin for glideslope) and remove antenna.
Installation
1. Turn battery & avionics switches off and pull out GPS 1 (5 amp) and GPS 2
(5 amp) circuit breakers as required on circuit breaker panel.
2. a. For GPS antenna:
i. Remove paint & primer from antenna mating surfaces to ensure
electrical ground.
ii. 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.
iii. 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.
b. For NAV antenna:
i. Install hardware and B322-10 spacers (thick edge inward) securing
antenna to tailcone. Verify security.
c. For glideslope antenna:
i. Install screws securing antenna to chin. Verify security.
3. Connect antenna cable to antenna. Verify security.
4. Perform ground checks per Part D steps 4 and 5.

APR 2019 Chapter 97 Avionics Page 97.7

97-15 GPS Installation (continued)
F. Scheduled Maintenance and Inspections

G. Special Maintenance and Inspections

1. Turn battery & avionics switches off. Open circuit breaker panel and upper
console.
2. Inspect condition of and verify no obvious damage to GPS(s), 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 4 and 5.

Page 97.8 Chapter 97 Avionics APR 2019

97-20 Radar Altimeter Installation
A. Description
The FreeFlight RA-4500 radar altimeter has ARINC 429 output for communication
with electronic displays such as the G500H EFIS system. Radar altitude data can be
displayed on the PFD portion of the Garmin GDU 620 display.
B. Schematic
Refer to Figure 98-13 for Radar Altimeter Installation electrical schematic.
C. Removal
RAD-40 Indicator
1. Turn battery & avionics switches off and pull out RADAR ALT (2 amp) circuit
breaker on circuit breaker panel.
2. Remove perimeter screws securing instrument face to upper console and carefully
pull face aft, or remove Garmin GDU 620 Display per § 95-70.
3. a. For Above-Console Installation: Remove hardware securing B560 enclosure
assembly to instrument console and remove hardware securing B560 faceplate
to RAD-40 Indicator.
b. For In-Console Installation: Supporting RAD-40 indicator, remove hardware
securing B421-1 visor assembly, A590-4 cover plate, and indicator to
instrument face.
4. Disconnect console harness from indicator and carefully remove indicator.
ATG-410 Tone Generator
1. Turn battery & avionics switches off and pull out RADAR ALT (2 amp) circuit
breaker on circuit breaker panel. Open instrument console or remove Garmin
GDU 620 Display per § 95-70.
2. Supporting ATG-410 tone generator, remove screws securing tone generator to
keel panel. Carefully remove tone generator and disconnect console harness.
RA-4000/RA-4500 Radar Altimeter
1. Turn battery & avionics switches off and pull out RADAR ALT (2 amp) circuit
breaker on circuit breaker panel. Hinge front left seat forward.
2. Disconnect airframe and antenna harnesses from RA-4000/RA-4500 radar
altimeter.
3. Supporting radar altimeter, remove screws securing radar altimeter to F542-2
support. Carefully remove radar altimeter from under left seat.

APR 2019 Chapter 97 Avionics Page 97.9

97-20 Radar Altimeter Installation (continued)
D. Installation
RAD-40 Indicator
1. Turn battery & avionics switches off and pull out RADAR ALT (2 amp) circuit
breaker on circuit breaker panel.
2. Connect console harness to RAD-40 Indicator.
3. a. For Above-Console Installation: Install hardware securing B560 faceplate to indi-
cator & install hardware securing B560 enclosure assembly to instrument console.
b. For In-Console Installation: Supporting indicator, install hardware securing
B421-1 visor assembly, A590-4 cover plate, and indicator to instrument face.
4. Install perimeter screws securing instrument face to upper console or install
Garmin GDU 620 Display per § 95-70.
5. Push in RADAR ALT (2 amp) circuit breaker on circuit breaker panel. Turn battery
& avionics switches on.
6. Perform appropriate functional checks per Freeflight Systems Instructions for
Continued Airworthiness. Turn battery & avionics switches off.
ATG-410 Tone Generator
1. Turn battery & avionics switches off and pull out RADAR ALT (2 amp) circuit
breaker on circuit breaker panel.
2. Connect console harness to ATG-410 tone generator.
3. Position tone generator on keel panel and install screws. Verify security.
4. Close instrument console or install Garmin GDU 620 Display per § 95-70.
5. Push in RADAR ALT (2 amp) circuit breaker on circuit breaker panel. Turn battery
& avionics switches on.
6. Perform appropriate functional checks per Freeflight Systems Instructions for
Continued Airworthiness. Turn battery & avionics switches off.
RA-4000/RA-4500 Radar Altimeter
1. Turn battery & avionics switches off and pull out RADAR ALT (2 amp) circuit
breaker on circuit breaker panel.
2. Connect airframe and antenna harnesses to radar altimeter.
3. Supporting RA-4000/RA-4500 radar altimeter, install screws securing radar
altimeter to F542-2 support. Verify security. Hinge front left seat aft.
4. Push in RADAR ALT (2 amp) circuit breaker on circuit breaker panel. Turn battery
& avionics switches on.
5. Perform appropriate functional checks per Freeflight Systems Instructions for
Continued Airworthiness. Turn battery & avionics switches off.
Page 97.10 Chapter 97 Avionics APR 2019
97-20 Radar Altimeter Installation (continued)
E. Antenna
Refer to § 6-80 for antenna locations & R66 Illustrated Parts Catalog (IPC) Chapter 6.
Removal
1. Turn battery & avionics switches off and pull out RADAR ALT (2 amp) circuit
breaker on circuit breaker panel.
2. Remove hardware securing F469 scuff plate and carpet assembly to floor,
remove plate, and peel back carpet as required. Remove hole plug.
3. Disconnect antenna cable from antenna.
4. Remove screws securing antenna to chin. Repeat steps for opposite-side
antenna.
Installation
1. Turn battery & avionics switches off and pull out RADAR ALT (2 amp) circuit
breaker on circuit breaker panel.
2. Connect antenna cable to antenna and install screws securing antenna to chin.
Verify security.
3. Install floor hole plug. Install hardware securing F469 scuff plate and carpet
assembly to floor. Repeat steps for opposite-side antenna.
4. Push in RADAR ALT (2 amp) circuit breaker on circuit breaker panel. Turn
battery & avionics switches on.
5. Perform appropriate functional checks per Freeflight Systems Instructions for
Continued Airworthiness. Turn battery & avionics switches off.
F. Scheduled Maintenance and Inspections
Refer to Freeflight Systems Instructions for Continued Airworthiness.
G. Special Maintenance and Inspections
1. Turn battery & avionics switches off. Open circuit breaker panel. Open instrument
console, remove perimeter screws securing instrument face to upper console, or remove
Garmin GDU 620 Display per § 95-70. Hinge front left seat forward as required.
2. Inspect condition of and verify no obvious damage to RAD-40 Indicator, ATG-
410 Tone Generator, RA-4000/RA-4500 Radar Altimeter, 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 close instrument console, install perimeter screws
securing instrument face to upper console, or install Garmin GDU 620 Display per
§ 95-70. Hinge front left seat aft as required.

APR 2019 Chapter 97 Avionics Page 97.11

97-30 Garmin GTX 33 Transponder Installation

NOTE
Refer to Garmin GTX 33 Transponder Maintenance Manual and
Instructions for Continued Airworthiness.

A. Description
The Garmin GTX 33 is a remote-mounted transponder with extended-squitter ADS-B
broadcast capability. The GTX 33 has no control panel face; it is controlled via the
Garmin GTN 600/700-series GPS navigator.
Refer to § 97-55 Garmin GTX 330 ES Transponder Installation.
B. Schematic
Refer to Figure 98-14 for Garmin GTX 33 Transponder Installation electrical schematic.
C. Removal
1. Turn battery & avionics switches off and pull out XPDR (5 amp) circuit breaker on
circuit breaker panel.
2. Remove hardware securing F640 face assembly to avionics panel and remove face.
3. Loosen screw and swing handle across GTX 33 transponder to unlock. Carefully
unplug/remove transponder from tray.
D. Installation
1. Turn battery & avionics switches off and pull out XPDR (5 amp) circuit breaker on
circuit breaker panel.
2. Carefully plug-in/install GTX 33 transponder in appropriate location in avionics tray.
3. Swing handle across transponder to lock and tighten screw. Verify equipment
security.
4. Install hardware securing F640 face assembly to avionics panel.
5. Push in XPDR (5 amp) circuit breaker on circuit breaker panel. Turn battery &
avionics switches on.
6. Perform appropriate functional checks per Garmin GTX 33 Transponder Maintenance
Manual and Instructions for Continued Airworthiness. Turn battery & avionics
switches off.

Page 97.12 Chapter 97 Avionics APR 2019

97-30 Garmin GTX 33 Transponder Installation (continued)
E. Antenna
Refer to § 6-80 for antenna locations & R66 Illustrated Parts Catalog (IPC) Chapter 6.

NOTE
Antenna installation depends on optional equipment installed.

Removal
1. Turn battery & avionics switches off and pull out XPDR (5 amp) circuit breaker
on circuit breaker panel.
2. Using plastic scraper, remove B270-1 sealant from around transponder antenna
at corners where it attaches to B322 plate/doubler.
3. Remove screws securing plate/doubler to cabin skin and disconnect antenna
cable from antenna. Remove hardware securing plate/doubler to antenna and
remove antenna.
Installation
1. Turn battery & avionics switches off and pull out XPDR (5 amp) circuit breaker
on circuit breaker panel.
2. Remove paint & primer from between cabin skin and B322 plate/doubler to
ensure electrical ground.
3. Install hardware securing transponder antenna to plate/doubler. Verify security.
Apply small bead B270-1 sealant (0.1 inch max in height) around antenna at
corners where it attaches to plate/doubler and allow to dry.
4. Connect antenna cable to antenna and install screws securing mounting plate
to cabin skin. Verify security.
5. Perform ground checks per Part D steps 4 and 5.
F. Scheduled Maintenance and Inspections

APR 2019 Chapter 97 Avionics Page 97.13

97-30 Garmin GTX 33 Transponder Installation (continued)
G. Special Maintenance and Inspections
1. Turn battery & avionics switches off. Open circuit breaker panel.
2. Remove GTX 33 transponder per Part C. Inspect condition of and verify no obvious
damage to transponder, radio tray, copper bus bars, circuit breaker, and wiring.
Verify no loose, chafed, or broken wires or terminals. Verify no evidence of arcing.
3. Secure circuit breaker panel. Install transponder per Part D.

Page 97.14 Chapter 97 Avionics APR 2019

97-40 Garmin GDL 69A XM Receiver Installation

NOTE
Refer to Garmin GDL 69A XM Receiver Instructions for Continued
Airworthiness.

A. Description
The GDL 69A XM Satellite Radio receives broadcast weather data and audio
entertainment. The GDL 69A has no control panel face; weather data and audio
controls are displayed on the G500H EFIS MFD or by a GTN 600/700-series GPS
navigator. The GDL 69A interfaces with the audio panel to distribute the audio signal.
A subscription to XM Satellite Radio service enables GDL 69A capability.
B. Schematic
Refer to Figure 98-15 for Garmin GDL 69A XM Receiver Installation electrical schematic.
C. Removal
1. Turn battery & avionics switches off and pull out XM (2 amp) circuit breaker on
circuit breaker panel.
2. Remove hardware securing F640 face assembly to avionics panel and remove face.
3. Loosen screw and swing handle across GDL 69A receiver to unlock. Carefully
unplug/remove receiver from tray.
D. Installation
1. Turn battery & avionics switches off and pull out XM (5 amp) circuit breaker on
circuit breaker panel.
2. Carefully plug-in/install GDL 69A receiver in appropriate location in avionics tray.
3. Swing handle across receiver to lock and tighten screw. Verify equipment security.
4. Install hardware securing F640 face assembly to avionics panel.
5. Push in XM (2 amp) circuit breaker on circuit breaker panel. Turn battery & avionics
switches on.
6. Perform appropriate functional checks per Garmin GDL 69A XM Receiver Instructions
for Continued Airworthiness. Turn battery & avionics switches off.

APR 2019 Chapter 97 Avionics Page 97.15

97-40 Garmin GDL 69A XM Receiver Installation (continued)
E. Antenna
Refer to § 6-80 for antenna locations & R66 Illustrated Parts Catalog (IPC) Chapter 6.

NOTE
Antenna installation depends on optional equipment installed.

Removal
1. Turn battery & avionics switches off and pull out XM (2 amp) circuit breaker on
circuit breaker panel.
2. Using plastic scraper, remove B270-1 sealant from around XM antenna at
corners where it attaches to F706-1 cowling.
3. Remove screws securing antenna to cowling and disconnect antenna cable
from antenna. Remove antenna and rubber gasket.
Installation
1. Turn battery switches off and pull out XM (2 amp) circuit breaker on circuit
breaker panel.
2. Install hardware securing XM antenna (with rubber gasket) to F706-1 cowling.
Verify security. Apply small bead B270-1 sealant (0.1 inch max in height)
around antenna at corners where it attaches to cowling and allow to dry.
3. Connect antenna cable to antenna. Verify security.
4. Perform ground checks per Part D steps 4 and 5.
F. Scheduled Maintenance and Inspections

G. Special Maintenance and Inspections

1. Turn battery & avionics switches off. Open circuit breaker panel.
2. Remove GDL 69A XM receiver per Part C. Inspect condition of and verify no
obvious damage to XM receiver, circuit breaker, and wiring. Verify no loose,
chafed, or broken wires or terminals. Verify no evidence of arcing.
3. Secure circuit breaker panel. Install XM receiver per Part D.

Page 97.16 Chapter 97 Avionics APR 2019

97-50 Avionics for R66 S/N 293, 520, 522, & Subsequent

97-51 Cyclic Grip Assembly

A. Description of New Features
The angle of the pilot’s cyclic grip can be adjusted fore and aft relative to the cross
tube. The most forward position provides the most control clearance at aft cyclic.
B. Grip Angle Adjustment
1. Loosen cap screws securing pilot's cyclic grip, block assembly, and bar to grip
weldment.
2. Rotate grip about weldment to desired angle. Special torque cap screws to 40
in.-lb.
C. Removal and Installation
Refer to § 67-12 for cyclic grip assembly removal and installation procedures.
D. Schematic
Refer to Figure 98-1 for F024 electrical system schematic.

97-52 Aspen EFD Electronic Flight Instrument System (EFIS) Installations

Refer to § 95-73 for Aspen EFD EFIS Installations.
A. Schematic
Refer to Figure 98-16 for Aspen EFD500H Display Installation electrical schematic.
Refer to Figure 98-17 for Aspen EFD1000H Display Installation electrical schematic.

JUL 2020 Chapter 97 Avionics Page 97.17

97-53 Garmin GTR 225B COM Radio Installation

NOTE
Refer to Garmin GTR 225B Maintenance Manual and Instructions
for Continued Airworthiness.

A. Description of New Features

The new C802-2 COM radio (Garmin GTR 225B) includes similar communication
features available in the earlier R66 COM radio (KY196A [28V]), but also includes an
airport frequency database, ability to monitor the standby frequency, and improved
user memory channel functionality. The new COM radio is a dual voltage unit,
suitable for use in 14V and 28V systems.
B. Schematic
Refer to Figure 98-9 for C802-2 COM Radio Installation electrical schematic.
C. Removal
1. Turn battery switch off and pull out COM radio (5 amp) circuit breaker on circuit
breaker 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 (5 amp) circuit breaker on circuit
breaker 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 (5 amp) circuit breaker on circuit breaker panel. Turn battery
& avionics switches on.
5. Perform appropriate functional checks per Garmin GTR 225B Pilot's Guide. Turn
battery & avionics switches off.
E. Antenna
Refer to § 6-80 for antenna locations and R66 Illustrated Parts Catalog (IPC) Chapter 6.

NOTE
Antenna installation depends on number of COM installations
and additional equipment installed.

Page 97.18 Chapter 97 Avionics JUL 2020

97-53 Garmin GTR 225B COM Radio Installation (continued)
E. Antenna (continued)
Removal
1. Turn battery switch off and pull out COM radio (5 amp) circuit breaker on circuit
breaker panel.
2. Using plastic scraper, remove B270-1 sealant from around COM antenna at
corners where it attaches to tailcone.
3. Disconnect antenna cable from antenna. As required, remove B270-13 sealant from
fastener holes. Remove screws securing antenna to tailcone & remove antenna.
Installation
1. Turn battery switch off and pull out COM radio (5 amp) circuit breaker on circuit
breaker 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.
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. Verify security.
6. Perform ground checks per Part D steps 4 and 5.
F. Scheduled Maintenance and Inspections

G. Special Maintenance and Inspections

1. Turn battery & avionics switches off. Open circuit breaker panel and upper console.
2. Inspect condition of and verify no obvious damage to COM radio, 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.
3. Secure circuit breaker panel and upper console. Perform ground checks per Part
D steps 4 and 5.

APR 2019 Chapter 97 Avionics Page 97.19

97-54 Garmin GDL 88 ADS-B In Receiver Installation

NOTE
Refer to Garmin GDL 88 Maintenance Manual and Instructions
for Continued Airworthiness.

A. Description of New Features

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 "In" equipment receives
data from other aircraft or from air traffic control. The R66 may be equipped with
ADS-B Out or with ADS-B Out and ADS-B In systems. Refer to § 97-15.
The ADS-B In system receives data via the C803-2 ADS-B (Garmin GDL 88) universal
access transceiver (used as a receiver) on frequencies 978 MHz and 1090 MHz.
Received data is displayed on the primary GPS screen. Refer to § 97-16.
B. Schematic
Refer to Figure 98-10 for C803-2 ADS-B Installation electrical schematic.
C. Removal
1. Turn battery switch off and pull out XPDR (5 amp) circuit breaker on circuit
breaker panel.
2. Under left front seat, disconnect airframe harness from GDL 88 receiver at
connectors.
3. Remove screws securing GDL 88 receiver to C904-1 mount assembly, and remove
GDL 88 receiver.
D. Installation
1. Turn battery switch off and pull out XPDR (5 amp) circuit breaker on circuit
breaker panel.
2. Under left front seat, position GDL 88 receiver on C904-1 mount assembly and
install screws. Verify security.
3. Connect airframe harness to GDL 88 receiver at connectors.
4. Push in XPDR (5 amp) circuit breaker on circuit breaker panel. Turn battery &
avionics switches on.
5. Perform appropriate functional checks per Garmin GDL 88 Pilot's Guide. Turn
battery & avionics switches off.

Page 97.20 Chapter 97 Avionics APR 2019

97-54 Garmin GDL 88 ADS-B In Receiver Installation (continued)
E. Antenna
Refer to § 6-80 for antenna locations and R66 Illustrated Parts Catalog (IPC) Chapter 6.

NOTE
Antenna installation depends on number of COM installations
and additional equipment installed.
Removal
1. Turn battery switch off and pull out XPDR (5 amp) circuit breaker on circuit
breaker panel.
2. Using plastic scraper, remove B270-1 sealant from around GDL 88 antenna at
corners where it attaches to belly.
3. Disconnect antenna cable from antenna. Remove hardware securing antenna
to belly and remove antenna.
Installation
1. Turn battery switch off and pull out XPDR (5 amp) circuit breaker on circuit
breaker panel.
2. Remove paint & primer from antenna mating surfaces to ensure electrical ground.
3. Install hardware securing antenna to belly. Apply small bead B270-1 sealant
around antenna at corners where it attaches to belly and allow to dry.
4. Connect antenna cable to antenna. Verify security.
5. Perform ground checks per Part D steps 4 and 5.
F. Scheduled Maintenance and Inspections

NOTE
All factory-installed Garmin units are “on condition” and do not
require scheduled periodic maintenance. Units feature a BIT
(Built-In Test) function during each initial power-up that will
detect internal failure(s) and alert pilot.
NOTE
Refer to § 97-60 for avionics software information.
G. Special Maintenance and Inspections
1. Turn battery & avionics switches off. Open circuit breaker panel and access left
front seat.
2. Inspect condition of and verify no obvious damage to GDL 88, 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 left front seat. Perform ground checks per Part
D steps 4 and 5.

APR 2019 Chapter 97 Avionics Page 97.21

97-55 Garmin GTX 330 ES Transponder Installation

NOTE
Refer to Garmin GTX 330 ES Maintenance Manual and
Instructions for Continued Airworthiness.

A. Description of New Features

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 R66 operation in certain airspace in the United States after January 1,
2020. ADS-B "In" equipment receives data from other aircraft or from air traffic
control. ADS-B In equipment is not required for R66 operation in the United States.
The R66 may be equipped with ADS-B Out or with ADS-B Out and ADS-B In systems.
Both ADS-B systems operate mostly automatically. ADS-B equipment is programmed
with aircraft specific-data at installation. ADS-B systems use 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.
The ADS-B In system receives data via a receiver on frequencies 978 MHz and 1090
MHz. Received data is displayed on the primary GPS screen.
ADS-B Out equipment (transponder and primary GPS) or ADS-B Out and ADS-B In
equipment (transponder, primary GPS, and receiver) 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. ADS-B In
system faults are annunciated on the primary GPS screen.
Change of aircraft registration may require ADS-B equipment programming by
qualified maintenance personnel.
Refer to R66 Pilot's Operating Handbook Section 9 for additional information.
B. Schematic
Refer to Figure 98-11 for C804-15 transponder & blind encoder electrical schematic.
C. Removal
1. Turn battery switch off and pull out XPDR (5 amp) circuit breaker on circuit
breaker panel.
2. Loosen radio key securing C804-15 transponder to avionics tray.
3. Carefully unplug/remove transponder from tray.

Page 97.22 Chapter 97 Avionics APR 2019

97-55 Garmin GTX 330 ES Transponder Installation (continued)
D. Installation
1. Turn battery switch off and pull out XPDR (5 amp) circuit breaker on circuit
breaker panel.
2. Carefully plug-in/install C804-15 transponder in appropriate location in avionics
tray.
3. Tighten radio key securing transponder to tray. Verify equipment security.
4. Push in XPDR (5 amp) circuit breaker on circuit breaker panel. Turn battery &
avionics switches on.
5. Perform appropriate functional checks per Garmin GTX 330 ES Pilot's Guide.
Turn battery & avionics switches off.
E. Antenna
Refer to § 6-80 for antenna locations and R66 Illustrated Parts Catalog (IPC) Chapter 6.

NOTE
Antenna installation depends on optional equipment installed.

Removal
1. Turn battery switch off and pull out XPDR (5 amp) circuit breaker on circuit
breaker panel.
2. Using plastic scraper, remove B270-1 sealant from around transponder antenna
at corners where it attaches to B322-11 mounting plate.
3. Remove screws securing mounting plate to cabin skin and disconnect antenna
cable from antenna. Remove hardware securing mounting plate to antenna
and remove antenna.
Installation
1. Turn battery switch off and pull out XPDR (5 amp) circuit breaker on circuit
breaker panel.
2. Remove paint & primer from between cabin skin and B322-11 plate to ensure
electrical ground.
3. Install hardware securing transponder antenna to mounting plate. Verify
security. Apply small bead B270-1 sealant (0.1 inch max in height) around
antenna at corners where it attaches to mounting plate and allow to dry.
4. Connect antenna cable to antenna and install screws securing mounting plate
to cabin skin. Verify security.
5. Perform ground checks per Part D steps 4 and 5.

APR 2019 Chapter 97 Avionics Page 97.23

97-55 Garmin GTX 330 ES Transponder Installation (continued)
F. Scheduled Maintenance and Inspections

G. Special Maintenance and Inspections

1. Turn battery & avionics switches off. Open circuit breaker panel and upper
console.
2. Inspect condition of and verify no obvious damage to 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.
3. Secure circuit breaker panel and upper console. Perform ground checks per Part
D steps 4 and 5.

97-56 Garmin GTN 600/700-series GPS Installation

NOTE
Refer to Garmin GTN 600/700 series Maintenance Manual and
Instructions for Continued Airworthiness.

A. Description of New Features

The new C831 GPS (Garmin GTN 600/700 series) includes similar navigation features
available in the earlier R66 GPS (Garmin GNS 400/500 series), but the interface
offers a combination of touch screen technology with traditional buttons and knobs.
One GTN 700 series, or one or two GTN 600 series, GPS(s) may be installed in the
pilot-side console location only.
Note: R66 ADS-B Out system requires Garmin GTN 600/700 series GPS. Refer to
§ 97-15.
B. Schematic
Refer to Figure 98-12 for C831 GPS installation electrical schematic.

Page 97.24 Chapter 97 Avionics APR 2019

97-56 Garmin GTN 600/700-series GPS Installation (continued)
C. Removal
1. Turn battery switch off and pull out GPS 1 (5 amp) and GPS 2 (5 amp) circuit
breakers as required on circuit breaker panel.
2. Loosen radio key securing C831 GPS(s) to tray in pilot's side console.
3. Carefully unplug/remove GPS(s) from tray.
D. Installation
1. Turn battery switch off and pull out GPS 1 (5 amp) and GPS 2 (5 amp) circuit
breakers as required on circuit breaker panel.
2. Carefully plug-in/install C831 GPS(s) in appropriate location in tray in pilot's side
console.
3. Tighten radio key securing GPS(s) to tray. Verify equipment security.
4. Push in GPS 1 (5 amp) and GPS 2 (5 amp) circuit breakers as required on circuit
breaker panel. Turn battery & avionics switches on.
5. Perform appropriate functional checks per Garmin GTN 600/700 series Pilot's
Guide. Turn battery & avionics switches off.
E. Antenna
Refer to § 6-80 for antenna locations and R66 Illustrated Parts Catalog (IPC) Chapter 6.

NOTE
Antenna installation depends on number COM installations and
additional equipment installed.

Removal
1. Turn battery switch off and pull out GPS 1 (5 amp) and GPS 2 (5 amp) circuit
breakers as required on circuit breaker panel.
2. Using plastic scraper, remove B270-1 sealant from around GPS antenna at
corners where it attaches to tailcone.
3. Disconnect antenna cable from antenna. As required, remove B270-13 sealant
from fastener holes. Remove screws securing antenna to tailcone and remove
antenna.

APR 2019 Chapter 97 Avionics Page 97.25

97-56 Garmin GTN 600/700-series GPS Installation (continued)
E. Antenna (continued)
Installation
1. Turn battery switch off and pull out GPS 1 (5 amp) and GPS 2 (5 amp) circuit
breakers as required on circuit breaker panel.
2. Remove paint & primer from antenna mating surfaces to ensure electrical
ground.
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.
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. Verify security.
6. Perform ground checks per Part D steps 4 and 5.
F. Scheduled Maintenance and Inspections

G. Special Maintenance and Inspections

1. Turn battery & 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[s] and faceplate may be also be removed).
2. Inspect condition of and verify no obvious damage to GPS(s), 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.

Page 97.26 Chapter 97 Avionics APR 2019

97-57 Electrical System Installation
A. Description of New Features
1. Main Switch Panel
The main switch panel is located at the top of the avionics stack. Rocker-
style switches are utilized for ergonomic comfort for this new location, and for
the new console geometry (earlier R66s utilized paddle-style switches). Some
secondary instruments such as OAT and clock and hourmeter are also relocated.
B. Schematic
Refer to Figure 98-13 for F024 electrical system schematic.

97-58 Intercom System Installation

NOTE
Refer to Garmin GMA 350H series Maintenance Manual and
Instructions for Continued Airworthiness.

A. Description of New Features

The new 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
pushbutton switch is depressed on the pilot's cyclic grip.
B. Schematic
Refer to Figure 98-14 for F060 Intercom System Installation (Garmin GMA 350H
Audio Control) electrical schematic.
C. Removal
1. Turn battery switch off & pull out ICS (5 amp) circuit breaker on circuit breaker 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 & pull out ICS (5 amp) circuit breaker on circuit breaker 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 ICS (5 amp) circuit breakers on circuit breaker panel. Turn battery &
avionics switches on.
5. Perform appropriate functional checks per Garmin GMA 350H series Pilot's Guide.
Turn battery & avionics switches off.

APR 2019 Chapter 97 Avionics Page 97.27

97-58 Intercom System Installation (continued)
E. Antenna
Refer to § 6-80 for marker beacon antenna location and R66 Illustrated Parts Catalog
(IPC) Figure 6-13.
Removal
1. Turn battery switch off and pull out ICS (5 amp) circuit breaker on circuit
breaker panel.
2. Using plastic scraper, remove B270-1 sealant from around CI 102 marker
beacon antenna at corners where it attaches to belly panel.
3. Remove hardware securing F794 forward belly panel to belly and disconnect
F850-210 antenna cable from antenna. Remove screws securing antenna to
panel and remove antenna.
Installation
1. Turn battery switch off and pull out ICS (5 amp) circuit breaker on circuit
breaker panel.
2. Remove paint and primer from antenna mating surfaces to ensure electrical
ground.
3. Apply light coat B270-11 adhesive to screw threads and install screws securing
CI 102 marker beacon antenna to F794 forward belly panel. Verify security.
4. Connect F850-210 antenna cable to antenna. Install screws securing forward
belly panel to belly. Verify security.
5. Apply small bead B270-1 sealant (0.1 inch max in height) around antenna at
corners where it attaches to belly panel and allow to dry.
6. Perform ground checks per Part D steps 4 and 5.
F. Scheduled Maintenance and Inspections

Page 97.28 Chapter 97 Avionics APR 2019

97-58 Intercom System Installation (continued)
G. Special Maintenance and Inspections
1. Turn battery & avionics switches off. Open circuit breaker panel and upper
console.
2. Inspect condition of and verify no obvious damage to audio control, 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.
3. Secure circuit breaker panel and upper console. Perform ground checks per Part
D steps 4 and 5.

97-60 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.

APR 2019 Chapter 97 Avionics Page 97.29

Intentionally Blank

Page 97.30 Chapter 97 Avionics APR 2019

Page 98.62 Chapter 98 Wiring Diagrams JUL 2020

CHAPTER 99

SPECIAL TOOLS

Section Title Page

99-10 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99.1

99-20 Illustrations and Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99.2

APR 2017 Chapter 99 Special Tools Page 99.i

Intentionally Blank

Page 99.ii Chapter 99 Special Tools APR 2017

CHAPTER 99

SPECIAL TOOLS

99-10 Special Tools

The following is a list of Robinson R66 special tools.

R66 special tools are to be used in conjunction with the applicable instructions for continued
airworthiness, for their designated maintenance task.

APR 2017 Chapter 99 Special Tools Page 99.1

99-20 Illustrations and Tasks
Refer to Figure 99-1.

Item Part Number Description Reference

1 MT054-1 Main Gearbox Drain Assembly MM § 12-11
2 MT122-6 Micrometer Assembly – Main Rotor Hub, Bolt Stretch MM § 62-10
3 MT146-4 Blocks – Swashplate Rigging (set of 2) MM § 18-30
4 MT147-1 Bleed Tool – Main Rotor Blade Spindle MM § 12-51
5 MT179-4 Balancing Bar – Tail Rotor Assembly Static Balance MM § 64-11
6 MT260-6 Tail Rotor Drive Shaft Runout Attachments Kit MM § 65-21
7 MT329-6 Plug – Main Rotor Hub Bearing Installation MM § 62-21

FIGURE 99-1 SPECIAL TOOLS

Page 99.2 Chapter 99 Special Tools APR 2017

99-20 Illustrations and Tasks (continued)
Refer to Figure 99-2.

Item Part Number Description Reference

1 MT352-1 Main Rotor Blade Trim Tab Gage MM § 18-13
2 MT354-4 or -7 Teeter Moment Tool MM § 62-32
3 MT357-2 0.375-inch diameter Reamer Various*
4 MT357-3 0.156-inch diameter Cobalt Steel Drill MM § 62-33
5 MT357-4 Hex Driver (Snap-On Part No. FABL8) MM § 65-40
6 MT357-5 Torque Adapter (Snap-On Part No. FRDH101) MM § 65-40
7 MT359-1 Spring Scale (0-30 lb) MM §§ 62-32,
67-22, & 67-41
* Ream bore after installation of A139-1 bearing to 0.376-0.375 inch diameter.

FIGURE 99-2 SPECIAL TOOLS

APR 2017 Chapter 99 Special Tools Page 99.3

99-20 Illustrations and Tasks (continued)
Refer to Figure 99-3.

Item Part Number Description Reference

1 MT384-1 Hydraulic Test Pump (U.S / Canada / Mexico – 110 V) MM § 12-33
2 MT384-2 Hydraulic Test Pump (Outside North America – 220 V) MM § 12-33
3 MT525-7 Main Rotor Blade Rigging Fixture MM § 18-40
4 MT525-9 Tail Rotor Blade Rigging Fixture MM § 18-60
5 MT526-8 Bender Assembly – Trim Tab, Main Rotor Blade (aluminum) MM § 18-13
6 MT527-1 Helicopter Lifting Fixture MM § 7-20
7 MT548-8 Fitting (engine hoist adapter) MM § 71-10

FIGURE 99-3 SPECIAL TOOLS

Page 99.4 Chapter 99 Special Tools APR 2017

99-20 Illustrations and Tasks (continued)
Refer to Figure 99-4.

Item Part Number Description Reference

1 MT549-1 Spacer – Spindle Boot (set of 2) MM § 62-10
2 MT549-2 Plate – Spindle Boot MM § 62-10
3 MT556-11 Kit Tools – Tail Rotor Hub Bearing Replacement MM § 64-41
4 MT569-2 Guide Assembly – Drill (main rotor hub nut) MM § 62-33
5 MT643-1 Support Weldment – Main Rotor Hub Bearing Installation MM § 62-21
6 MT759-1 Blocks – Cyclic Rigging MM § 18-41
7 2020HR ACES Probalancer Analyzer (or equivalent dynamic balancer) MM § 18-10

FIGURE 99-4 SPECIAL TOOLS

APR 2017 Chapter 99 Special Tools Page 99.5

99-20 Illustrations and Tasks (continued)
Refer to Figure 99-5.

Item Part Number Description

1 MT850-1 Engine Stand Assembly (RR300)
2 AN970-4* Washer – Tap Test Tool
3 MT990-1 Charger Assembly (BatteryMinder – 24 VDC, 120 VAC, 50/60 Hz)
MT990-2 Charger Assembly (BatteryMinder – 24 VDC, 240 VAC, 50/60 Hz)
* Or 1965 or later U.S. quarter dollar coin in good condition.

FIGURE 99-5 SPECIAL TOOLS

Page 99.6 Chapter 99 Special Tools APR 2017

99-20 Illustrations and Tasks (continued)
Refer to Figure 99-6.

Item Part Number Description*

1 R6683 Tow Cart Crate (31 in. x 38 in. x 66.50 in.)
2 R5387 Windshield Box (21.75 in. x 40 in. x 66 in.; cardboard. Holds up to four windshields.)
3 R5352 Main Rotor Blade Crate (21.75 in. x 17 in. x 206.50 in.)
4 R5385 Push-Pull Tube/Tail Rotor Drive Shaft Crate (10.25 in. x 11.50 in. x 192 in.)
* Dimensions are approximate and expressed in inches. Dimensions are provided in height x width x length.

FIGURE 99-6 SHIPPING CRATES

APR 2017 Chapter 99 Special Tools Page 99.7

99-20 Illustrations and Tasks (continued)
Refer to Figure 99-7.

Item Part Number Description*

1 R5386 Cabin Door Crate (23.75 in. x 34 in. x 60 in.; holds [1] bubble or [2] regular doors)
2 R5388 Tailcone Crate (27.25 in. x 24 in. x 192 in.)
3 R5702 Main Rotor Blade/Tailcone Crate (28 in. x 30 in. x 208 in.)
4 R7982 Main Rotor Gearbox Crate (27 in. x 28.75 in. x 89.50 in.)
* Dimensions are approximate and expressed in inches. Dimensions are provided in height x width x length.

FIGURE 99-7 SHIPPING CRATES

Page 99.8 Chapter 99 Special Tools APR 2017

CHAPTER 100

REVISION LOG
Section Title Page

— Revision Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100.1

JUL 2020 Chapter 100 Revision Log Page 100.i

Intentionally Blank

Page 100.ii Chapter 100 Revision Log JUL 2020

JUL 2020 Chapter 100 Revision Log Page 100.9

Intentionally Blank

Page 100.10 Chapter 100 Revision Log JUL 2020

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