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CHAPTER 8
FLIGHT CONTROLS (Continued)
Section Title
Page
8.542
Bellcrank Installation
8.57
8.550
A120-3 Aft Bellcrank
8.57
8.551
Bellcrank Removal
8.57
8.552
Bellcrank Installation
8.57
8.560
A031-1 Pitch Control
8.57
8.561
Pitch Control Removal
8.57
8.562
Pitch Control Installation
8.57
8.570
Tail Rotor Pitch Links
8.58
8.571
Tail Rotor Pitch Link Removal
8.58
8.572
Tail Rotor Pitch Link Installation
8.58
8.600
A203 Yoke and A205 Fork Assemblies
8.60
8.610
Bearing Removal
8.60
8.615
C648-2 Bearing Installation
8.60
8.620
A139-1 Bearing Installation
8.60
8.630
B115-1 Bearing Installation
8.62
8.640
Yoke and Fork Assembly Installation
8.63
OCT 2014
Chapter 8 Flight Controls
Page 8.iii
Intentionally Blank
Page 8.iv
Chapter 8 Flight Controls
OCT 2014
CHAPTER 8
FLIGHT CONTROLS
8.000 Flight Controls
8.001 Introduction
This section covers removal and installation procedures for cyclic controls, collective
controls, tail rotor controls and their related components.
WARNING
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.
8.002 Description (See Figures 8-1 and 8-2)
Dual controls are standard equipment and all primary controls are actuated through push-
pull tubes and bellcranks. Bearings used throughout the control system are either sealed
ball bearings or have self-lubricated Teflon liners.
Flight controls are conventional. The cyclic stick appears to be different but the grip
moves the same as in other helicopters due to the free hinge at the center pivot. The
cyclic grip is free to move vertically, allowing the pilot to rest his forearm on his knee if
he chooses.
The collective stick is also conventional with a twist grip throttle control. When the
collective is raised, the throttle is opened by an interconnecting linkage. An electronic
governor makes minor throttle adjustments required to maintain RPM.
8.100 Cyclic Controls
8.110 Cyclic Assembly
8.111 Removal of Cyclic Assembly
a. Remove left seat back, center horizontal and vertical panels.
b. Remove collective assembly per § 8.211.
c. Remove screws holding mixture and carburetor heat control cable covers to cyclic
box cover.
d. Remove roll pin from cyclic friction knob and remove knob.
e. Unscrew right trim knob from trim shaft.
f. Remove screws holding cyclic box cover to cyclic box and to side panels.
g. Lift cyclic box cover and disconnect post light wire.
OCT 2014
Chapter 8 Flight Controls
Page 8.1
FIGURE 8-1 MAIN ROTOR FLIGHT CONTROLS
Page 8.2
Chapter 8 Flight Controls
OCT 2014
8.222 Collective Spring Installation (continued)
c) On installation of the spring assembly, be sure to cut and remove the restraining
safety wire.
d) Check to make sure that the spring coils are not binding with collective stick full down.
Adjust spring assembly as required per § 8.223 or 8.224. Install collective cover.
WARNING
Failure to remove the safety wire or allowing the spring coils to
bind can limit the control travel creating a safety-of-flight hazard.
e) Install co-pilot seatback. Tighten seatback screws. Tighten four (4) fuel valve
plate attach screws.
WARNING
Ensure proper fuel valve handle orientation.
f) Install fuel valve handle. Verify proper orientation using gascolator drain. (See Fuel
Flow Check § 12.600.)
8.223 Collective Spring Adjustment for A038-1 thru -4 Assembly
a) Small force adjustments may be made by screwing the lower rod end in or out.
Install the MT294-1 collective spring tool. Remove the lower bolt and loosen the
adjustment. After reinstallation, ensure that the spring coils do not bottom out with
the collective full down. The maximum extension for the bottom rod end is 1.1
inches provided the spring coils do not bottom (See Figure 8-7).
b) Remove the collective spring per § 8.221.
c) Place spring assembly in a soft-jawed vise.
d) Compress the spring slightly and cut the safety wire.
e) Carefully open the vise to relieve the spring tension and remove the spring.
f) Install a spring selected from the table in § 8.220 to obtain the desired trim force.
g) Compress the spring assembly in a vise to a dimension of 4.30/4.00 inch between
the rod end center lines. Safety wire with 0.032 inch diameter stainless steel
safety wire (see Figure 8-7).
h) Reinstall the collective spring assembly per § 8.222.
OCT 2018
Chapter 8 Flight Controls
Page 8.33
8.224 Collective Spring Adjustment for A038-5, -6, or -7 Assembly
Large spring force adjustments are made by changing spring. Small spring force
adjustments may be made as follows:
a. Remove collective spring cover.
b. Loosen palnut and jamnut on lower rod end.
c. With collective up, rotate spring by hand to increase or decrease spring force
(lower rod end is right-hand thread; upper rod end is left-hand thread). Screwing
rod end in decreases collective-up force. Extending rod ends increases collective-
up force.
WARNING
Ensure that spring coils are not binding with collective stick full
down after making adjustment. Binding spring coils can limit
flight control travel.
d. Standard torque jamnut and palnut per § 23-32.
e. Install collective spring cover.
8.225 Collective Friction Adjustment (see Figure 8-5)
To adjust collective friction:
a. Loosen nut (item 5) on friction lever and position lever in locked position.
b. Turn screw (item 15) in threaded collective attachment fitting clockwise to
increase friction, counter-clockwise to decrease friction.
c. Adjust locked friction to 12 to 20 pounds measured at collective grip, using a
spring scale pulling up from bottom of travel.
WARNING
Collective friction greater than 20 pounds may prevent aircraft
from entering autorotation.
d. Tighten nut (item 5) on friction lever.
Page 8.34
Chapter 8 Flight Controls
OCT 2018
8.400 Swashplate and Main Rotor Pitch Links
8.410 Swashplate
8.411 Swashplate Removal
NOTE
Rigging check is not required if push-pull tube rod end bearing
center-to-center dimension has not changed.
1. Remove main rotor hub and blade assembly per §§ 26-20 and 26-10.
2. Disconnect and remove A203 yoke halves.
3. Remove droop stops and elastic teeter stops.
4. Remove swashplate boot.
5. Disconnect three push-pull tubes and rod end of lower A205 fork assembly from
lower, non-rotating swashplate.
6. Lift swashplate off slider tube.
OCT 2018
Chapter 8 Flight Controls
Page 8.39
8.412 Swashplate Installation
CAUTION
Swashplate plastic balls are obsolete and must be replaced.
1.
Verify swashplate rotates freely.
2.
On swashplate ear opposite interrupter, attach pitch link’s lower rod end with five
AN970-4 washers and two AN960-416L washers under bolt head, one A115-1
spacer on each side of rod end, with the small washers between spacer and large
washers. Install additional AN960-416L washer on bolt inboard of inner A115-1
spacer and insert bolt into swashplate ear. Washer stack-up must be located on
outside of ear. Install washers under nut as required to expose two to four threads
after torquing. Standard torque nut per § 23-32. Install palnut, standard torque per
§ 23-32, and torque stripe per Figure 2-1.
3.
On interrupter-side swashplate ear, attach pitch link with an A214-3 washer under
bolthead, one A115-1 spacer on each side of pitch link rod end, and one AN960-
416L washer between A115-1 spacer and swashplate ear.
4.
On interrupter-side swashplate ear, install A115-1 spacer on protruding length of
bolt, then A205 fork assembly rod end (rod end shank pointing up), another A115-1
spacer, one A214-3 washer, and the nut. Standard torque nut per § 23-32. Install
palnut, standard torque per § 23-32, and torque stripe per Figure 2-1.
5.
Attach A204 arm to A205 fork installed in previous step. If fork has plastic A139-
1 bearings, line ream and spot face bearings for correct fit per § 8.600. If fork has
C648-2 bearings (dark-brown colored face & bore), install a combination of A117-
45, -46, and/or -47 shims between A105-17 journal and A141-43 washer on nut
side to provide 0.010/0.001 inch axial play in joint. Refer to Figure 2-8. Verify 2.5
in.-lb maximum pivot friction.
6.
Install swashplate and attached pitch links, fork, and arm onto slider tube assembly
atop main rotor gearbox.
7.
Slide boot over A251 main rotor shaft and set in place.
8.
Install A203 yoke assembly onto A251 shaft using A210-1 key to position yoke on
shaft. Radiused edge of A210-1 key goes into flange slot in A251 shaft. Standard
torque nut per § 23-32. Install palnut, standard torque per § 23-32, and torque
stripe per Figure 2-1.
CAUTION
Tighten and torque bolt through A210-1 key first.
Page 8.40
Chapter 8 Flight Controls
OCT 2018
8.412 Swashplate Installation (continued)
9.
Install opposite clamping bolt in chord-arm side of yoke. As applicable, special
torque NAS1305 or NAS6605 bolt per § 23-33, or standard torque NAS1304 or
NAS6604 bolt per § 23-32. Install palnut, standard torque per § 23-32, and torque
stripe per Figure 2-1.
NOTE
A small space between chord-arm side yoke halves adjacent to
driveshaft is normal. Do not exceed bolt torque limits.
10.
Connect A204-1 arm to A203 yoke assembly. If yoke has plastic A139-1 bearings,
line ream and spot face bearings for correct fit per § 8.600. If yoke has C648-2
bearings (dark-brown colored face & bore), install a combination of A117-45, -46,
and/or -47 shims between A105-17 journal and A141-43 washer on nut side to
provide 0.010/0.001 inch axial play in joint. Refer to Figure 2-8. Verify 2.5 in.-lb
maximum pivot friction.
11.
Install A255 counterweights and AN970-4 washers on A203 yoke arm as required
for balance.
12.
Attach lower A205 fork’s rod end to left side of middle of three lugs grouped
together on lower swashplate. Connect forward push-pull tube rod ends to left
side of remaining two forward lugs. Aft push-pull tube rod end attaches to right
side of lower swashplate aft lug. A214-3 safety washer required between bolthead
and A115-1 spacer. A115-1 spacers are required on each side of all rod end balls.
Standard torque bolts per § 23-32. Install palnuts, standard torque per § 23-32, and
torque stripe per Figure 2-1.
13.
Position boot on upper swashplate and ty-rap in place. Ensure upper portion of boot
clamps on shaft between upper flange and A203 yoke halves.
14.
Temporarily install teeter hinge bolt and journals. Install droop stops and elastic
teeter stops. Ensure teeter stop brackets are oriented per Figure 26-5. Standard
torque bolts per § 23-32. Install palnut, standard torque per § 23-32, and torque
stripe per Figure 2-1. Remove teeter hinge bolt and journals.
15.
Verify no binding or interference with control movement throughout flight control
travel.
16.
Install main rotor hub and blades per §§ 26-20 and 26-10.
17.
Track and balance main rotor per § 10.200.
8.413 Reserved
8.414 Reserved
8.415 Reserved
OCT 2018
Chapter 8 Flight Controls
Page 8.41
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Page 8.42
Chapter 8 Flight Controls
OCT 2018
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OCT 2018
Chapter 8 Flight Controls
Page 8.43
Intentionally Blank
Page 8.44
Chapter 8 Flight Controls
OCT 2018
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OCT 2018
Chapter 8 Flight Controls
Page 8.45
Intentionally Blank
Page 8.46
Chapter 8 Flight Controls
OCT 2018
CHAPTER 9
ROTOR SYSTEMS
Section Title
Page
9.000
Description
9.1
9.100
Main Rotor
9.1
9.200
Tail Rotor
9.26C
9.210
Tail Rotor Assembly Removal
9.26C
9.212
Tail Rotor Installation with Spherical Teeter Bearings
9.27
9.213
Tail Rotor Installation with Elastomeric Teeter Bearings
9.30
9.214
Tail Rotor Hub Spherical Bearing Replacement
9.32A
9.215
Tail Rotor Hub Elastomeric Bearing Replacement
9.32B
9.220
Inspection and Repair of Tail Rotor Blades
9.33
OCT 2018
Chapter 9 Rotor Systems
Page 9.i
Intentionally Blank
Page 9.ii
Chapter 9 Rotor Systems
OCT 2018
CHAPTER 9
ROTOR SYSTEMS
9.000 Description
Refer to Chapter 26 for main rotor description.
The tail rotor has two all-metal blades and a teetering hub with a fixed coning angle. The
pitch change bearings have self-lubricated liners. The teeter hinge bearings are elastomeric
or have self-lubricated liners. The tail rotor blades are constructed with aluminum skins
and root fittings. Maintaining the paint finish will reduce corrosion and erosion.
9.100 Main Rotor
This section has been moved to Chapter 26 Main Rotor.
OCT 2018
Chapter 9 Rotor Systems
Page 9.1
Intentionally Blank
Page 9.2
Chapter 9 Rotor Systems
OCT 2018
9.200 Tail Rotor
9.210 Tail Rotor Assembly Removal
1. Mark or tag each pitch link and corresponding blade for reinstallation. Remove hardware
securing pitch links to tail rotor blades, noting hardware removed.
NOTE
Tail rotor pitch link-to-blade attach bolts may be different lengths
and/or have different washers installed under nut for balancing.
2. Remove nut and A141-14 washer securing A119-1 bumper to tail rotor gearbox output
shaft.
3. Remove teeter hinge bolt, then slide tail rotor assembly and bumper, and A130-1
spacers (A030-1 hub assembly only), off of shaft.
OCT 2014
Chapter 9 Rotor Systems
Page 9.26C
FIGURE 9-11 TAIL ROTOR ASSEMBLY INSTALLATION (A008-4 ASSEMBLY SHOWN)
Page 9.26D
Chapter 9 Rotor Systems
OCT 2014
CHAPTER 10
RIGGING, TRACK AND BALANCE
Section
Title
Page
10.000 Rigging, Track and Balance
10.1
10.001 Introduction
10.1
10.002 Rod End Adjustment Procedure for Rigging
10.1
10.100 Rigging
10.2
10.110 Main Rotor Flight Controls
10.2
10.111 Cyclic Controls
10.2
10.112 Swashplate
10.3
10.113 Collective Control
10.3
10.120 Main Rotor
10.3
10.121 Cyclic Travel Rigging
10.8
10.122 Collective Travel Rigging
10.11
10.130 Tail Rotor Flight Controls
10.12
10.131 Pedals
10.12
10.132 A316 Bellcrank
10.12
10.133 A331 Bellcrank
10.12
10.134 A120-1 Bellcrank
10.15
10.135 Tail Rotor Pitch Links
10.15
10.140 Tail Rotor Rigging
10.15
10.150 Throttle Correlation Rigging
10.19
10.200 Track and Balance
10.21
10.210 Equipment Requirements
10.21
10.220 Equipment Installation
10.21
10.221 Main Rotor Equipment Installation
10.21
10.222 Tail Rotor Equipment Installation
10.23
10.230 Main Rotor Track and Balance Procedure
10.27
10.231 Main Rotor Balance Adjustments
10.28
10.232 Main Rotor Pitch Link Adjustment
10.28
10.233 Main Rotor Trim Tab Adjustment
10.31
10.234 Main Rotor Track and Balance Trouble Shooting
10.33
10.240 Tail Rotor Balance Procedure
10.35
10.250 Autorotational RPM Adjustment
10.38
OCT 2018
Chapter 10 Rigging, Track and Balance
Page 10.i
Intentionally Blank
Page 10.ii
Chapter 10 Rigging, Track and Balance
OCT 2018
CHAPTER 10
RIGGING, TRACK AND BALANCE
10.000 Rigging, Track and Balance
10.001 Introduction
This section contains the procedures necessary to rig the main rotor flight controls,
tail rotor flight controls and throttle correlation. The track and balance procedures in
this section are to be used in conjunction with Chadwick-Helmuth balancing equipment
instructions.
10.002 Rod End Adjustment Procedures For Rigging
The following procedure is a standard for the adjustment of rod ends on the R22 helicopter.
1.
Loosen the palnut and jamnut on the rod end.
2.
Screw the rod end in or out of the push-pull tube or pitch link as required to obtain the
proper rigging adjustment.
3.
After adjustment of the rod end, check the witness hole in the push-pull tube or pitch
link to ensure the rod end is installed far enough to cover the hole. This should be
checked using a piece of .020” safety wire. The safety wire must not pass through
the witness hole into the push-pull tube or pitch link.
4.
Align the rod ends on both ends of the push-pull tube or pitch link so they will have
maximum misalignment clearance with the bellcrank clevis or arm (both rod ends
must move “stop to stop”). Collective rigging settings are made by readjusting the
total length of the pitch links. Adjustments (turns on the upper rod end or hex portion
of the pitch link) to each pitch link will be the same. The pitch link length may be
adjusted in three ranges; coarse, medium and fine. Adjustments are made as follows:
a. Coarse length adjustments to the length are made by rotating the coarse-threaded
section of the hex portion of the pitch link (the upper rod end is disconnected, the
lower rod end remains connected). Loosen the jamnut on the coarse threads only.
Increase blade angle by unscrewing the hex from the lower pitch link. Decrease
the angle by screwing the hex portion into the barrel. One full turn changes the
blade angle by approximately .72 degrees.
b. Medium length adjustments are made by rotating the upper rod end only. Disconnect
the rod end from the blade and loosen the rod end jamnuts. Increase blade angle
by unscrewing the rod end from the hex portion of the pitch link. Decrease the
angle by screwing the rod end into the hex. One full rod end turn changes the
blade by approximately .48 degrees.
c. The fine length adjustments are made by rotating only the hexagonal portion of the
pitch link. The upper and lower rod ends remain connected. Loosen the jamnuts
above the hex. Increase blade angle by screwing the hex out of the lower barrel.
Decrease blade angle by screwing the hex into the lower barrel. One full turn of
the hex portion changes the blade angle approximately .24 degrees.
5.
Torque rod end jamnuts and palnuts per § 1.300.
OCT 2014
Chapter 10 Rigging, Track and Balance
Page 10.1
10.100 Rigging
10.110 Main Rotor Flight Controls
10.111 Cyclic Controls
The cyclic control travel is non-adjustable and is controlled by A211-1 stop plate
attached to the cyclic box assembly.
NOTE
If the A121-1 push-pull tube length has been changed or the
length of the A205 fork was changed, they must be readjusted
to the dimensions shown in Figure 8-3.
a. Place the cyclic stick against the aft stop and the collective control full down.
b. Adjust the A121-3 push-pull tube to obtain a clearance of .130 inch between the
aft arm of the jack shaft and the main rotor gearbox upper cap flange.
Page 10.2
Chapter 10 Rigging, Track and Balance
OCT 2014
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