Robinson R22 Helicopter. MAINTENANCE MANUAL (2018)

CHAPTER 15

FURNISHINGS

Section Title

Page

15-00

Description

15.1

15-10

Seat Harnesses

15.1

15-20

Seat and Seat Back Assemblies

15.2

15-21

Seat Assemblies

15.2

15-22

Seat Back Assemblies

15.2

15-30

Carpet

15.4

15-40

Insulation (Foam and Headliner)

15.5

15-50

General Maintenance

15.6

15-51

Pilot’s Operating Handbook (POH) Strap Replacement

15.6

15-52

License Holder Replacement

15.6

15-53

Map Pocket Replacement

15.6

15-60

Emergency Equipment

15.7

15-61

Emergency Locator Transmitter (ELT)

15.7

15-62

Fire Extinguisher

15.8

OCT 2018

Chapter 15 Furnishings

Page 15.i

CHAPTER 15

FURNISHINGS

15-00 Description

The seats are not adjustable but each helicopter is delivered with a cushion which can be

placed behind the pilot to position him farther forward. This allows shorter pilots to reach

the pedals, the cyclic grip in its most forward position, and controls on the center console.

Each seat is equipped with a combined lap belt and inertia reel shoulder strap. The inertia

reel is normally free but will lock if there is sudden movement as would occur in an accident.

A baggage compartment is located under each seat. Seat cushions hinge forward for

access.

15-10 Seat Harnesses

A. Removal

1. Hinge seat assemblies forward.

2. Remove hardware securing F628-8 buckle assemblies to inboard anchors. Remove

hardware securing lap belt fittings to outboard anchors.

3. Remove shoulder strap guide covers. Remove hardware securing guides to A259

bulkhead.

4. Remove inertia reel covers. Remove hardware securing reels to bulkhead. Remove

A628-6 connector assemblies.

B. Installation

1. Install hardware securing A628-6 connector assembly inertia reels to A259

bulkhead. Install reel covers. Verify security.

2. Install hardware securing shoulder strap guides to bulkhead. Standard torque bolts

per § 23-32. Install guide covers. Verify security.

3. Install hardware securing F628-8 buckle assemblies to inboard anchors; rotate

buckles 20° forward from vertical. Standard torque bolts per § 23-32. Verify

security.

4. Install hardware securing lap belt fittings to outboard anchors. Standard torque

bolts per § 23-32. Verify security.

OCT 2018

Chapter 15 Furnishings

Page 15.1

15-20 Seat and Seat Back Assemblies

15-21 Seat Assemblies

A. Removal

Remove hardware securing seat assembly to support and remove seat.

B. Installation

Position seat assembly on support and install hardware. Verify security.

15-22 Seat Back Assemblies

A. Removal

Left Seat Back

1. Remove screws securing pilot’s collective boot and ring to A654-4 (vertical)

panel assembly, remove ring, and unsnap boot. Remove screws securing panel

to cabin and remove panel.

2. Remove screws securing A670-1 (fuel) valve’s A798 plates to A003-13 seat

back assembly and remove A798-1 plate.

3. Tilt seat assembly forward and remove screws securing co-pilot’s collective

boot and ring to seat back, remove ring, and unsnap boot. Remove screws

securing seat back to cabin and remove seat back. (Remove A798-3 plate.)

Right Seat Back

1. Remove screws securing pilot’s collective boot and ring to A654-4 (vertical)

panel assembly, remove ring, and unsnap boot. Remove screws securing panel

to cabin and remove panel.

2. Remove screws securing A003-14 seat back assembly to cabin and remove

seat back.

Page 15.2

Chapter 15 Furnishings

OCT 2018

FIGURE 15-1 A798-1 PLATE ORIENTATION (VIEW LOOKING DOWN)

15-22 Seat Back Assemblies (continued)

B. Installation

Left Seat Back

1. Position A798-3 plate on A670-1 (fuel) valve. Tilt seat assembly forward

and position A003-13 seat back assembly on cabin and install screws. Verify

security.

2. Install screws securing co-pilot’s collective boot and ring to seat back and snap-

up boot. Verify security.

3. Refer to Figure 15-1. Install A798-1 plate on seat back as shown. Special

torque screws to 16 in.-lb.

4. Install screws securing A654-4 (vertical) panel assembly to cabin. Install screws

securing pilot’s collective boot and ring to panel and snap-up boot. Verify

security.

Right Seat Back

1. Refer to Figure 15-1. Tilt seat assembly forward and position A003-14 seat

back assembly on cabin and install screws. Verify security.

2. Install screws securing A654-4 (vertical) panel assembly to cabin. Install screws

securing pilot’s collective boot and ring to panel and snap-up boot. Verify

security.

OCT 2018

Chapter 15 Furnishings

Page 15.3

15-22 Seat Back Assemblies (continued)

C. Back Rest Assembly (Cushion) Replacement

1. Remove seat back assembly per Part A.

2. Drill out rivets securing back rest assembly (cushion) to seat back panel and

deburr holes. Remove cushion.

3. Center and straighten new back rest 1.00 ± 0.10 inch above top edge of seat

back panel. Match drill seat back panel #30 holes through back rest. Deburr

holes and clean up debris.

4. Attach back rest cushion to seat back panel with rivets. Verify security.

15-30 Carpet

A. Removal

1. Floor carpets: Remove hardware securing scuff plates (and carpet) to cabin floor

and remove scuff plates, if installed.

CAUTION

Use caution when removing adhered carpet if carpet is intended

for reuse.

2. Starting at corners, gently peel back carpet by hand, or with plastic wedge or putty

knife.

3. Dampen old adhesive with Dupont Prep-Sol (or equivalent) to facilitate removal.

B. Installation

1. Verify proper carpet fit. Trim as required (do not trim carpet welt).

2. Apply B270-8 adhesive to bonding surface and carpet backing. Press carpet to

surface, smooth wrinkles, and remove excess adhesive prior to curing.

3. Install hardware securing scuff plates (and carpet) to cabin floor if removed. Verify

security.

Page 15.4

Chapter 15 Furnishings

OCT 2018

15-40 Insulation (Foam and Headliner)

A. Removal

NOTE

Use caution not to damage surface underneath insulation when

removing insulation with tools.

NOTE

Insulation is installed using adhesive, except under seat

assemblies. Order new insulation as required; reuse of removed

insulation is not recommended.

1. Peel off insulation by hand.

2. Using plastic wedge or putty knife, carefully remove residual insulation and old

adhesive.

3. Wipe bonding surface with clean cloth, wet with acetone.

B. Installation

1. Verify proper insulation fit. Trim as required.

2. Apply B270-8 adhesive to bonding surface and insulation backing. Press insulation

to surface, smooth wrinkles, and remove excess adhesive prior to curing.

OCT 2018

Chapter 15 Furnishings

Page 15.5

15-50 General Maintenance

15-51 Pilot's Operating Handbook (POH) Strap Replacement

A. Removal

Remove POH. Drill out rivets securing POH retaining strap to chin and remove strap.

Deburr holes and clean up debris.

B. Installation

Cleco POH retaining strap to chin. Progressively remove clecos and install rivets.

Verify security. Install POH.

15-52 License Holder Replacement

A. Removal

Remove contents. Drill out rivets securing license holder to chin and remove license

holder. Deburr holes and clean up debris.

B. Installation

Cleco license holder to chin. Progressively remove clecos and install rivets. Verify

security. Install contents and tuck holder under frame.

15-53 Map Pocket Replacement

A. Removal

Remove contents. Drill out rivets securing map pocket to seat support. Remove

pocket, washers, and retaining strips. Deburr holes and clean up debris.

B. Installation

1. Fold (long) outboard pocket edge around (long) A913-1 strip, align holes, and

align holes with front of forward seat box. Cleco in place.

2. Pull material taut, fold (short) inboard pocket edge around (short) A913-2 strip,

align holes, and align holes with front of forward seat box. Cleco in place. Trim

excess material.

3. Progressively remove clecos and install washers and rivets.

Page 15.6

Chapter 15 Furnishings

OCT 2018

15-60 Emergency Equipment

15-61 Emergency Locator Transmitter (ELT)

A. Description

The ELT activates when subjected to a significant change in velocity (as in an

accident), by remote control switch located on the cyclic control panel, or by a

switch on the ELT transmitter. Refer to § 33-80 for system description.

Refer to Kannad Aviation AF Integra / AF-H Integra or 406 AF-Compact/406 AF-

Compact (ER) ELT Installation and Operation Manual for maintenance requirements

and procedures. Refer to § 1.100 for scheduled maintenance.

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.

OCT 2018

Chapter 15 Furnishings

Page 15.7

15-62 Fire Extinguisher

CAUTION

Extinguisher is rated for a storage and operating temperature

120°F (49°C). If operating conditions would expose

extinguisher to higher temperatures (e.g. long term parking in

the sun in a hot climate), remove extinguisher and store it in a

cooler area between flights.

A. Inspection

Every month: Visually inspect fire extinguisher and perform weight check (a scale

with 1 gram precision or better is required). Remove extinguisher from service if

weight decreases by more than 3.2 grams per year, or total weight falls below 500

grams. If desired, order one G654-15 decal (blank maintenance log) and attach to

extinguisher, to record weight checks.

Every 12 years: Remove fire extinguisher from service. Year of manufacture is

labeled on bottom of extinguisher; remove extinguisher from service at end of 12th

year from labeled date.

B. Bracket Removal

1. Unlatch fire extinguisher bracket and remove extinguisher.

2. Remove hardware securing bracket to chin and remove bracket.

C. Bracket Installation

1. Install hardware securing fire extinguisher bracket to chin. Select screw length

as required to provide 0.00-0.06 inch thread exposure. Verify security.

2. Install fire extinguisher and latch bracket.

Page 15.8

Chapter 15 Furnishings

OCT 2018

CHAPTER 16

DIMENSIONS AND DESCRIPTIONS

16-10 Version Description

Refer to § 3.200 for Type Certificate Data Sheet.

WARNING

Refer to R22 Illustrated Parts Catalog (IPC) for specific part

number differences between versions.

R22 Standard:

Approved March 16, 1979. Serial numbers 0002 thru 0199, except 0175.

Lycoming O-320-A2B or Lycoming O-320-A2C engine normally rated at

150 horsepower and derated to 124 horsepower. 80/87 minimum grade

aviation gasoline. Gross weight 1300 pounds. Stabilizer angle 1.8-2.3

degrees nose up.

R22 HP:

Serial numbers 0175, 0200 thru 0255, 0257 thru 0300, 0302 thru

0349, 0352 thru 0356. Lycoming O-320-B2C engine normally rated

at 160 horsepower and derated to 124 horsepower.

100LL or 91/96

minimum grade aviation gasoline. Gross weight 1300 pounds. Stabilizer

angle 1.8-2.3 degrees nose up.

R22 Alpha:

Approved October 12, 1983. Serial numbers 0256, 0301, 0350, 0351,

0357 thru 0500. Lycoming O-320-B2C engine derated to 124 horsepower.

Extended lower steel frames. Tailcone higher than Standard/HP. Aft

battery installation. Gross weight 1370 pounds. Stabilizer angle 2.8

-3.3 degrees nose down. Auxiliary fuel tank optional for serial numbers

0457 and subsequent.

R22 Beta:

Approved August 12, 1985. Serial numbers 0501 thru 2570. Lycoming

O-320-B2C engine derated to 124 horsepower.

131 horsepower five-

minute take off rating. Extended lower steel frames. Higher tailcone

than Standard/HP. Aft battery installation. Seven-hole instrument panel.

Larger oil cooler.

1370 pounds gross weight. Stabilizer angle 2.8-3.3

degrees nose down. Auxiliary fuel tank optional. A569-5 low-rpm

warning unit with starter lockout feature installed in serial number 2115

and subsequent. Starter lockout prevents starter activation at less than

62% rotor rpm when actuator is not fully disengaged; starter may be

activated above 69% rotor rpm to allow an in-flight engine start.

OCT 2018

Chapter 16 Dimensions and Descriptions

Page 16.1

16-10 Version Description (continued)

R22 Mariner:

Approved September 12, 1985. Serial numbers 0364, 0501 thru

2570 eligible (suffix “M” added to ship serial number). Similar to Beta

configuration except includes utility floats and additional corrosion

protection. Different tailcone with 1.8-2.3 degrees nose-up horizontal

stabilizer angle. Battery in nose when floats installed. Float stabilizer on

lower vertical stabilizer in place of tail skid. May be flown without floats

VFR day or night. Day VFR flight only with floats installed. Auxiliary fuel

tank optional. Marine radio package optional.

Instrument

Alpha, Beta, or Beta II configuration with 10-hole instrument panel. VMC

Trainer:

operations only.

Police

Alpha, Beta, or Beta II configuration with searchlight, police radio package,

Helicopter:

and 70 amp alternator.

R22 Beta II:

Approved January 31, 1996. Serial numbers 2571 and subsequent.

Lycoming O-360-J2A engine derated to 124 horsepower maximum

continuous power. 131 horsepower 5-minute take-off rating. Carburetor

heat assist. 1370 pounds gross weight. Stabilizer angle 2.8-3.3 degrees

nose down. Throttle only engine governor standard. A569-5 low-rpm

warning unit with starter lockout feature standard. Auxiliary fuel system

optional.

R22 Mariner II:

Approved January 31, 1996. Serial numbers 2571 thru 3414 eligible

(suffix “M” added to ship serial number). Similar to Beta II configuration

except includes utility floats and additional corrosion protection. Battery

in nose when floats installed. Different tailcone with 1.8-2.3 degrees

nose-up horizontal stabilizer angle. Float stabilizer on lower vertical

stabilizer in place of tail skid. May be flown without floats VFR day or

night. Day VFR flight only with floats installed. Marine radio package

optional.

16-20 Datum

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

16-30 Method of Measurement

Fuselage station, tailcone station, water line station, and butt line station values are

measured in inches, rounded to the nearest hundredth.

Page 16.2

Chapter 16 Dimensions and Descriptions

OCT 2018

16-50 Station Locations

Reserved.

16-60 Access and Inspection Panels

Refer to R22 Illustrated Parts Catalog Chapter 6 for access and inspection panel locations.

16-61 B526 Screws and B527-08 Washers

B526 (TORX Plus®) truss head screws may be used to secure cowlings and access

panels. A B527-08 nylon washer may be used under a B526 screw head to further

protect thin or painted surfaces.

B526 screws are interchangeable with MS27039C080_ screws used to secure cowlings

and access panels as follows:

PART:

INTERCHANGEABLE WITH:

MS27039C0806 screw

B526-6 screw

MS27039C0807 screw

B526-8 screw

MS27039C0808 screw

B526-8 screw

B526 screws are interchangeable with AN525-832R_ & AN526C832R_ screws as

follows:

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 16.6

Chapter 16 Dimensions and Descriptions

OCT 2018

16-70 Antenna Locations

NO. ANTENNA

PART NO.

NO. ANTENNA

PART NO.

NAV

CI 259E

ADF

KA44B

NAV

CI 259E (W/DIPLEXER)

Cowling GPS

GA 35

RH Belly FM

CI 292-3

Fwd Tailcone COM

CI 121 or CI 248-5

RH Belly FM

CI 177-20

Fwd Tailcone COM/GPS

CI 2580-200

RH Belly FM

CI 273 OR CI 271

RMS/GPS

921-00003-001

RH Belly COM

CI 122

Aft Tailcone COM

CI 121 or CI 248-5

RH Belly FM

CI 272-1

Aft Tailcone GPS/COM

CI 2580-200

LH Belly FM

CI 292-3

LH Belly FM

CI 177-20

LH Belly FM

CI 273 OR CI 271

Marker Beacon

CI 102

Transponder/UAT (ADS-B) . . CI 105-16 OR KA60, FWD

Transponder

CI 105-16 OR KA60, AFT

DME

CI 105-16 OR KA60

FIGURE 16-4 ANTENNA LOCATIONS

OCT 2018

Chapter 16 Dimensions and Descriptions

Page 16.7

CHAPTER 17

JACKING AND HOISTING

17-10 Jacking

CAUTION

When jacking helicopter, use mechanical or locking hydraulic

jacks, when available. Unlocked hydraulic jacks are subject

to pressure-loss which can affect critical measurements during

leveling or cause a raised helicopter to become unstable.

CAUTION

Never jack helicopter in windy conditions.

CAUTION

Perform jacking on a clean, flat, hard surface free of water,

oil, solvent, grease, or residue that could cause equipment or

personnel to slip during jacking procedure.

CAUTION

Do not actuate jacks from underneath helicopter. Remain clear

of landing gear skid tubes when helicopter is raised.

OCT 2018

Chapter 17 Jacking and Hoisting

Page 17.1

17-10 Jacking (continued)

A. Jacking

Two methods may be used to jack helicopter:

a. Refer to Figure 17-1. Place a foam-covered contour block under vertical

firewall. Install skid stand under tail. Place an appropriate capacity jack under

each end of contour block.

CAUTION

Contour block must be directly under vertical firewall to support

weight of helicopter.

b. Place an appropriate capacity jack under each (landing gear) aft cross tube,

one inch inboard of elbow fittings, and under the ground handling ball as

required.

CAUTION

Ground handling ball must slide unrestricted across a flat surface

during jacking. When weighing, verify ball is not under side

load which could produce an erroneous weight indication.

Position jack levers for convenient access and engage jacks. Sandbag jacks for

increased stability, as required.

Actuate jacks slowly and simultaneously (one person per jack recommended),

maintaining helicopter stability. Raise helicopter to required height (at least 4

inches off ground if removing landing gear).

CAUTION

Minimize personnel movement around raised helicopter.

B. Lowering

CAUTION

Skids spread as aircraft weight settles on landing gear.

1. Slowly and simultaneously (one person per jack recommended) lower each jack

ram, maintaining helicopter stability. Lower aircraft to ground.

2. Clear jacking equipment from area.

OCT 2018

Chapter 17 Jacking and Hoisting

Page 17.3

17-20 Hoisting

CAUTION

Avoid hoisting helicopter in windy conditions.

CAUTION

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

that could cause equipment or personnel to slip during hoisting

procedure.

CAUTION

Remain clear of area beneath helicopter when helicopter is

raised. Minimize personnel movement around raised helicopter.

A. Hoisting with Lifting Fixture

1. Refer to Figure 17-2. Verify hoisting equipment has minimum load capacity of 1000

lb.

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

3. Remove two spring pins and four nylon bushings from MT234-1 lifting fixture and

install bushings in main rotor hub lightening holes. Position lifting fixture on hub

then insert spring pins through fixture and bushings until pins lock. Verify security.

4. Connect hoist to lifting fixture. Verify security.

5. Stabilize helicopter as required by guiding tail skid, but do not exert force (tail skid

is secondary structure). Raise helicopter to required height.

B. Hoisting with Nylon Rope

1. Refer to Figure 17-2. Verify hoisting equipment has minimum load capacity of

1000 lb. Verify minimum work load limit for 1-inch diameter twisted or double

braided (preferred) soft nylon rope is 1000 lb.

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

3. Insert rope through main rotor hub lightening holes, form a double loop, and knot

ends. Connect hoist to nylon rope. Verify security.

4. Stabilize helicopter as required by guiding tail skid, but do not exert force (tail skid

is secondary structure). Raise helicopter to required height.

OCT 2018

Chapter 17 Jacking and Hoisting

Page 17.5

CHAPTER 18

WEIGHT AND BALANCE

18-10 Leveling

NOTE

Perform leveling and weighing in a zero-wind environment.

NOTE

Verify spirit level is calibrated by placing level on a designated

surface and noting bubble position. Rotate spirit level 180°;

verify bubble is in the same position.

18-11 Leveling at Lower Right Side Frame Tube & Aft Landing Gear Cross Tube

NOTE

Use this leveling method for R22 Standard & R22 HP models only.

1. Place a bubble level on lower right steel tube frame horizontal member at location

marked LEVEL HERE.

2. Level helicopter longitudinally by placing shims under landing gear skid tubes or jacks

under outboard edge of aft cross tube.

3. Place bubble level on center of landing gear aft cross tube.

4. Level helicopter laterally by placing shims under landing gear skid tubes or jacks under

outboard edge of aft cross tube.

5. Recheck level per steps 1 & 3 and adjust as required.

OCT 2018

Chapter 18 Weight and Balance

Page 18.1

18-12 Leveling at Main Rotor Hub

NOTE

Use this leveling method for all R22 models.

1. Place a bubble level atop MR hub.

NOTE

Level must be parallel to teeter hinge bolt.

2. Rotate main rotor until teeter hinge bolt is aligned with longitudinal axis of helicopter.

3. Level helicopter longitudinally by placing shims under landing gear skid tubes or jacks

under outboard edge of aft cross tube.

4. Rotate main rotor until teeter hinge bolt is aligned with lateral axis of helicopter.

5. Level helicopter laterally by placing shims under landing gear skid tubes or jacks under

outboard edge of aft cross tube.

NOTE

Jacks may be used under aft cross tube 1 inch inboard from

each elbow.

6. Recheck level per steps 2 & 4 and adjust as required.

18-13 Leveling at Keel Panels

NOTE

Use this leveling method for all R22 models.

1. Remove horizontal panel between seat bottoms and remove cyclic box cover.

2. Place a bubble level on top edge of right keel panel per Figure 18-1 Detail A.

3. Level helicopter longitudinally by placing shims under landing gear skid tubes or jacks

under outboard edge of aft cross tube.

4. Place a bubble level across two keel panels per Figure 18-1 Detail B.

5. Level helicopter laterally by placing shims under landing gear skid tubes or jacks under

outboard edge of aft cross tube.

6. Recheck level per steps 2 & 4 and adjust as required.

OCT 2018

Chapter 18 Weight and Balance

Page 18.3

18-20 Weighing and CG Calculation

Reweigh helicopter when helicopter empty weight and empty weight center of gravity have

been modified and if the accuracy of additional calculations is suspect.

Maintain a continuous record of the helicopter’s weight and balance using the Weight and

Balance Record in R22 Pilot’s Operating Handbook (POH) Section 6.

NOTE

Verify scales are calibrated. Operate scales according to scale

manufacturer’s instructions.

NOTE

Never weigh the helicopter in the wind. Weigh helicopter on a

level, flat, hard surface in a zero-wind environment for accurate

scale readings.

18-21 Preparing Helicopter for Weighing

1. Defuel helicopter per § 22-52.

2. Service engine oil per R22 Pilot’s Operating Handbook (POH) Section 8. Fill main and

tail gearboxes to center of sight glass with A257-2 oil.

3. Clean aircraft per POH Section 8. Verify helicopter is completely dry.

4. Remove items that are not installed equipment (tools, rags, charts, etc.) from baggage

compartments and stowage areas.

5. Verify cowlings, removable panels, cabin doors, removable controls, and POH are

installed.

6. Verify Equipment List/Weight and Balance Data sheet (RF 134) and modifications

recorded in the Weight and Balance Record correspond with installed equipment and

recorded equipment locations.

Page 18.4

Chapter 18 Weight and Balance

OCT 2018

18-22 Weighing Procedure and Calculations

NOTE

• Arm is the distance in inches from datum.

• Datum is located 100 inches forward of main rotor centerline.

• CG (arm) is determined by dividing total moment by total weight.

Refer to § 18-20. Prepare helicopter for weighing per § 18-21.

Hoist helicopter per § 17-20 approximately one foot above the ground. Have one

person hold tail of helicopter while hoisting to stabilize helicopter.

With main rotor blades oriented approximately fore and aft, raise both blades off of

droop stops to allow hub to teeter freely. Raise tail slightly and allow to settle.

Refer to Figure 18-2. With aircraft hanging freely and steady, use a water level and

measure difference in vertical height between tail rotor gearbox centerline and cabin

belly at vertical firewall. Ensure no air bubbles in water level tube.

Record height difference:

inches

Determine longitudinal center of gravity:

114.47 - [0.315 x (height difference from step 4)] =

inches

Place a 1000-lb capacity (minimum) scale under each skid. Locate center of scales

approximately 10 inches forward of (ground handling wheel ) skid supports.

Lower helicopter until it rests entirely on scales. Helicopter must be well balanced

on scales before releasing tail. Be sure helicopter is level laterally by placing level on

center of aft landing gear cross tube.

Determine empty weight:

Right scale reading:

Left scale reading:

Tare (leveling shims, hoist fixture, etc.):

Empty weight:

OCT 2018

Chapter 18 Weight and Balance

Page 18.5

18-22 Weighing Procedure and Calculations (continued)

Determine CG with full fuel and minimum solo pilot:

a. Bladder tank(s):

i. With aux tank:

(CG from step 5) x (Empty weight from step 8) + 28495

(Empty weight from step 8) + 303

in.

ii. Without aux tank:

(CG from step 5) x (Empty weight from step 8) + 22064

(Empty weight from step 8) + 240

in.

b. All-aluminum tank(s):

i. With aux tank:

(CG from step 5) x (Empty weight from step 8) + 30180

(Empty weight from step 8) + 319

in.

ii. Without aux tank:

(CG from step 5) x (Empty weight from step 8) + 23011

(Empty weight from step 8) + 249

in.

10. If CG from step 9 is aft of aft limit (refer to R22 Pilot’s Operating Handbook [POH]

Section 2 for model-specific data), determine required nose ballast:

[CG from step 5 - (model’s aft limit)] x (Empty weight from step 8) - 2358

64.5

11. Adjust weight and balance to correct for drained unusable fuel and ballast:

Longitudinal CG

Item

Weight (lb)

(arm, inches)

Moment (in.-lb)

Multiply empty weight from

step 8 by CG from step 5

Nose ballast:

37.5

10.2*, 6.0**,

Unusable fuel (add):

or 3.6***

100.0

* Bladder tanks

** All-aluminum tank(s) with aux tank

*** All-aluminum tank(s) without aux tank

Page 18.6

Chapter 18 Weight and Balance

OCT 2018

18-30 Fixed Ballast

NOTE

Maximum allowable nose ballast is 10.0 lb.

CAUTION

Altering fixed ballast can appreciably affect helicopter center of

gravity (CG). If fixed ballast information is unknown, reweigh

helicopter per § 18-22.

Remove screws and hinge upper console assembly aft. Insert foam support or equivalent

between console and cyclic to protect instrument faces.

Refer to Figure 8-3. Remove hardware securing A941-2 or -3 ballast plate(s), if installed,

to A363-1 cover.

If A941 ballast attach holes are not previously drilled, use A941 ballast as template and

mark hole locations. Drill 0.198 inch diameter (#8 drill size) hole at marked locations.

Remove or install ballast plates per calculations in § 18-22. Select NAS6603 bolt length

to meet torque requirements per § 23-30. Install hardware, standard torque bolts per §

23-32, and torque stripe per Figure 2-1.

Remove foam, hinge upper console assembly forward, and install screws. Verify

security.

Reweigh and/or calculate basic empty weight and CG per § 18-22.

Revise Weight and Balance Record in R22 Pilot's Operating Handbook (POH) Section 6

to reflect ballast removal or installation using the following data:

Longitudinal

Lateral

Weight

Lateral Arm

Arm

Moment

Nose ballast

0-10.0 lb

37.5 in.

Variable

0.0 in.

0.0 in.-lb

OCT 2018

Chapter 18 Weight and Balance

Page 18.9

CHAPTER 19

GROUND HANDLING

19-10 Ground Handling

19-11 Ground Handling Wheels

NOTE

R22 ground handling wheels are installed outboard of landing

gear skid tubes. A063-1 wheel assemblies are interchangeable

(may be installed in right or left skid support). When wheels are

installed and in locked position, handle on right skid tube points

forward and handle on left skid tube points aft.

CAUTION

Handle has a tendency to snap over when raising and lowering the

helicopter. Grip handle firmly with both hands during operation.

CAUTION

Remain clear of landing gear skid tubes when helicopter is

raised.

WARNING

Remove ground handling wheels for flight.

OCT 2018

Chapter 19 Ground Handling

Page 19.1

19-11 Ground Handling Wheels (continued)

A. Installation

NOTE

Verify proper inflation of ground handling wheel tires. Maximum

tire inflation pressure is 60 psi (4 bar).

NOTE

Refer to Figure 19-2 for float ship landing gear ground handling

wheels installation.

1. Refer to Figure 19-1. Hold ground handling wheel assembly outboard of skid with

handle left, wheel right, and spindle pointed inboard. Insert spindle completely

into skid-mounted support, then pull handle in rightward arc (raises helicopter) until

handle is in locked position, parallel with the skid.

2. Repeat step to install second wheel assembly (helicopter will rest on skid toes).

Removal

NOTE

Refer to Figure 19-3 for float ship landing gear ground handling

wheels removal.

1. Refer to Figure 19-1. Pull ground handling wheel handle in leftward arc (lowers

helicopter) until handle is in unlocked position, parallel with the skid. Remove

spindle from skid-mounted support and remove wheel assembly.

2. Repeat step to remove second wheel assembly.

OCT 2018

Chapter 19 Ground Handling

Page 19.3

INSTALLATION

1. Pull tail down. Insert forward blocks

at their lower height under both skids

at forward marks.

2. Push tail up. Insert rear blocks at

their lower height under both skids at

rear marks.

3. Pull tail down. Move forward blocks

“inside” to their upper height under

skid tubes.

4. Push tail up. Slide rear blocks out

(upper height of rear blocks is not

used) and insert wheels under skids

at rear marks.

NOTE

Adjust wheel placement as necessary

to reduce force required to pull tail

down.

5. Pull tail down and remove forward

blocks. Installation is completed.

FIGURE 19-2 FLOAT LANDING GEAR GROUND HANDLING WHEELS INSTALLATION

Page 19.4

Chapter 19 Ground Handling

OCT 2018

19-12 Moving Helicopter on Ground Handling Wheels

1. Position main rotor blades approximately fore and aft and apply rotor brake.

2. Install ground handling wheels per § 19-11.

3. Verify ground handling area is free of foreign object debris.

4. Have one person pull down on tail rotor gearbox until skid tubes are parallel with the

ground. During ground handling, balance helicopter to minimize wear on forward skid

shoes and rear extensions.

NOTE

Steer helicopter by gripping the tail rotor gearbox, aft tailcone

section, or inboard part of horizontal stabilizer between tailcone

and vertical stabilizers.

CAUTION

Do not steer helicopter by gripping the tail rotor guard, vertical

stabilizers, outboard part of horizontal stabilizer, tail rotor, tail

rotor controls, or tail skid.

5. If additional help is needed, a second person may push on one of the aft vertical frame

tubes or on the nose.

19-13 Ground Handling Carts

The R22 can be handled by one person using the MT900-1 or MT950-1 ground handling cart.

MT900 and MT950 Operating Instructions, Maintenance Manuals, and Illustrated Parts

Catalogs are available online at www.robinsonheli.com.

Page 19.6

Chapter 19 Ground Handling

OCT 2018

19-20 Trailering

CAUTION

Trailering the R22 is not normally recommended. Most trailers

large enough to accommodate the helicopter are designed for

much heavier loads; the trailer’s springs and shock absorbers

will not function properly when lightly-loaded. Also, without

support, the tailcone can resonate with trailer vibrations,

subjecting the tailcone to greatly amplified loads.

If trailering is unavoidable, observe the following precautions:

1. Load trailer with ballast to an average weight the trailer is designed to carry.

2. Support the tailcone. Cushion support point(s) to prevent tailcone damage.

3. Perform one of the following options:

a. Remove main rotor blades per § 26-10. Pack blades in shipping crate.

b. Fabricate blade supports to unload droop stops. Position supports approximately

five feet from blade tips. Cushion support points to prevent blade damage.

4. Restrain tail rotor to prevent teetering.

5. Fuel helicopter per § 22-51.

6. Protect windshield, windows, rotor systems, and all fragile equipment from exposure

to highway debris and subsequent damage.

7. After trailering, perform 100-hour maintenance and inspection per § 2.400.

OCT 2018

Chapter 19 Ground Handling

Page 19.7

CHAPTER 20

PARKING AND STORAGE

20-10 Parking

1. Place cyclic control in neutral and apply friction.

2. Put collective full down and apply friction.

3. Align rotor blades approximately fore and aft. Apply rotor brake. Install main rotor

blade tie-down(s) in windy conditions per § 20-12.

CAUTION

Do not pull down on blades to teeter rotor. To lower a blade,

push up on opposite blade.

4. During storm conditions, helicopter should be hangared or moved to a safe area (refer

to § 20-11).

20-11 Parking in High Wind or Turbulent Air

A. High Wind or Turbulent Air

Helicopter should be hangared or moved to a safe area during storm conditions or

when storm conditions are forecasted. When parking helicopter in high winds or

when aircraft is exposed to prop/rotor wash or jet blast:

1. Position helicopter with nose pointed in the direction of prevailing wind or

turbulent air.

2. Park helicopter per § 20-10. Position rotor blades slightly offset from fore and

aft to prevent aft blade from flapping into tailcone, and apply rotor brake.

3. If helicopter is hangared, turn fuel shutoff valve off.

OCT 2018

Chapter 20 Parking and Storage

Page 20.1

20-11 Parking in High Wind or Turbulent Air (continued)

B. Extreme Conditions

In extreme conditions, at the operator’s discretion:

1. Remove main rotor blades per § 26-10. Remove tail rotor assembly per § 9.210.

Store main rotor blades and tail rotor assembly in hangar or safe area.

2. Remove main rotor pitch links per steps below, or temporarily secure links

together using ty-rap(s) or safety wire:

a. Mark an “X” on one pitch link lower rod end and corresponding swashplate

ear using a colored grease pencil. Mark an “O” on opposite link and

corresponding swashplate ear.

b. Remove hardware securing pitch links to swashplate assembly.

3. Remove tail rotor pitch links per steps below:

a. Refer to Figure 9-11. Tag each pitch link with corresponding blade serial

number. Disconnect pitch links from tail rotor blades; keep associate

balancing hardware with each link.

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

20-12 Main Rotor Blade Tie-Downs

CAUTION

Overtightening tie-down straps can damage main rotor blades.

Maximum tie-down tension is 5 lb.

1. Park helicopter per § 20-10.

2. Refer to Figure 20-1. Slide MT290-1 tie-down jacket over forward (lowered) main

rotor blade tip, white lettering facing down. Tie strap to windshield center post or

thread strap through post and secure hook and loop tape. Push up on secured blade

to remove slack in tie-down strap.

3. As required, install MT290-1 tie-down on aft main rotor blade. Slide jacket over

blade tip, white lettering facing down. Wrap strap around tailcone forward of strobe

light, then tie around strobe light base or secure hook and loop tape around strobe

light base. Push up on secured blade to remove slack in tie-down strap.

OCT 2018

Chapter 20 Parking and Storage

Page 20.3

20-13 Main Rotor Blade Supports

Reserved.

20-20 Storage (Greater than 30 days)

Record the date helicopter is prepared and placed in storage.

CAUTION

To minimize risk of electrical discharge: when disconnecting

battery, disconnect negative (ground) cable from battery first,

then the positive cable. When connecting battery, connect

positive cable to battery first, then the negative (ground) cable.

Turn battery off. Remove cotter rings and wing nuts securing battery box cover to box

and remove cover. Remove hardware securing cables to battery. Remove battery.

Inspect and service battery according to battery manufacturer’s instructions.

Preserve engine for storage per Lycoming Service Letter no. L180 (current revision).

Fill main and tail gearboxes to center of sight glass with A257-2 oil.

Fuel helicopter per R22 Pilot’s Operating Handbook (POH) Section 8.

NOTE

Fuel lubricates bladder inner liner and keeps it from drying out

or cracking. Refuel helicopter after run-ups during storage.

Clean aircraft per POH Section 8. Verify helicopter is completely dry.

Refinish main rotor blades per § 26-10. Refinish tail rotor blades per § 9.220. If blade

painting is not feasible, wax blades.

Position helicopter in a hangar or protected environment.

Apply suitable non-drying corrosion preventive compound to A166 clutch shaft adjacent

to seals (where shaft enters and exits upper sheave).

10.

Open door vents or remove doors to ventilate cabin as required.

11.

Close and latch access doors.

NOTE

During storage, periodically inspect helicopter for corrosion;

helicopters stored in humid environments will require more

frequent inspection.

Page 20.4

Chapter 20 Parking and Storage

OCT 2018

CHAPTER 21

PLACARDS AND MARKINGS

21-10 Placards and Markings

Refer to R22 Illustrated Parts Catalog Chapter 11 for placard and marking locations.

A. Removal

To remove previously installed decals, start at corners and slowly peel off decal by

hand or using a plastic wedge. Avoid damaging or removing paint or primer from

surfaces. Remove decal entirely.

B. Installation

Verify surfaces are clean and dry before attaching decals. Use a clean cloth wet

with acetone or mild soapy water to clean surfaces, but use caution when using

acetone near silk-screened lettering on console and circuit breaker panel. Acetone

can smudge or remove silk-screened letters. Attach decal and rub decal surface with

finger, applying slight pressure.

OCT 2018

Chapter 21 Placards and Markings

Page 21.1

CHAPTER 22

SERVICING

Section Title

Page

22-10

Main Rotor Gearbox

22.1

22-11

Cleaning Chip Detector

22.3

22-12

Cleaning Sight Gage

22.3

22-13

Main Rotor Gearbox Drain and Flush

22.4

22-20

Tail Rotor Gearbox

22.5

22-21

Cleaning Chip Detector

22.6

22-22

Cleaning Sight Gage

22.6

22-23

Tail Rotor Gearbox Drain and Flush

22.7

22-30

Clutch Assembly Lubricant Inspection and Servicing

22.8

22-40

Clutch Actuator Upper and Lower Bearings

22.9

22-41

Upper Bearing Lubrication

22.9

22-42

Lower Bearing Lubrication

22.10

22-50

Fuel System

22.11

22-51

Fueling

22.11

22-52

Defueling

22.11

22-60

Main Rotor Blades

22.13

22-61

Pitch Bearing Housing

22.13

OCT 2018

Chapter 22 Servicing

Page 22.i

CHAPTER 22

SERVICING

22-10 Main Rotor Gearbox

NOTE

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

NOTE

Verify aircraft is on level ground when evaluating gearbox oil

level.

WARNING

Refer to Safety Data Sheets (SDS) and observe precautions

when working in proximity to hazardous materials.

A. Draining Oil

1. Run-up helicopter for approximately five minutes at 70-75% RPM per R22 Pilot’s

Operating Handbook (POH) Section 4 as required to warm oil and expedite draining.

2. Disconnect chip detector wiring from airframe harness at connectors. Remove

chip detector from housing.

3. Refer to Figure 22-1. Insert MT054-1 drain assembly (or MT053-1 drain assembly

for threaded chip detector) into housing. Position drain hose overboard into a

suitable drain container. Jam wedge between firewall and drain assembly to

open valve and drain oil. Remove drain assembly after oil has drained.

B. Adding Oil

1. Install chip detector in housing, if removed. (Special torque threaded chip detector

per § 23-33.) Connect chip detector wiring to airframe harness at connectors.

2. Remove gearbox filler-plug. Fill gearbox to center of sight glass using A257-2 oil.

Rotate rotor system by hand for several revolutions and pull down on tail rotor

gearbox several times. Check gearbox oil level and adjust as required. Install

gearbox filler-plug and special torque plug per § 23-33.

3. Run-up helicopter approximately five minutes at 70-75% RPM per R22 Pilot’s

Operating Handbook (POH) Section 4.

4. Check gearbox oil level, and adjust as required.

OCT 2018

Chapter 22 Servicing

Page 22.1

22-11 Cleaning Chip Detector and Chip Detector Housing

WARNING

Refer to Safety Data Sheets (SDS) and observe precautions

when working in proximity to hazardous materials.

1. Disconnect chip detector wiring from airframe harness at connectors. For tail gearbox

chip detector, place suitable drain container below gearbox. Remove chip detector

from housing or gearbox.

2. Clean chip detector using a toothbrush and approved solvent (refer to § 23-70).

Remove debris using compressed air or masking tape; do not use a magnet. Dry chip

detector using compressed air or a lint-free cloth. Inspect condition.

3. Connect chip detector wiring to airframe harness at connectors. Turn battery on.

Touch detector’s magnet to airframe and verify appropriate gearbox caution light

illuminates. Turn battery off. Disconnect chip detector wiring from airframe harness

at connectors.

4. Install chip detector in housing or gearbox. Special torque threaded chip detector per

§ 23-33. Connect chip detector wiring to airframe harness at connectors.

5. Turn battery on. Depress push-to-test button(s) and verify appropriate gearbox caution

light illuminates. Turn battery off.

6. As required, remove filler-plug. Fill gearbox to center of sight glass using A257-2 oil.

Rotate rotor system by hand for several revolutions and pull down on tail rotor gearbox

several times. Check gearbox oil level and adjust as required. Install filler-plug in

gearbox and special torque plug per § 23-33.

22-12 Cleaning Sight Gage

1. Drain main rotor gearbox oil per § 22-10.

2. Remove sight gage from gearbox.

3. Clean sight glass using a toothbrush and approved solvent (refer to § 23-70). Dry

sight gage using compressed air or a lint-free cloth. Inspect condition.

4. Install sight gage in gearbox and special torque gage per § 23-33. Verify security.

OCT 2018

Chapter 22 Servicing

Page 22.3

22-13 Main Rotor Gearbox Drain And Flush

WARNING

Refer to Safety Data Sheets (SDS) and observe precautions

when working in proximity to hazardous materials.

Run-up helicopter for approximately five minutes at 70-75% RPM per R22 Pilot’s

Operating Handbook (POH) Section 4 as required to warm oil and expedite draining.

Disconnect chip detector wiring from airframe harness at connectors. Remove chip

detector from housing.

Refer to Figure 22-1. Insert MT054-1 drain assembly (or MT053-1 drain assembly

for threaded chip detector) into housing. Position drain hose overboard into a suitable

drain container. Jam wedge between firewall and drain assembly to open valve and

drain oil.

Remove drain assembly after oil has drained. Install chip detector (special torque

threaded chip detector per § 23-33). Connect chip detector wiring to airframe harness

at connectors.

Remove filler-plug. Fill gearbox to center of sight glass using SAE30, SAE40, SAE50,

or SAE20W50 mineral oil. Install filler-plug and special torque plug per § 23-33.

Run-up helicopter for approximately five minutes at 70-75% RPM per POH Section 4.

After shutdown, drain mineral oil per steps 2 thru 4. Remove drain assembly after oil

has drained.

Remove chip detector housing. Clean chip detector and housing using a toothbrush

and approved solvent (refer to § 23-70). Remove debris using compressed air or

masking tape; do not use a magnet. Dry chip detector and housing using compressed

air or a lint-free cloth. Inspect condition.

Connect chip detector wiring to airframe harness at connectors. Turn battery on.

Touch detector’s magnet to firewall and verify MR CHIP caution light illuminates. Turn

battery off. Disconnect chip detector wiring from airframe harness at connectors.

10.

Install chip detector housing in gearbox and special torque housing per § 23-33.

Install chip detector in housing. (Special torque threaded chip detector per § 23-33.)

Connect chip detector wiring to airframe harness at connectors.

11.

As required, remove sight gage and clean glass using approved solvent (refer to

§ 23-70). Install sight gage and special torque gage per § 23-33.

12.

Remove filler-plug. Fill gearbox to center of sight glass using A257-2 oil. Rotate rotor

system by hand for several revolutions and pull down on tail rotor gearbox several

times. Check gearbox oil level and adjust as required. Install filler-plug in gearbox and

special torque plug per § 23-33.

13.

Turn battery on. Depress push-to-test MR CHIP button and verify caution light

illuminates. Turn battery off.

Page 22.4

Chapter 22 Servicing

OCT 2018

22-20 Tail Rotor Gearbox

NOTE

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

NOTE

Verify aircraft is on level ground when evaluating gearbox oil

level.

WARNING

Refer to Safety Data Sheets (SDS) and observe precautions

when working in proximity to hazardous materials.

A. Draining Oil

1. Cut and discard ty-raps as required and disconnect chip detector wiring from

airframe harness at connectors.

2. Place a suitable drain container under tail rotor gearbox to catch oil, then remove

chip detector.

B. Adding Oil

1. Install chip detector in tail gearbox and special torque detector per § 23-33.

2. Connect chip detector wiring and install ty-raps, as required. Cinch ty-raps until

snug without over-tightening, and trim tips flush with heads.

3. Turn battery switch on. Verify TR CHIP caution light illuminates when test button

is depressed. Turn battery switch off.

4. Remove gearbox filler-vent plug and fill gearbox with A257-22 lubricant to center

of sight glass. Rotate rotor system by hand for several revolutions and pull down

on tail rotor gearbox several times. Check gearbox oil level and adjust as required.

5. Install filler-vent plug in gearbox and special torque plug per § 23-33.

OCT 2018

Chapter 22 Servicing

Page 22.5

22-21 Cleaning Chip Detector

1. Drain tail rotor gearbox oil per § 22-20.

2. Clean chip detector using a toothbrush and approved solvent (refer to § 23-70).

Remove debris using compressed air or masking tape; do not use a magnet. Dry chip

detector using compressed air or a lint-free cloth. Inspect condition.

3. Connect chip detector wiring to airframe harness at connectors. Turn battery switch

on. Touch detector’s magnet to airframe and verify TR CHIP caution light illuminates.

Turn battery switch off. Disconnect chip detector wiring from airframe harness at

connectors.

4. Install chip detector in gearbox and special torque detector per § 23-33. Connect chip

detector wiring to airframe harness at connectors. Verify security.

5. Turn battery switch on. Depress push-to-test button and verify TR CHIP caution light

illuminates. Turn battery switch off.

12-22 Cleaning Sight Gage

1. Drain tail rotor gearbox oil per § 22-20.

2. Remove sight gage from gearbox.

3. Clean sight gage using a toothbrush and approved solvent (refer to § 23-70). Dry

sight gage using compressed air or a lint-free cloth. Inspect condition.

4. Install sight gage in gearbox and special torque gage per § 23-33. Verify security.

Page 22.6

Chapter 22 Servicing

OCT 2018

22-23 Tail Rotor Gearbox Drain And Flush

WARNING

Refer to Safety Data Sheets (SDS) and observe precautions

when working in proximity to hazardous materials.

Run-up helicopter for approximately five minutes at 70-75% RPM per R22 Pilot’s

Operating Handbook (POH) Section 4 as required to warm oil and expedite draining.

Disconnect chip detector wiring from airframe harness at connectors. Place a suitable

drain container below tail rotor gearbox and remove chip detector.

Remove filler-plug. Fill gearbox to center of sight gage using SAE30, SAE40, SAE50,

or SAE20W50 mineral oil. Install filler-plug and special torque plug per § 23-33.

Run-up helicopter for approximately five minutes at 70-75% RPM per POH Section 4.

After shutdown, drain mineral oil per step 2.

Clean chip detector using a toothbrush and approved solvent (refer to § 23-70).

Remove debris using compressed air or masking tape; do not use a magnet. Dry chip

detector and housing using compressed air or a lint-free cloth. Inspect condition.

Connect chip detector wiring to airframe harness at connectors. Turn battery on.

Touch detector’s magnet to airframe and verify TR CHIP caution light illuminates. Turn

battery off. Disconnect chip detector wiring from airframe harness at connectors.

Install chip detector in gearbox and special torque detector per § 23-33. Connect chip

detector wiring to airframe harness at connectors.

As required, remove sight gage and clean glass using approved solvent (refer to

§ 23-70). Install sight gage and special torque gage per § 23-33.

10.

Remove filler-plug. Fill gearbox to center of sight gage using A257-2 oil. Rotate rotor

system by hand for several revolutions and pull down on tail rotor gearbox several

times. Check gearbox oil level and adjust as required. Install filler-plug in gearbox and

special torque plug per § 23-33.

11.

Turn battery on. Depress push-to-test TR CHIP button and verify caution light

illuminates. Turn battery off.

OCT 2018

Chapter 22 Servicing

Page 22.7

22-30 Clutch Assembly Lubricant Inspection and Servicing

A. Clutch Assemblies with A168-4 (Forward) Retainer

WARNING

Avoid contaminating drive belts and sheaves with lubricant.

Clean contaminated surfaces with mild soap and water solution,

followed by a warm water rinse. Place a clean, absorbent rag

beneath MT147-2 fittings, when installed, to catch any drips.

Open main rotor gearbox compartment access doors.

Rotate clutch shaft until bolts securing yokes to shaft are vertical. Engage rotor

brake.

Remove A168-4 (forward) retainer’s top B289-3 screw and install clean MT147-2

fitting. Attach drain hose.

Rotate sheave until fitting and attached drain hose are on bottom. Route drain hose

into a suitable, clean container. Remove top B289-3 screw and allow lubricant to

drain into container.

Install second clean MT147-2 fitting at top of retainer and connect a clean supply

of A257-4 lubricant to fitting. Flush sprag clutch housing until exiting lubricant is

obviously red. Disconnect lubricant supply and allow lubricant to drain completely

into container.

Strain all lubricant from container through a 180-200 micron paint filter/strainer.

Fluid may be dark, and may sparkle with very fine metallic debris; this is normal. If

metallic debris is trapped in the filter/strainer, remove clutch assembly and return

it to RHC, or an R22 Service Center authorized to overhaul clutch assemblies, for

disassembly and inspection.

If metallic debris is not found in the filter, attach drain hose to top fitting. Route

drain hose into a suitable container. Connect a clean supply of A257-4 lubricant

to bottom fitting. Fill sprag clutch housing thru bottom fitting until no air bubbles

are visible in drain hose. Shut-off fluid flow.

Remove top fitting and install screw. Rotate sheave until opposite fitting is on

top. Remove fitting and verify lubricant level contacts threads; add lubricant as

required. Install forward screw.

Close main rotor gearbox compartment access doors.

B. Clutch Assemblies with Retainer without B289-3 Screws

1. Perform clutch assembly (aft) seal replacement per § 7.213.

Page 22.8

Chapter 22 Servicing

OCT 2018

22-40 Clutch Actuator Upper and Lower Bearings

The actuator upper bearing is located on the clutch shaft, and the actuator lower bearing is

located on the fanshaft. Failure of either actuator bearing in flight could cause loss of power

to rotor system and result in a serious accident. Refer to § 2.110 for general indications

of bearing failure. In addition, just before failure of an actuator bearing, clutch light may

flicker (on and off in less than one second) constantly or illuminate for a longer time than

usual. Do not be confused with normal retensioning in flight (light on for up to 8 seconds,

then off). Flight should not be resumed until cause of abnormal clutch light illumination has

been determined.

Perform the following bearing inspections whenever an actuator bearing discrepancy is

suspected or fanwheel is removed:

22-41 Upper Bearing Lubrication

WARNING

Refer to Safety Data Sheets (SDS) and observe precautions

when working in proximity to hazardous materials.

NOTE

Kl-115 Special Tools Kit (syringe and probe) required to perform

the following procedure.

1. Fill syringe with 2-3 grams A257-12 grease (refer to § 23-70). Note: 2.5 grams of

grease fills a 0.5 inch (13 mm) long space inside a syringe body with a 0.63 inch (16

mm) inner diameter.

2. Thoroughly clean an accessible portion of A184 bearing assembly aft rubber seal and

surrounding surface.

3. Gently press plastic tip of syringe against cleaned seal inner lip until lip deflects inward

and tip slips into bearing. Do not damage seal. Inject grease with syringe perpendicular

to seal. Withdraw syringe. Part of seal’s inner lip remains deflected inward.

4. Slide tip of steel probe under seal inner lip and return deflected portion of lip to original

position. Do not damage seal.

5. Run-up helicopter for approximately two minutes 104% RPM per R22 Pilot’s Operating

Handbook (POH) Section 4. Shut down, inspect bearing, and clean off any escaped grease.

WARNING

Bearing used in A184 bearing assembly has modified internal

clearance for use on R22. Do not substitute any other bearing.

OCT 2018

Chapter 22 Servicing

Page 22.9

22-42 Lower Bearing Lubrication

WARNING

A181-1 & A181-3 bearings are obsolete and must be removed

from service.

Remove fanwheel per § 6.210.

Disconnect lower end of belt tension actuator from bearing housing.

Rotate bearing housing. Verify no roughness, scraping, or excessive looseness (0.010

inch maximum axial play). Verify no seal damage, and no heat damage. Lubricate

bearing:

a. Remove four perimeter screws, nuts, and washers.

b. Remove bearing block with attached outer race (bearing outer race is split type).

Forward seal retainer, forward seal, bearing inner race and bearing rollers will

remain on fan shaft.

c. Clean parts, including seals, and inspect for obvious damage.

d. Lubricate bearing by filling openings on both sides of roller cage with A257-12

grease, but do not fill spaces between rollers.

e. Reassemble. Ensure forward seal fits properly into recess provided in forward

seal retainer (not applicable to Rev L bearings).

f. Standard torque MS24694-S61 screws per § 23-32.

g. Rotate bearing housing. Verify no roughness and no excessive looseness.

Inspect bearing inner race on fanshaft. No movement or fretting is allowed between

inner race and fanshaft.

If any indication of bearing failure is found, replace A007-3 or -5 shaft and bearing

assembly per § 7.290.

Install fanwheel per § 6.220.

If bearing was lubricated, inspect & clean off any escaped grease after balancing

fanwheel.

Page 22.10

Chapter 22 Servicing

OCT 2018

22-50 Fuel System

WARNING

Refer to Safety Data Sheets (SDS) and observe precautions

when working in proximity to hazardous materials.

WARNING

Always fuel or defuel helicopter in a well-ventilated area. No

smoking within 100 feet of aircraft during fueling.

22-51 Fueling

1. Turn battery switch off.

2. Ground helicopter and ground fuel vehicle. Ground fuel vehicle to helicopter.

3. Verify proper grade of aviation fuel. See R22 Pilot's Operating Handbook (POH)

Section 2 for approved fuel grades and instructions for use of anti-ice additive.

NOTE

Refer to Figure 2-4A. Verify A689-6 fuel cap is revision J or

subseqent if bladder tanks are installed (revision J or subsequent

caps may also be used on all-aluminum tanks).

4. Remove fuel cap(s) and fuel helicopter as required.

5. Install fuel cap(s); verify security.

6. Remove grounding equipment.

22-52 Defueling

1. Turn battery switch and fuel valve off.

2. Place suitable drain container beneath carburetor and ground container to helicopter.

3. Disconnect fuel hose assembly from carburetor.

4. Turn fuel valve on to drain fuel. (Perform low-fuel switch operation check per § 12.430,

if desired.)

5. Connect fuel hose assembly to carburetor, special torque hose assembly nut per

§ 23-33, and torque stripe per Figure 2-1.

OCT 2018

Chapter 22 Servicing

Page 22.11

22-60 Main Rotor Blades

22-61 Pitch Bearing Housing

NOTE

MT147-1 Main rotor blade spindle air bleed tool includes supply

container, hose assemblies, and bleed fittings.

WARNING

Refer to Safety Data Sheets (SDS) and observe precautions

when working in proximity to hazardous materials.

Remove main rotor blades per § 26-10.

Refer to Figure 22-2. Place a suitable drain container below main rotor pitch horn.

Remove two B289-2 bolts from pitch horn and drain fluid.

Install MT147-2 bleed fittings into pitch horn openings. Attach drain hose assembly

to (top) bleed fitting, secure with two wraps of lockwire. Position drain hose into drain

container.

Place supply container with sufficient A257-4 fluid approximately 3 feet above spindle.

Route fill hose assembly into drain container and open brass valve. Open supply

container plastic valve and purge air from fill hose. Close valves.

Connect brass valve to (bottom) bleed fitting by tightening brass compression sleeve.

Open valves and fill spindle housing until no air bubbles are visible in drain hose

assembly. Massage spindle boot, oscillate spindle, and raise blade tip up & down to

remove trapped air.

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.

Special torque B289-2 bolts per § 23-33 and torque stripe per Figure 2-1.

Repeat steps for opposite blade.

OCT 2018

Chapter 22 Servicing

Page 22.13

CHAPTER 23

STANDARD PRACTICES

Section Title

Page

23-10

Cleaning

23.1

23-20

Lubrication

23.3

23-30

Torque Requirements

23.5

23-31

Torque Stripe

23.7

23-32

Standard Torques

23.8

23-33

Special Torques

23.9

23-34

D210-series Nuts on Critical Fasteners

23.13

23-40

Non-Destructive Testing

23.14

23-41

Magnetic Particle Inspection

23.14

23-42

Fluorescent Penetrant Inspection

23.15

23-50

Corrosion Control

23.15

23-60

Priming and Painting

23.16

23-70

Approved Materials

23.19

23-71

Paint Strippers

23.19

23-72

Solvents and Cleaners

23.19

23-73

Fillers and Putty

23.20

23-74

Torque Seal

23.20

23-75

Primers

23.21

23-76

Powder Coat

23.21

23-77

Paints

23.22

23-78

Lubricants

23.25

23-79

Adhesives and Sealants

23.26

23-80

Miscellaneous Practices

23.28

23-81

Part Interchangeability

23.28

23-82

Thermal Fitting Parts

23.28

23-83

Replacement Component Identification (Data) Plates

23.28

23-84

Crimp Inspection

23.29

23-85

Storage Limits

23.30

23-86

B526 Screws and B527-08 Washers

23.30

OCT 2018

Chapter 23 Standard Practices

Page 23.i

CHAPTER 23

STANDARD PRACTICES

23-10 Cleaning

CAUTION

Wash helicopter exterior surfaces, windshields, and windows

with mild soap and water. Harsh abrasives, alkaline soaps, or

detergents can scratch painted or plastic surfaces, or cause

corrosion of metal. Protect areas where cleaning solution could

cause damage.

CAUTION

Never use high-pressure spray to clean helicopter. Never blow

compressed air into main or tail rotor blade tip drain holes, pitot

tube, or static ports.

WARNING

Refer to Safety Data Sheet (SDS) and observe precautions

when working in proximity to hazardous materials.

A. Cleaning Exterior Surfaces

1. Rinse away loose dirt and debris from exterior surface with clean water.

2. Apply mild soap and clean warm water solution to exterior surface using a clean,

soft cloth, sponge, or soft bristle brush. Use caution near antennas and sensitive

equipment.

3. Remove oil and grease using a cloth wetted with aliphatic naphtha.

4. Rinse all surfaces thoroughly.

5. If desired, polish painted surfaces with a good quality automotive wax using soft

cleaning cloths, or a chamois cloth, free of abrasive debris.

OCT 2018

Chapter 23 Standard Practices

Page 23.1

23-10 Cleaning (continued)

B. Cleaning Windshield and Windows

CAUTION

Do not use gasoline, other alcohols, benzene, carbon tetrachlo-

ride, thinner, acetone, or window (glass) cleaning sprays.

1. Rinse away loose dirt and debris from windshield and windows with clean water.

2. Apply mild soap and clean warm water solution, or aircraft plastic cleaner, to

windshield and windows using a clean, soft cloth or sponge in a straight back and

forth motion. Do not rub harshly.

3. Remove oil and grease using a cloth wetted with isopropyl alcohol (rubbing alcohol)

or aliphatic naphtha.

4. After cleaning plastic surfaces, apply a thin coat of hard polishing wax. Rub lightly

with a soft cloth. Do not use a circular motion.

5. To remove scratches, rub windshield or windows with jeweler’s rouge then hand

polish with commercial plastic polish. Polish in figure eight motion.

C. Cleaning Seat Assemblies and Back Rests

1. Vacuum and brush, then wipe with damp cloth. Dry immediately.

2. Soiled upholstery, except leather, may be cleaned with a good upholstery cleaner

suitable for the material. Follow manufacturer’s instructions. Avoid soaking or

harsh rubbing.

3. Leather should be cleaned with saddle soap or a mild hard soap and water.

D. Cleaning Carpet

Remove loose dirt with a whisk broom or vacuum. For soiled spots and stains, use

nonflammable dry cleaning liquid.

Page 23.2

Chapter 23 Standard Practices

OCT 2018

23-20 Lubrication

WARNING

Refer to Safety Data Sheets (SDS) and observe precautions

when working in proximity to hazardous materials.

Most bearings are sealed or self-lubricated and do not require periodic lubrication. Bearings

with scheduled lubrication intervals are listed in Table 1-1 (see Chapter 1).

Engine lubrication requirements are located in the R22 Pilot’s Operating Handbook, the

appropriate model Lycoming Operator’s Manual, and Lycoming Service Instruction No.

1014 (current revision).

Main and tail gearboxes require servicing when indicated by sight gage level. Additionally,

change gearbox oil and clean respective sight gage when oil becomes so dirty its level

cannot be determined.

WARNING

A257-2 oil is the only approved oil for use in gearboxes.

When installing a new or overhauled gearbox, drain and flush gearbox after the first 4

hours of flight or first chip light, whichever occurs first. Thereafter, change gearbox oil at

intervals listed in Table 1-1 (see Chapter 1).

OCT 2018

Chapter 23 Standard Practices

Page 23.3

Given

Symbols

Y = Unknown

Y = Torque wrench setting

= 135 in.-lb

T = Torque applied to fastener

= 10 in.

L = Length of torque wrench

= 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

T x L

135 x 10

1350

Solve for Y =

= 117.39

L + A

10 + 1.5

11.5

Set torque wrench to 117 in.-lb to torque fastener to 135 in.-lb.

FIGURE 23-1 LENGTHENING TORQUE WRENCH EFFECTIVE LENGTH

Given

Symbols

Y = Unknown

Y = Torque wrench setting

= 135 in.-lb

T = Torque applied to fastener

= 10 in.

L = Length of torque wrench

= 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

T x L

135 x 10

1350

Solve for Y =

= 158.82

L - A

10 - 1.5

8.5

Set torque wrench to 159 in.-lb to torque fastener to 135 in.-lb.

FIGURE 23-2 SHORTENING TORQUE WRENCH EFFECTIVE LENGTH

Page 23.4

Chapter 23 Standard Practices

OCT 2018

23-30 Torque Requirements

A. Tool Calibration

Dimensions and tolerances given in this manual are critical. Calibrate measuring tools

per manufacturer’s recommendation at least once a year, when tool is dropped, misused,

or calibration is suspect. Measuring tools include torque wrenches, micrometers,

calipers, dial indicators, spring scales, protractors, and balancing equipment.

WARNING

Proper torque is critical. Always use calibrated wrenches and

undamaged, properly lubricated (where applicable) hardware.

Ensure clamping surfaces are clean, and clamp only bare metal

or wet-primed surfaces. Improper torque or dirty or painted

clamping surfaces may result in loss of clamp-up, hardware or

part damage, and premature failure.

B. Torque Value

Torque fasteners to standard dry values listed in § 23-32 unless otherwise specified.

If torque is applied by rotating bolt, increase torque value by 10% to account for

higher friction at bolt head and shank.

For example, the torque wrench setting for an NAS6605 bolt used with an MS21075

nutplate is determined as follows:

NAS6605 bolt (5 indicates 5/16 inch size) dry torque per § 23-32

240 in.-lb

Add 10% because torque must be applied at bolt head

+ 24 in.-lb

Torque wrench setting

264 in.-lb

C. Secondary Locking Mechanism

A secondary locking mechanism is required on all critical fasteners. B330 stamped

nuts (palnuts) serve as the secondary locking mechanism in most areas on the

helicopter, and are torqued per § 23-32. Palnuts must be replaced when removed.

The R22 Illustrated Parts Catalog (IPC) lists secondary locking mechanisms for specific

fasteners.

OCT 2018

Chapter 23 Standard Practices

Page 23.5

23-30 Torque Requirements (continued)

D. Critical Fastener

CAUTION

D210-series nuts, which supersede MS21042L-series and

NAS1291-series nuts, are required on critical fasteners.

WARNING

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.

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.

Page 23.6

Chapter 23 Standard Practices

OCT 2018

23-30 Torque Requirements (continued)

E. Torque Requirements

CAUTION

Never substitute AN bolts for NAS bolts. NAS bolts have higher

tensile strength.

Any self-locking nut whose drag has deteriorated appreciably must be replaced.

Damaged hardware must be replaced.

Bolt and nut are to be clean and dry except when assembly procedure specifies

anti-seize or thread-locking compound.

If chattering or jerking occurs, disassemble and re-torque fastener.

If special adapters which change effective length of torque wrench are used, final

torque value must be calculated using formulas in Figures 23-1 and 23-2.

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.

Refer to Part A. Torque wrenches must be calibrated annually, when dropped, or

when a calibration error is suspected.

23-31 Torque Stripe

WARNING

Refer to Safety Data Sheet (SDS) and observe precautions

when working in proximity to hazardous materials.

Refer to Figure 2-1. Lacquer-paint Torque Seal® is applied to all critical fasteners after

palnut installation in a stripe (“torque stripe”) extending from the fastener’s exposed

threads across both nuts and onto the component. Subsequent rotation of the nut or bolt

can be detected visually. Position torque stripes for maximum visibility during preflight

inspections. Approved Torque Seal® is listed in § 23-74.

OCT 2018

Chapter 23 Standard Practices

Page 23.7

23-32 Standard Torques

NOTE

1. Torque values are in inch-pounds unless otherwise specified.

2. Torque values include nut self-locking torque.

3. Increase torque values 10% if torqued at bolt head.

4. Wet indicates threads lubricated with A257-9 anti-seize.

5. For elbow and tee fittings which require alignment, torque to indicated

value, then tighten to desired position.

6. Tolerance is ± 10% unless range is specified.

7. Unless otherwise specified, thread sizes 8-32 and smaller are not used for

primary structure and do not require control of torques.

FASTENER SERIES

SIZE

EXAMPLE FASTENER

DRY TORQUE

10-32

NAS6603

50 in.-lb

1/4-28

NAS6604

120 in.-lb

NAS6603 thru NAS6608 Bolts

NAS1303 thru NAS1308 Bolts

5/16-24

NAS6605

240 in.-lb

NAS623 Screws

3/8-24

NAS6606

350 in.-lb

NAS1351 & NAS1352 Screws

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

1/4-28

AN4

90 in.-lb

AN8 Bolts

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

5/16-24

B330-16 (MS27151-16)

20-40 in.-lb

STAMPED NUTS

(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

1/4-28

AN316-4

40 in.-lb

ROD END JAM NUTS

(AN315 and AN316)

5/16-24

AN316-5

80 in.-lb

3/8-24

AN316-6

110 in.-lb

Page 23.8

Chapter 23 Standard Practices

OCT 2018

23-33 Special Torques

These torques are non-standard and supersede those in § 23-32.

NOTE

1. Torque values are in inch-pounds unless otherwise specified.

2. Torque values include nut self-locking torque.

3. Increase torque values 10% if torqued at bolt head.

4. Wet indicates threads lubricated with A257-9 anti-seize.

5. For elbow and tee fittings which require alignment, torque to indicated

value, then tighten to desired position.

6. Tolerance is ± 10% unless range is specified.

7. Unless otherwise specified, thread sizes 8-32 and smaller are not used for

primary structure and do not require control of torques.

AREA

(QUANTITY) FASTENER

TORQUE

(1) AN320-15 nut (1½ inch socket) on A007-3 shaft assembly

183-233 ft-lb wet

DRIVE

(1) AN320-18 nut (1¹¹/₁₆ inch socket) on A007-5 shaft assembly

340-400 ft-lb wet

SYSTEM

(6) NAS6606-24H bolts, lower sheave

300 in.-lb

EMPENNAGE

(4) NAS6603-2 & (4) NAS6603-5 bolts, vertical stabilizer attach

70 in.-lb

(1) AN320-15 or AN320-18 nut - see DRIVE SYSTEM

(8) or (12) NAS6603-3 or -6 bolts and D210-3 nuts, cone-to-

FANWHEEL

70 in.-lb

fanwheel

(6) NAS6605-12, -13, or -14 bolts, hub

300 in.-lb

(1) A457-15 bulkhead union and nut

285 in.-lb

(1) A657-1 nut, fuel valve elbow-to-bulkhead union

120 in.-lb

(1) A726-1 line assembly, bulkhead union-to-gascolator

285 in.-lb

(2) B254-3 strainer assembly, tank outlets

200 in.-lb wet

(1) B283 hose assembly nuts, gascolator-to-carburetor

120 in.-lb

(5) B289-1 bolts, fuel sender (torque in criss-cross pattern)

37 in.-lb

(2) B330-5 palnut, fuel sender ground stud

9 in.-lb

(2) B330-6 palnut, fuel sender center stud

11 in.-lb

FUEL SYSTEM

(1) D205-32 hose assembly nuts, main tank-to-fuel valve

120 in.-lb

(1) D205-33 hose assembly nuts, tank interconnect

120 in.-lb

(1) D205-34 hose assembly nuts, main tank drain

60 in.-lb

(1) D210-4 nut, gascolator mounting plug

70 in.-lb

(16) AN805 nuts, fuel primer line

20-30 in.-lb

(1) AN815-4D union, main tank, drain hose (bladder tanks)

145 in.-lb

(1) AN815-6D union, main tank, tank interconnect hose

200 in.-lb

(1) AN894D4-2 bushing, primer system

50-65 in.-lb

(1) AN894D6-4 bushing, primer system

110-130 in.-lb

OCT 2018

Chapter 23 Standard Practices

Page 23.9

23-33 Special Torques (continued)

AREA

(QUANTITY) FASTENER

TORQUE

(1) AN924-4D nut, main tank, drain valve (bladder tanks)

145 in.-lb

(1) AN924-5D nut, low-fuel warning switch

150 in.-lb

(4) MS27039C1-06 screws, fuel valve

16 in.-lb

FUEL SYSTEM

(continued)

(4) MS27039DD1-26 screws, air bypass door

22-25 in.-lb

(1) MS27769D2 plug, gascolator

60 in.-lb

Primer system line assembly nuts, flared end fittings

20-30 in.-lb

(1) B277-052 clamp, lower rib

50 in.-lb

FUSELAGE

(1) D210-5 nut, tow ball

240 in.-lb

(8) MS51861-37C screws, door hinges

36 in.-lb

(4) AN4-25A bolts, ground handling support

70 in.-lb

LANDING

GEAR

(56) NAS6604 bolts, floats to skids and skid extensions

50 in.-lb

(2 per blade) A722-4 screw, tip weight retaining

40 in.-lb wet

MAIN ROTOR

(2 per blade) B289-2 self-sealing bolts in pitch horn

70 in.-lb

BLADE

(2 per blade) NAS1351N3-10P screw, cover retaining

40 in.-lb wet

(1) AN320-8 nut, gearbox pinion

290-410 in.-lb

(1) AN10-41A bolt, gearbox mounting

90 ft-lb dry torqued from

(3) A650-1 fittings, gearbox mounting

bolt head or nut

(requires MS21044N10 nuts)

(1) F650-3 bolt, gearbox mounting

65 ft-lb, wet

(3) A650-3 fittings, gearbox mounting

torque from bolt head or nut

(requires D210-10 nuts)

MAIN ROTOR

(6) NAS1352-4-14 screws in end cover

140 in.-lb

GEARBOX

Large nut 150 in.-lb

(1) chip detector (threaded, non-quick-disconnect type)

Small nut 75 in.-lb

(1) chip detector housing

150 in.-lb

(1) nut, chip detector wiring

4-6 in.-lb

(1) filler plug

150 in.-lb

(1) sight gage

150 in.-lb

New bolt: 0.016-0.017 inch

(1) NAS630-80 (or MS21250-10080) teeter hinge bolt;

elongation (stretch), wet

(2) NAS630-80 (or MS21250-10080) coning hinge

Used bolt: 0.015-0.017

bolts in A154-1 hub

inch elongation, wet, &

MAIN ROTOR

cotter pin holes must align

HUB

New bolt: 0.011-0.012 inch

elongation (stretch), wet

(2) NAS632-82 (or MS21250-12082) coning hinge

Used bolt: 0.010-0.012

bolts in B370-1 hub

inch elongation, wet, &

cotter pin holes must align

Page 23.10

Chapter 23 Standard Practices

OCT 2018

23-33 Special Torques (continued)

AREA

(QUANTITY) FASTENER

TORQUE

OVERTRAVEL

(1) A486 screw, upper rod end

37 in.-lb

SPRING

(1) A058-5 carburetor air temp probe

36-48 in.-lb

(1) A760-1 oil temperature sender

300 in.-lb

(2) B277-024 clamps, carb heat scoop

30 in.-lb

(2) A740-1 manifold pressure line nuts

25-35 in.-lb

(4) AN818-8 nuts, oil cooler line (stainless-steel lines)

40 ft-lb

(4) AN818-8 nuts, oil cooler line (aluminum lines)

230-260 in.-lb

(1) AN894D4-3 bushing, manifold pressure line,

135-150 in.-lb

at firewall

(4) MS20074-04-04 bolts, airbox-to-carburetor

30 in.-lb

(1) 3080-00038 cylinder head temperature probe

70-80 in.-lb

(1) bolt, alternator belt tension

204 in.-lb

(4) bolts, D723-1 oil adapter

90-100 in.-lb

96 in.-lb initial, 204 in.-lb

(4) carburetor-to-engine nuts

final, torque in a crisscross

pattern

(8) exhaust riser flange nuts, plain

160-180 in.-lb

(8) exhaust riser flange nuts, self-locking

200-220 in.-lb

(2) ground strap-to-engine nuts

96 in.-lb

POWERPLANT

(1) nut, B315-1 clip for magneto harness clamp

60 in.-lb

(1) nut on A462-1 carburtetor heat control wire-to-slider

25-30 in.-lb

valve attach fitting

(1) nut on A462-4 mixture control wire-to-carburetor

25-30 in.-lb

mixture arm attach fitting

420 in.-lb wet with A257-10

(8) spark plugs

thread lubricant

(1) thermostatic oil cooler bypass valve

290-310 in.-lb

(6 per cover) NAS1352-4H10P valve cover retaining screws

25 in.-lb cold engine,

when used with clean, dry, red silicon gasket on clean,

20 in.-lb warm engine

dry valve cover and cylinder head mating surfaces

(1) terminal retaining nut, alternator output terminal (use

back-up wrench on stud retaining nut to prevent loss

50 in.-lb

of stud clamp-up)

(2) terminal retaining nuts, D748-3 alternator field and

aux terminals (use back-up wrench on stud retaining

14 in.-lb

nuts to prevent loss of stud clamp-up)

(2) terminal retaining nuts, D748-4 alternator field and

aux terminals (use back-up wrench on stud retaining

20 in.-lb

nuts to prevent loss of stud clamp-up)

(1) terminal retaining nut, oil temperature sender

20 in.-lb

OCT 2018

Chapter 23 Standard Practices

Page 23.11

23-33 Special Torques (continued)

AREA

(QUANTITY) FASTENER

TORQUE

(2) NAS1351-8H40P internal-wrenching screws

70-75 ft-lb wet

STEEL TUBE

120 in.-lb with

(3) NAS6604-3 bolts - (1) lower-left frame aft strut-to-upper

FRAME

B270-1 on shank to

frame, and (2) on removable aft, right strut

seal strut holes

(2) NAS1352N08-6 screws, magnetic pick-up bracket

35 in.-lb

(16) NAS1352N08-8 screws

35 in.-lb

SWASHPLATE

(1) NAS6605-8 bolt clamping early revision A203 yokes

190 in.-lb

(1 per link) 21FKF-616 jam nut, main rotor pitch link barrel

100 in.-lb

(1) B549-1 retainer, input seal

70 ft-lb wet

(3) MS20074-04-06 bolts, gearbox-to-tailcone mounting

100 in.-lb

(8) MS20074-04-06 bolts on A021 gearbox

60 in.-lb

(12) MS20074-04-06 bolts on B021 gearbox

100 in.-lb

(1) NAS679A4 nut, A031 pitch control housing stud

90 in.-lb

(1) NAS679A4 nut, A119-1 bumper retainer

120 in.-lb

70 ft-lb wet with

(1) D210-8 nut retaining B546 input yoke on B021 gearbox

B270-11

TAIL ROTOR

GEARBOX

(1) NAS1304-38 bolt, spherical tail rotor teeter (delta) hinge

150 in.-lb

(1) NAS6604-38 bolt, elastomeric tail rotor teeter (delta) hinge

150 in.-lb

(1) chip detector on A021 gearbox

100 in.-lb

(1) chip detector on B021 gearbox

60 in.-lb

(1) nut, chip detector wiring on B021 gearbox

4-6 in.-lb

(1) filler plug vent assembly

100 in.-lb

(1) sight gage on A021 gearbox

150 in.-lb

(1) sight gage on B021 gearbox

100 in.-lb

WINDSHIELD

(24) AN526C832R12 screws, on center outside retainer

16 in.-lb

Page 23.12

Chapter 23 Standard Practices

OCT 2018

23-34 D210-series Nuts on Critical Fasteners

When performing maintenance that involves disassembly of a critical fastener (joints with

a secondary lock), reassemble the fastener using a D210-series nut.

If a fastener is disassembled that has an MS21042L-series or NAS1291-series nut with

a B330-series palnut or B332-series lockwasher (secondary lock),

replace MS21042L08 nut or NAS1291-08 nut with D210-08 nut,

replace 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.

OCT 2018

Chapter 23 Standard Practices

Page 23.13

23-40 Non-Destructive Testing

WARNING

Refer to Safety Data Sheet (SDS) and observe precautions

when working in proximity to hazardous materials.

23-41 Magnetic Particle Inspection

Ferromagnetic steel parts are inspected for structural defects using magnetic particle

inspection. Steel parts covered by this specification are inspected per ASTM E1444 wet

continuous process with ultra-violet light. Applicable requirements and limitations of the

above standard apply.

Procedures and equipment used to perform the inspection shall conform to requirements of

ASTM E1444. Produce magnetization using direct current. A magneto test penetrameter

or a 30-60 gauss meter is used to verify the direction and effectiveness of all magnetic

fields produced. Whenever possible, parts shall be inspected with both circular and

longitudinal magnetization, but at least in two directions at right angles to each other.

Minimum duration of application is ½ second.

Pre- and post-solvent clean parts using PCBTF or similar solvent. Demagnetizing is

accomplished using AC±3 oersteds maximum. Verify part is demagnetized using a magnetic

field strength indicator which does not exceed an absolute value above three gauss.

Area of part to be examined, position of part, directions of magnetization to be used and

method of establishing the magnetization are presented within the inspection section of

individual parts. Record the size and location of all rejectable indications.

A. Inspection Criteria

Parts (except gears) which are inspected by magnetic particle inspection shall be

accepted or rejected according to the following criteria:

Acceptable indications:

Indications smaller than 0.015 inch are not considered rateable.

Indications caused by sharp changes in cross-section or part geometry.

Rejectable indications:

Indications interpreted as cracks, seams, laps, shuts, or any flaws which are

open to the surface.

Indications oriented at an angle of more than 15 degrees from the longitudinal

axis with length exceeding 0.125 inch.

Circumferential indications on any shoulder or fillet (changes in diameter).

Any indications which break over an edge, shoulder, fillet radius, keyway,

spline, or an adjacent area of part more than 0.015 inch.

Indications caused by undercuts at the toe of a weld.

Indications caused by cracks in the weld or parent metal.

Indications caused by inclusions in weld material exceeding 0.1 inch in length.

Page 23.14

Chapter 23 Standard Practices

OCT 2018

23-42 Fluorescent Penetrant Inspection

This specification provides for surface inspection of parts fabricated from nonmagnetic

materials to detect discontinuities open to the surface, such as cracks, cold shuts, laps,

porosity and other surface defects.

Applicable requirements and limitations of ASTM E1417 shall apply. After inspection is

complete, solvent clean parts.

The step-by-step procedure and equipment used to perform the inspection shall be

accomplished per ASTM E1417.

A. Inspection Criteria

Parts inspected by fluorescent penetrant method shall be accepted or rejected

on basis of acceptance limits specified. If acceptance limits are not specified,

rejectable surface defects and any of the following:

Cracks

Seams

Cold shuts or laps

Surface inclusions

In castings, aligned discontinuous surface indications other than cracks, cold

shuts and inclusions are rejectable if more than 3/8 inch in length.

23-50 Corrosion Control

[Reserved].

OCT 2018

Chapter 23 Standard Practices

Page 23.15

23-60 Priming and Painting

This specification outlines preparation and application requirements for primers and topcoat.

Primers provide corrosion protection and a final finish or a base for topcoat. Use only

approved materials listed in § 23-70.

Do not prime or paint with a topcoat finish the following areas (unless directed):

Sliding friction joints.

Stainless steel parts.

Swivel joints and adjustable rod ends.

Plastic, rubber, electrical components and wires or similar materials.

Bolted joints where torque is a specific requirement for clamping action.

Bearing press fit or close tolerance slip fit joints (except where wet chromate primer is

part of the assembly procedure).

WARNING

Refer to Safety Data Sheet (SDS) and observe precautions

when working in proximity to hazardous materials.

A. Priming

1. Cleaning

a. Alkaline clean is the preferred method for cleaning aluminum and stainless

steel except where immersion is not practical. Do not immerse assembled

components.

b. Do not alkaline clean steel as it may cause a corrosive reaction. Clean steel

using QSOL 220 or equivalent solvent.

c. Extremely greasy or dirty parts may be pre-cleaned in a solvent vapor bath

or hand wiped with QSOL 220 or equivalent solvent.

d. Air dry. Do not touch cleaned parts with bare hands.

2. Surface Preparation

Unless otherwise specified, chemical conversion coating is the standard treatment

before priming aluminum. However, if bare or clad aluminum is primed without

conversion coating, the following procedure must be used:

a. Alkaline clean if immersion is practical, otherwise wipe clean with QSOL

220 or equivalent degreasing agent.

b. Lightly scuff the surface with Scotch-Brite pads.

c. Wipe with a tack rag to remove any foreign material or damp wipe with

QSOL 220 or equivalent solvent.

d. Air dry. Do not touch parts with bare hands.

Page 23.16

Chapter 23 Standard Practices

OCT 2018

23-60 Priming and Painting (continued)

A. Priming (continued)

3. Primer Application

Apply primer after mixing per manufacturers recommendations. Allowable

thickness of primer is 0.0005 - 0.0020 inch, per coat. For parts with internal

openings, such as tubes, prime the inside as follows:

a. Thin primer to watery consistency using required reducer.

b. Pour in primer, slosh around, then drain immediately.

c. Dry parts at least six hours before using.

4. Inspection

Inspect for complete coverage and (excessive thickness) runs in paint. If primer

has runs, strip part and re-prime. Refer to § 23-70 for approved methods.

NOTE

Primed areas that have been sanded to bare metal must have

conversion coating (if required) and primer re-applied prior to

topcoat to restore anti-corrosion properties.

B. Painting

Prior to liquid topcoat application, ensure surfaces have been cleaned and primed.

In general, most parts will be cleaned and primed as detail parts. However, in some

cases, such as the gearbox assembly, this is not practical and primer and topcoat are

applied on the assembled component.

Previously primed surfaces, or primed surfaces that have completely cured require the

following preparation before paint:

1. Lightly sand using 220-grit or finer aluminum-oxide abrasive paper.

2. Lightly scuff with Scotch-Brite pads (optional).

3. Wipe with clean cloth and QSOL 220 or equivalent solvent.

4. Wipe with tack cloth.

5. Apply topcoat.

OCT 2018

Chapter 23 Standard Practices

Page 23.17

Robinson R22 Helicopter. MAINTENANCE MANUAL (2018) - page 6