Robinson R-66 Series Lithium-Ion Maintenance Manual

CHAPTER 18

TRACK AND BALANCE

Section Title Page

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

18-11 Preparing Helicopter for Main Rotor Track and Balance . . . . . . . . . . . . . . 18.3

18-12 Flight Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.5

18-13 Track Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.7

18-14 Balance Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.10

18-15 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.11

18-16 Autorotational RPM Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.12

18-20 Tail Rotor Dynamic Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.17

18-21 Preparing Helicopter for Tail Rotor Dynamic Balance . . . . . . . . . . . . . . . . 18.17

18-22 Ground Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.19

18-23 Balance Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.19

18-30 Main Rotor Flight Control Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.21

18-40 Main Rotor Blade Angle Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.23

18-41 Collective Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.24

18-42 Cyclic Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.26

18-50 Tail Rotor Flight Control Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.28

18-51 Pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.28

18-52 Forward Bellcrank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.28

18-53 Intermediate Bellcrank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.28

18-60 Tail Rotor Blade Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.29

18-70 Fan Shaft and Engine Shaft Balancing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.33

18-71 Preparing Helicopter for Fan Shaft and Engine Shaft Balancing . . . . . . . . . 18.33

18-72 Ground Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.34

MAY 2015 Chapter 18 Track and Balance Page 18.i

Intentionally Blank

Page 18.ii

Chapter 18 Track and Balance MAY 2015

CHAPTER 18

TRACK AND BALANCE

18-10 Main Rotor Track and Balance

NOTE

Calibrate track and balance equipment per manufacturer's recommendation, at least once a year, or if equipment is dropped, misused, or calibration is suspect.

NOTE

The Chadwick-Helmuth Vibrex system, the TEC ACES system, the Dynamic Solutions Systems’ MicroVib system, or equivalent equipment is required to perform dynamic rotor balancing and in-flight track checks.

25 OCT 2010 R66 Maintenance Manual Chapter 18 Track and Balance

Page 18.1

Page 18.2

FIGURE 18-1 MAIN ROTOR BALANCING EQUIPMENT INSTALLATION

Chapter 18 Track and Balance R66 Maintenance Manual 25 OCT 2010

18-11 Preparing Helicopter for Main Rotor Track and Balance

NOTE

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

CAUTION

Cable security is critical; helicopter will be flown at V

NE

.

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

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

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

4. Install magnetic pickup onto swashplate bracket. Set (swashplate-mounted) interrupterto-pickup gap to 0.030 inch ± 0.010 inch and tighten pickup nuts against bracket.

Safety nuts using 0.020-inch diameter lockwire. Recheck gap.

5. Pull collective stick full up, push cyclic stick full left, and apply frictions. Connect proper cable to magnetic pickup. Route cable down seam and to base of mast fairing, across the cabin roof left side, and through the aft left door vent door. Attach the cable to the fuselage using MS21919WDG3 clamps and existing fasteners, or secure cable every

12 inches with duct tape. Release control frictions and verify sufficient cable slack and freedom of controls through full range of travel.

6. Connect proper cable to vibration transducer. Connect transducer, magnetic pickup, and tracker or strobe cables to analyzer. If strobe light is used, battery power may be accessed thru auxiliary power socket located on circuit breaker panel. Neatly stow and secure excess cables.

7. Verify security of installation.


Page 18.3

DATE

PAGE

SERIAL NO.

CHORD ARM WEIGHTS

(1) A255-1 Weight = (8) AN970-4 Washers

(1) A255-2 Weight = (3) A255-1 Weights

TIP WEIGHTS

(1) AN960-10 Washer = (2) AN960-10L Washers

(1) C298-2 Weight

(1) C298-3 Weight

(1) C298-4 Weight

=

=

(5) AN960-10 Washers

= (11) AN960-10 Washers

(4) C298-3 Weights

TEETER HINGE SHIMS

C117-8 0.012 inch

C117-9 0.015 inch

C117-10 0.020 inch

C117-11 0.025 inch

BALANCE

CLOCK IPS HOVER

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Adjustment:

CLOCK IPS HOVER

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Adjustment:

CLOCK IPS HOVER

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Adjustment:

CLOCK IPS

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FIGURE 18-2 MAIN ROTOR TRACK AND BALANCE CHART

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Page 18.4

Chapter 18 Track and Balance R66 Maintenance Manual

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25 OCT 2010

18-12 Flight Checks

NOTE

Run-up and shutdown helicopter throughout procedure as required per R66 Pilot's Operating Handbook (POH) Section 4.

NOTE

Refer to Section 18-15 for track and balance troubleshooting procedures.

WARNING

Tail rotor balancing equipment must be removed for flight.

WARNING

Do not exceed V

NE

of helicopter during flight checks.

1. Prepare helicopter for main rotor track and balance per Section 18-11.

2. Make a photocopy of Figure 18-2; use copy to record flight data. Check main rotor blade track in a hover and record data. Maximum blade spread in a hover is 0.25 inch.

Adjust track per Section 18-13 as required, record change, and recheck blade track in a hover. Repeat step as required until blade track is within limits.

3. Check main rotor balance in a hover and record data. Maximum vibration allowance is 0.2 ips (inches per second). Adjust balance per Section 18-14 as required, record data, and recheck balance in a hover. Repeat step as required until main rotor balance is within limits.

4. Fly helicopter at 50, 60, 70, 80, 90, 100, 110, 120, 130, and 140 knots. Check main rotor blade track at each airspeed and record data. Maximum blade spread between airspeeds is 3/8 inch. Adjust trim tab(s) per Section 18-13 as required and record data.

Repeat step as required until blade track is within limits.

5. Recheck main rotor balance in a hover per step 3.

6. Perform autorotation RPM check per Section 18-16. Recheck main rotor balance in a hover per step 3.

7. Evaluate collective trim, longitudinal cyclic trim, and lateral cyclic trim. Adjust as required. Recheck main rotor balance in a hover per step 3.

8. Remove track and balance equipment. Torque stripe fasteners. Reinstall removable controls, as required.


Page 18.5

Coarse Length Adjustment

Rod End and Fitting

• One full turn changes blade angle 0.88º.

Medium Length Adjustment

(Upper) Rod End Only

• One-half rod end turn changes blade track 0.25 inch.

• One full rod end turn changes blade angle 0.48º.

Fine Adjustment

Fitting Only

• One full turn changes blade track 0.25 inch.

• One full turn changes blade angle 0.40º.

Page 18.6

FIGURE 18-3 MAIN ROTOR PITCH LINK


18-13 Track Adjustment

A. Main Rotor Blade Pitch Link

Refer to R66 Illustrated Parts Catalog (IPC) Figure 62-5.

NOTE

Shorten high pitch blade when adjusting track in a hover.

NOTE

During rigging, adjust both pitch links exactly the same for collective adjustments.

1. Refer to Figure 18-3. For coarse length adjustment, adjust rod end and fitting per the following steps: a. Cut and discard pitch link assembly safety wire. Using backup wrench on link assembly, loosen jam nut in middle of pitch link. Remove hardware securing upper rod end to blade pitch horn.

b. Rotate rod end and fitting to shorten or lengthen pitch link as required. One full turn changes blade angle by approximately 0.88°.

c. Refer to Figure 5-1. Verify rod end threaded shank blocks passage of 0.020-inch diameter lockwire through pitch link witness hole. Install hardware securing rod end to pitch horn and torque fastener per Section 20-32.

d. Position rod ends to allow as much pitch link rotation as possible without binding.

Using backup wrench on link assembly, torque jam nut per Section 20-32. Safety fitting to link assembly using 0.032-inch diameter lockwire.

e. Repeat steps on opposite pitch link as required. Torque stripe per Figure 5-1.

2. For medium length adjustment, adjust rod end only per the following steps: a. Using backup wrench on fitting, loosen upper rod end palnut and jam nut. Remove hardware securing rod end to blade pitch horn.

b. Rotate rod end to shorten or lengthen pitch link as required. One-half rod end turn changes blade track approximately 0.25 inch. One full rod end turn changes blade angle by approximately 0.48°.

c. Refer to Figure 5-1. Verify rod end threaded shank blocks passage of 0.020-inch diameter lockwire through pitch link witness hole. Install hardware securing rod end to pitch horn and torque fastener per Section 20-32.

d. Position rod ends to allow as much pitch link rotation as possible without binding.

Using backup wrench on fitting, torque rod end jam nut and palnut per Section

20-32.



Page 18.7

Page 18.8

FIGURE 18-4 MAIN ROTOR BLADE TRIM TAB


18-13 Track Adjustment (continued)

A. Main Rotor Blade Pitch Link (continued)

3. For fine adjustment, adjust fitting only per the following steps: a. Remove and discard pitch link assembly safety wire. Using backup wrench on link assembly, loosen jam nut in middle of pitch link. Using backup wrench on fitting, loosen upper rod end palnut and jam nut.

b. Rotate fitting to shorten or lengthen pitch link as required. One full turn changes blade track approximately 0.25 inch. One full turn of fitting changes blade angle approximately 0.40°. For finer adjustment, count hex flats while rotating fitting.

c. Refer to Figure 5-1. Verify rod end threaded shank blocks passage of 0.020-inch diameter lockwire through pitch link witness hole.

d. Using backup wrench on link assembly, torque jam nut per Section 20-32. Using backup wrench on fitting, torque rod end jam nut and palnut per Section 20-32.

Safety fitting to link assembly using 0.032-inch diameter lockwire.


B. Main Rotor Blade Trim Tab

NOTE

To correct for a "climbing" blade condition (blade spread that exceeds 3/8 inch with forward airspeed), bend high blade trim tab down.

CAUTION

Do not use other helicopter manufacturers' trim tab bending tools. Use of these tools will damage Robinson blades.

CAUTION

MT352-1 gage must contact trim tab trailing edge. If gage does not contact tab trailing edge, tab is bent beyond limit.

CAUTION

Tighten MT526-8 bending tool bolt to bend tab; do not use tool as a lever.

CAUTION

Bend tab upward only when absolutely necessary; bending tab upward can increase rotor vibration.

1. Using felt tip marker, ink mark main rotor blade trim tab per Figure 18-4. Mark line with a measuring point in the center of the tab (approximate).


Page 18.9


B. Main Rotor Blade Trim Tab (continued)

2. Position MT352-1 gage chordwise across blade upper surface and tab trailing edge.

Zero dial indicator on measuring point.

3. Position MT526-8 bending tool on tab per Figure 18-4. Slide tool completely over tab until tool stops contact blade trailing edge. Double-rib side of tool should contact tab upper surface to bend tab down. Double-rib side of tool should contact tab bottom surface to bend tab up.

4. Tighten MT526-8 bending tool bolt to bend tab. Make slight bends and remeasure tab with MT352-1 gage. Bend trim tab 0.015 inch (down) to effect dynamic movement of main rotor blade tip approximately 0.2 inch (downward).

18-14 Balance Adjustment

WARNING

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

A. Tip Weights (Spanwise Balance Adjustment)

1. Remove screws securing tip cover to blade. Balance rotor assembly spanwise by adjusting tip weights as required per Figure 18-2. Washers may be trimmed.

Special torque fasteners securing tip weights per Section 20-33. Install tip cover and standard torque fasteners per Section 20-32.

(1) AN960-10 or NAS1149F0363P Washer = (2) AN960-10L or NAS1149F0332P Washers

(1) C298-2 Weight

(1) C298-3 Weight

(1) C298-4 Weight

= (5) AN960-10 or NAS1149F0363P Washers


= (4) C298-3 Weights

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

1. Remove and discard teeter hinge nut cotter pin. Remove nut, thrust washer, and any shims.

2. Have two people cone the main rotor blades. Push out teeter hinge bolt (and any shims) with another bolt.

3. Balance rotor assembly chordwise by moving (or exchanging) existing teeter hinge shims to other side of bolt (under head or under nut) as required per Figure 18-2.

Install teeter hinge bolt per Section 62-10.

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

1. Balance rotor assembly chordwise by adjusting chord arm weights or washers per

Figure 18-2. Total weight not to exceed four A255-2 weights (or equivalent).

(1) A255-1 Weight

(1) A255-2 Weight

= (8) AN970-4 Washers

= (3) A255-1 Weights

Page 18.10



B. Main Rotor Blade Trim Tab (continued)

2. Position MT352-1 gage chordwise across blade upper surface and tab trailing edge.

Zero dial indicator on measuring point.

3. Position MT526-8 bending tool on tab per Figure 18-4. Slide tool completely over tab until tool stops contact blade trailing edge. Double-rib side of tool should contact tab upper surface to bend tab down. Double-rib side of tool should contact tab bottom surface to bend tab up.

4. Tighten MT526-8 bending tool bolt to bend tab. Make slight bends and remeasure tab with MT352-1 gage. Bend trim tab 0.015 inch (down) to effect dynamic movement of main rotor blade tip approximately 0.2 inch (downward).


WARNING


A. Tip Weights (Spanwise Balance Adjustment)

1. Remove screws securing tip cover to blade. Balance rotor assembly spanwise by adjusting tip weights as required per Figure 18-2. Washers may be trimmed.

Special torque fasteners securing tip weights per Section 20-33. Install tip cover and standard torque fasteners per Section 20-32.

(1) AN960-10 or NAS1149F0363P Washer = (2) AN960-10L or NAS1149F0332P Washers

(1) C298-2 Weight

(1) C298-3 Weight

(1) C298-4 Weight



= (4) C298-3 Weights

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

1. Remove and discard teeter hinge nut cotter pin. Remove nut, thrust washer, and any shims.

2. Have two people cone the main rotor blades. Push out teeter hinge bolt (and any shims) with another bolt.

3. Balance rotor assembly chordwise by moving (or exchanging) existing teeter hinge shims to other side of bolt (under head or under nut) as required per Figure 18-2.

Install teeter hinge bolt per Section 62-10.

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

1. Balance rotor assembly chordwise by adjusting chord arm weights or washers per

Figure 18-2. Total weight not to exceed four A255-2 weights (or equivalent).

(1) A255-1 Weight

(1) A255-2 Weight

= (8) AN970-4 Washers

= (3) A255-1 Weights

18-15 Troubleshooting

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

Symptom Probable Cause

1. Excessive Cyclic or

Stick Shake

Main rotor (MR) out of track.

Rough or binding A205-7 fork assembly (upper swashplate).

Brinelled spindle bearing

(rough movement).

Rough blade surface (chipped paint).

Rough or binding pitch links.

MR blade boot misaligned.

MR teeter or coning hinge binding.

MR blade trim tabs bent upward.

Blade mismatch.

Correction

Track and balance per Section 18-10.

Replace or refer to Section 67-40.

Send blade(s) to RHC for spindle bearing replacement.

Repair blades per Section 62-60.

Replace pitch link rod ends

Realign or replace boot per Section 62-11.

Replace bearings per Section 62-21.

Bend trim tabs evenly down per Section 18-13.

Send blade(s) to RHC for replacement.

2. Excessive Ship

Vibration

MR out of track and balance.

MR teeter or coning hinge friction.

MR teeter or coning hinge binding.


(rough movement).

MR teeter hinge bearings worn.

3. Excessive Cyclic

Stick Forces


(rough movement).

4. Intermittent Blade

Track Picture

MR teeter or coning hinge friction

MR coning hinge binding.

MR teeter hinge not "broken-in."


(rough movement).

5. Radical Changes to

Cyclic Trim

MR teeter hinge bearings worn.


(rough movement).

Track and balance per Section 18-10.

Adjust hinge friction per Section 62-32.





Adjust hinge friction per Section 62-32.


Track and balance per Section 18-10. Adjust track to minimize error.





Page 18.11

18-16 Autorotational RPM Adjustment

Use the following procedure for checking and adjusting autorotational RPM:

WARNING

Failure to properly adjust autorotational RPM (RPM too low) may prevent the rotorcraft from achieving proper RPM at low gross weights.

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

Take-Off gross weight:

Take-Off hourmeter reading:

2. Set the altimeter to 29.92” Hg (1013.2 millibars) prior to performing the autorotation.

Autorotate with the collective control firmly held against the down stop with an airspeed of 50 KIAS.

WARNING

Do not allow the rotor to overspeed when performing autorotation checks. Progressively lengthen both main rotor pitch link rod ends until full down collective can be obtained without overspeeding the rotor.

Take at least 3 RPM readings at 500 to 1000 foot altitude intervals.

Record the following in-flight data:

Test #

1

2

3

4

5

Hourmeter

Reading OAT

Pressure

Altitude

Test %

RPM

Page 18.12


18-16 Autorotational RPM Adjustment (continued)

3. After test flight, determine the following:

Test # 1

Elapsed Time (in-flight hourmeter reading minus take-off hourmeter reading):

Pounds of Fuel Consumed

(elapsed time x 140 lb/hr):

Test Gross Weight

(take-off gross weight minus fuel consumed):

Test Longitudinal Center of Gravity:

2 3 4 5

Chart % RPM*:

Test % RPM (from in-flight data):

RPM Correction

(chart % RPM minus test % RPM):

*Perform step 4 to obtain value.

4. Refer to Figure 18-5. To find Chart % RPM, perform the following: a. Start at outside air temperature, and draw a vertical line up to pressure altitude.

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

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

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

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


Page 18.13

AUTOROTATION RPM

COLLECTIVE FULL DOWN

50 KIAS

One full turn of rod ends = approximately 3 ½ % RPM change

One full turn of rod end = 1 ⅙ turns of barrel

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

Page 18.14

FIGURE 18-5 AUTOROTATION RPM ADJUSTMENT


Intentionally Blank


Page 18.15

Page 18.16

FIGURE 18-6 TAIL ROTOR BALANCING EQUIPMENT INSTALLATION


18-20 Tail Rotor Dynamic Balance

NOTE


NOTE


18-21 Preparing Helicopter for Tail Rotor Dynamic Balance

NOTE

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

WARNING

Ensure cable(s) cannot entangle tail rotor.

1. Clean tail rotor blades per Section 20-10. Inspect tail rotor rod ends and elastomeric bearings per Sections 5-33 and 5-34.

2. Track tail rotor blades per Section 64-10.

3. Refer to Figure 18-6. If using photocell to obtain clock angle, install a target tape spanwise on inboard side of one arm of tail rotor hub; if using Strobex, install a target tape spanwise on outboard side of hub.

4. Using appropriate hardware, attach bracket(s) to vibration transducer, and photocell, if used. Secure bracket to tail rotor gearbox output shaft cap at forward, top attachment bolt. Orient vibration transducer vertically.

5. Connect cable(s) to transducer, and photocell, if used. Route cable(s) forward and into cabin; wrap around tailcone several times, and secure with duct tape. If using Strobex, route cable to a position located approximately 20 feet to left of tail rotor. Place sandbags (or similar) on cable to prevent cable movement.

6. Connect cable(s) to balancer. Verify security of installation.

SEP 2012 R66 Maintenance Manual Chapter 18 Track and Balance

Page 18.17

DATE

PAGE

SERIAL NO.

PITCH HORN-TO-PITCH LINK FASTENER (CHORDWISE) WEIGHTS

(1) NAS1149F0463P Washer = (2) NAS1149F0432P Washers

(1) A214-3 Washer

(1) A141-14 Washer

= (3.5) NAS1149F0432P Washers

= (5) NAS1149F0432P Washers

BLADE-TO-HUB OUTBOARD FASTENER (SPANWISE) WEIGHTS

(1) C141-23 Washer = (3.5) NAS1149F0663P Washers

(1) C141-24 Washer =

(2) NAS1149F0632P

(7) NAS1149F0663P Washers

(1) NAS1149F0663P Washer

BALANCE

CLOCK IPS

CLOCK IPS

ADJUSTMENT:

ADJUSTMENT:

CLOCK IPS

ADJUSTMENT:

CLOCK IPS

ADJUSTMENT:

FIGURE 18-7 TAIL ROTOR DYNAMIC BALANCE CHART

Page 18.18

Chapter 18 Track and Balance R66 Maintenance Manual SEP 2012

18-22 Ground Checks

NOTE


NOTE

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

WARNING

Tail rotor balancing equipment must be removed for flight.

1. Prepare helicopter for tail rotor dynamic balance per Section 18-21.

2. Make a photocopy of Figure 18-7; use copy to record ground check data. Check tail rotor balance at 99-101% RPM on ground and record data. Maximum vibration allowance is

0.2 ips (inches per second). (If using Chadwick-Helmuth system, set Function Knob on

Balancer to appropriate channel, set balancer RPM Range knob to X10, and set RPM to

231. During ground run, view tail rotor assembly target tape through Strobex and tune

Balancer by adjusting RPM dial.)

3. Adjust balance per Section 18-23 as required, record change, and recheck balance.

Repeat steps 2 and 3 as required until tail rotor balance is within limits.

4. Remove track and balance equipment. Install tail rotor gearbox output shaft cap forward, top attachment bolt and special torque per Section 20-33. Install 0.032-inch diameter lockwire securing cap retaining hardware and safety in pairs.

WARNING



Refer to R66 Illustrated Parts Catalog (IPC) Figure 64-1. Refer to Section 64-11 for tail rotor assembly static balance procedure.

A. Pitch Horn-to-Pitch Link Fastener (Chordwise Balance Adjustment)

Chordwise dynamic balance is achieved by varying NAS6604 bolt length and nut-side washers on tail rotor blade pitch horn-to-pitch link fastener. Select bolt length and washers as required to balance tail rotor assembly chordwise per Figure 18-7, and to meet torque requirements per Section 20-30. Standard torque nut and palnut per

Section 20-32, but do not torque stripe.

B. Blade-to-Hub Outboard Fastener (Spanwise Balance Adjustment)

Spanwise dynamic balance is achieved by varying nut-side washer size on tail rotor blade-to-hub outboard fastener. Four washers are required under outboard nuts. Select a combination of four washers to balance tail rotor assembly spanwise per Figure 18-7, placing largest washers closest to hub assembly. Standard torque nuts and palnuts per

Section 20-32, but do not torque stripe.


Page 18.19

FIGURE 18-8 SWASHPLATE AND COLLECTIVE CONTROL RIGGING

Page 18.20

FIGURE 18-9 A205-5 SWASHPLATE FORK RIGGING


18-30 Main Rotor Flight Control Rigging

NOTE

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

For collective adjustments, both pitch links must be adjusted exactly the same.

Track and balance helicopter per Sections 18-10 & 18-20 as required after adjusting flight controls.

NOTE

Cyclic stick travel is non-adjustable. Travel is limited by A211-4 stop attached to the cyclic box assembly.

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

A333-1 stop integral to the collective stick friction assembly.

Perform the following check to verify collective travel and swashplate travel do not interfere.

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

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

PART NUMBER DIMENSION

C121-1 = 51.15 ± 0.03 inches

F121-1 = 32.36 ± 0.03 inches

G205-1 = 5.40 ± 0.03 inches

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

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

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

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

7. Refer to Figure 18-9. Adjust swashplate A205-5 lower fork assembly (non-rotating) to

3.70 ± 0.03 inch, and upper fork assembly (rotating) to 3.85 ± 0.03 inch.


Page 18.21

Page 18.22

FIGURE 18-10 MAIN ROTOR BLADE RIGGING


18-40 Main Rotor Blade Angle Rigging

A. Procedure

NOTE

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

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

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

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

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

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

B. Measuring Blade Angles

NOTE

Hydraulic flight controls must be pressurized while measuring blade angles.

WARNING

Never adjust flight controls while hydraulics are pressurized.

Hydraulic forces can cause injury.

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

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

3. Hang a 6-inch length of masking tape from one blade tip for reference. Zero Kell-Strom

KS113 propeller protractor (or equivalent) on top of the main rotor hub, parallel to the teeter hinge bolt, at location marked “LEVEL HERE”. During zeroing, point protractor face toward the blade with hanging tape. When taking blade angle readings, always point protractor face toward the blade with hanging tape.

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


Page 18.23

18-41 Collective Travel

NOTE

Lengthening pitch links increases blade angles.

NOTE

When making adjustments, keep pitch links as close to neutral

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

A. Collective Down

1. Refer to Figure 18-8. Position collective stick full up and apply friction. Place

MT759-1 rigging blocks around cyclic stick in cyclic box assembly. Verify top of ball is flush with tube within 0.030 inch. Adjust all swashplate push-pull tubes exactly the same amount as required (one full turn = 0.48°).

2. Position collective stick full down and apply friction.

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

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

BLUE BLADE

Pitch horn forward

Pitch horn aft +

=

°

°

°

RED BLADE

Pitch horn forward

Pitch horn aft +

=

°

°

°

÷ 2 = ° ÷ 2 = °

5. Blade angles must average between 1.0° and 2.0° for collective down position.

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

NOTE

After making adjustments, position collective stick full up and apply friction. Verify top of swashplate ball is flush with tube within 0.030 inch per Figure 18-8. Adjust all swashplate pushpull tubes exactly the same amount as required (one full turn =

0.48°). Lengthening all push-pull tubes increases blade angles.

Page 18.24


18-41 Collective Travel

B . Collective Up

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


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

BLUE BLADE

Pitch horn forward °

RED BLADE


Pitch horn aft +

=

°

°

Pitch horn aft +

=

°

°

÷ 2 = ° ÷ 2 = °

4. For collective up position, blade angles must average between 12.5° and 13.5° more than collective down position average. Adjust main rotor blade pitch links per

Section 18-13 as required (one full barrel turn = 0.72°) until blade angles, when blades are positioned pitch horn forward, are within 0.2°. Adjust pitch links until blade angles, when blades are positioned pitch horn aft, are also within 0.2°.

NOTE

Remeasure collective down blade angles after making adjustment for collective up blade angles.

NOTE

After making adjustments, position collective stick full up and apply friction. Verify top of swashplate ball is flush with tube within 0.030 inch per Figure 18-8. Adjust all swashplate pushpull tubes exactly the same amount as required (one full turn =

0.48°). Lengthening all push-pull tubes increases blade angles.


Page 18.25

18-42 Cyclic Travel

A. Cyclic Left

1. Position collective stick full down. Position cyclic stick in the longitudinal neutral

(mid travel) position, and against left stop. Apply control frictions; sandbag cyclic stick as required.

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

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

BLUE BLADE

Pitch horn right °

RED BLADE

Pitch horn right °

Pitch horn left +

=

°

°

Pitch horn left +

=

°

°

÷ 2 = ° ÷ 2 = °

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

B. Cyclic Right

1. Position collective stick full down. Position cyclic stick in the longitudinal neutral

(mid travel) position, and against right stop. Apply control frictions; sandbag cyclic stick as required.

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

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

BLUE BLADE

Pitch horn right

Pitch horn left +

=

°

°

°

RED BLADE

Pitch horn right

Pitch horn left +

=

°

°

°

÷ 2 = ° ÷ 2 = °

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

NOTE

Remeasure cyclic left blade angles after making adjustment for cyclic right blade angles.

Page 18.26


18-42 Cyclic Travel (continued)

C. Cyclic Forward

1. Position collective stick full down. Position cyclic stick in the lateral neutral (5 inches to left of right stop) position, and against forward stop. Apply control frictions; sandbag cyclic stick as required.


3. Measure and record blade angles per § 18-40 Part B to determine the values below.

Rotate blades 180 ° and align per step 2 as required.

BLUE BLADE


RED BLADE


Pitch horn aft +

=

°

°

Pitch horn aft +

=

°

°

÷ 2 = ° ÷ 2 = °

4. Blade angles must average between 13.50° and 14.25° for cyclic forward position.

Adjust swashplate aft push-pull tube as required (one full turn = 0.44°). A coarse adjustment can be made by adjusting swashplate forward push-pull tubes exactly the same amount (one full turn = 0.6°).

D. Cyclic Aft

1. Position collective stick full down. Position cyclic stick in the lateral neutral (5 inches to left of right stop) position, and against aft stop. Apply control frictions; sandbag cyclic stick as required.


3. Measure and record blade angles per § 18-40 Part B to determine the values below.

Rotate blades 180 ° and align per step 2 as required.

BLUE BLADE

Pitch horn forward

Pitch horn aft +

=

°

°

°

RED BLADE

Pitch horn forward

Pitch horn aft +

=

°

°

°

÷ 2 = ° ÷ 2 = °

4. Blade angles must average between 13.50° and 14.25° for cyclic aft position.

Adjust swashplate aft push-pull tube as required (one full turn = 0.44°). A coarse adjustment can be made by adjusting swashplate forward push-pull tubes exactly the same amount (one full turn = 0.6°).

NOTE

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

MAY 2015 Chapter 18 Track and Balance Page 18.27

18-50 Tail Rotor Flight Control Rigging

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

18-51 Pedals

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

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

18-52 Forward Bellcrank

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

18-53 Intermediate Bellcrank

With left pedal at stop, adjust the C121-17 push-pull tube length as required to obtain

0.35 ± 0.03 inch between two faces of pitch control assembly and the housing.

Page 18.28

FIGURE 18-11 TAIL ROTOR BLADE RIGGING


18-60 Tail Rotor Blade Rigging

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

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

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

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

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

6. Have a second person hold one blade tip at the left pedal track mark with the left pedal against its stop. Position MT525-2 rigging fixture on the aft blade, against the inboard surface. Position propeller protractor against the fixture, measure the blade angle, and record data below. Rotate the tail rotor 180°, and record the opposite blade angle.

Pedals Full Left

Blue Blade

Red Blade +

=

÷ 2 =

°

°

°

° (18.5/19.0° required)

7. Difference between blue and red blade angles may not exceed 0.4°. If blade angles exceed this limit, remove tail rotor assembly per § 64-10, rotate assembly one-half revolution, and install assembly per § 64-10. Repeat previous steps. If blade angles still exceed relative limit, contact RHC Technical Support for replacement blade assistance.

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

9. Have a second person hold one blade tip at the right pedal track park with the right pedal against its stop. Position MT525-2 rigging fixture on the aft blade, against the inboard surface. Position propeller protractor against the fixture, measure the blade angle, and record data below. Rotate the tail rotor 180°, and record the opposite blade angle.

Pedals Full Right

Blue Blade

Red Blade +

=

÷ 2 =

°

°

°

° (15.5/16.5° required)

10. Adjust C121-17 push-pull tube rod ends per § 5-33 and Figures 5-1 & 5-2 as required to obtain blade angle between 15.5° and 16.5°. If adjusted, recheck left pedal blade angles per previous steps.


18-60 Tail Rotor Blade Rigging (continued)

11. If the blade angle range for left and right pedal settings cannot be obtained using the preceding steps, pedal total travel is either too great or too small. Use the following procedure to check and adjust pedal travel: a. Add right and left pedal blade angles together. If total is less than 34.0°, pedal total travel is too small. If total is greater than 35.5°, pedal total travel is too great.

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

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

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

12. Balance tail rotor per § 18-20.

Page 18.30


Intentionally Blank


Page 18.32

FIGURE 18-12 FAN SHAFT AND ENGINE SHAFT BALANCING


18-70 Fan Shaft and Engine Shaft Balancing

NOTE


NOTE


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

NOTE

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

1. Remove tailcone cowling per § 53-23. Clean F196-1 fan shaft weldment, G174-

1 fanwheel assembly, and F642 shaft weldment. Inspect condition of flex plates, weldment flanges, and adjacent yokes. Verify proper fastener installation and unbroken torque stripe.

2. Refer to Figure 18-12.

a. Fan Shaft: Using a #8 screw, attach vibration transducer and photocell (cables pointed up) to mounting bracket(s). Secure bracket(s) to top of tailcone at the forward nutplate, aiming photocell toward center of shaft.

b. Engine Shaft: Using appropriate hardware, attach photocell (cable pointed outboard toward access door) to mounting bracket. Secure bracket to F020-1 frame assembly using MS21919WDG16 clamp and associated hardware, aiming photocell toward center of shaft.

3. Install a target tape on each shaft weldment and align tape with a flange arm. Verify photocell beam will hit target tape. (Tape becomes the 12 o'clock position.)

4. Route cable(s) forward into cabin; secure cables to cabin with duct tape.

5. Connect cable(s) to balancer. Verify security of installation.


18-72 Ground Checks

NOTE


NOTE

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

WARNING

Fan shaft and engine shaft balancing equipment must be removed for flight.

1. Prepare helicopter for fan shaft and engine shaft balance per § 18-71.

2. Configure balance equipment per manufacturer's instructions.

3. Ground run helicopter at 100% RPM (2114 fan shaft RPM and 6016 engine shaft

RPM). Verify cyclic stick and tail rotor pedals are in neutral position.

4. Determine vibration level per balance equipment manufacturer's instructions. Maximum vibration allowance is 0.2 IPS (inches per second). If reading is over 0.2 IPS: a. Fan Shaft: Adjust balance by selecting one or more NAS1149D0463J,

NAS1149F0432P, NAS1149F0463P, A214-3, or A141-14 washers as required and install under one nut of intermediate flex plate (tail rotor driveline) fastener.

b. Engine Shaft: Adjust balance by selecting one or more NAS1149D0463J,

NAS1149F0432P, NAS1149F0463P, A214-3, or A141-14 washers as required and install under one nut of aft flex plate (engine driveline) fastener.

NOTE

If a large diameter washer is installed at a shaft flange, also install one NAS1149F0432P washer against flange to prevent flange damage (not required for flat flange). Additionally, an

NAS6604-5, -6, -7, or -8 bolt may be substituted for a bolt at a flex plate fastener; verify thread engagement meets torque requirements per § 20-30.

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

Page 18.34


Robinson R-66 Series Lithium-Ion Maintenance Manual

AUTOROTATION RPM

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