Robinson R66 - Page 2

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SUBSCRIPTION ORDER AND RENEWAL FORMS

Subscription order and renewal forms are located at www.robinsonheli.com.

WARRANTY INFORMATION

Helicopter and parts warranty information is located at www.robinsonheli.com.

Page ii

Introduction APR 2019

Main Page

Table of Contents7
- Chapter 13
- Introduction3
  - Table of Contents7
- R66 Maintenance Manual Revisions9
- Component Maintenance Authorization10
- Maintenance Record10
- R66 Maintenance Authorization10
- Maintenance Manual and Illustrated Parts Catalog References11
- Notations11
- Definitions and Abbreviations12
- Service Information14
- Assembly Instructions for R66 Helicopter Crated for Export15
- Helicopter Servicing21
  - Scheduled Maintenance and Inspections21
  - Additional Component Maintenance22
Airworthiness Limitations29
- Chapter 4 Airworthiness Limitations31
- Life-Limited Components31
  - Time-In-Service Records31
  - Fatigue Life-Limited Parts32
- Type Certificate Data Sheet (TCDS)32
- Airworthiness Limitations39
Table of Contents41
- Chapter 542
- Section Title42
- General Procedures43
- Introduction43
- Reserved]43
- Operation Checks for 100-Hour/Annual Inspection50
- 100-Hour/Annual Inspection87
- 2000-Hour/12-Year Inspection91
- Special Maintenance and Inspections97
Table of Contents111
- Chapter 6 Dimensions and Descriptions113
- Datum113
- Method of Measurement113
- Version Description113
- External Dimensions115
- Baggage Compartment Dimensions116
- Station Diagrams118
  - Fuselage Station (FS) Locations118
  - Tailcone Station (TS) Locations119
Page 8.I133
- Leveling135
  - Leveling for Weight and Balance135
  - Leveling for Rigging137
- Weighing139
  - Preparing Helicopter for Weighing139
  - Weighing Procedure and Calculations141
- Fixed Ballast145
  - Nose Ballast145
  - Empennage Ballast147
Page 10.I155
- Parking157
- Storage (Greater than 30 Days)162
Table of Contents167
- Chapter 12169
- Main Rotor Gearbox169
- Servicing169
- Chip Detector and Sight Gage171
- Filter Replacement171
- Tail Rotor Gearbox175
- Hydraulic System177
- Fuel System181
  - Fueling181
  - Defueling182
- Main Rotor Blades185
  - Pitch Bearing Housing185
- Engine Oil Servicing186
- Engine) Compressor Rinse and Wash187
  - Drainage Spotface Inspection During Cleaning or Rinsing of RR300 Engine 12.17A188
- Air Conditioning System190
- Lubrication of Swashplate Bearings193
Table of Contents195
- Chapter 18 Track and Balance197
- Main Rotor Track and Balance197
- Tail Rotor Dynamic Balance219
- Main Rotor Flight Control Rigging223
- Main Rotor Blade Angle Rigging225
  - Collective Travel226
  - Cyclic Travel228
- Tail Rotor Flight Control Rigging230
- Tail Rotor Blade Rigging231
- Fan Shaft and Engine Shaft Balancing235
  - Preparing Helicopter for Fan Shaft and Engine Shaft Balancing235
  - Ground Checks237
Table of Contents239
- Chapter 20 Standard Practices241
- Cleaning241
- Lubrication243
- Torque Requirements245
- Non-Destructive Testing268
  - Magnetic Particle Inspection268
  - Fluorescent Penetrant Inspection269
- Corrosion Control269
- Priming and Painting269
- Approved Materials272
- Storage Limits282
- Miscellaneous Practices283
20-94 Crimp Inspection285
- Description287
- Ventilation289
  - Nose Vent289
- Air Conditioning291
- Cabin Heat297
Table of Contents301
- Chapter 22303
- Description303
- Pitch) Servo Assembly305
- Roll) Servo Assembly306
- Flight Control Computer307
- Control Panel308
- Cyclic Grip Assembly309
- Maintenance310
  - Scheduled Maintenance and Inspections310
  - Special Maintenance and Inspections312
Table of Contents315
- Description317
- Seat Harnesses319
  - Seat Harness Removal319
  - Seat Harness Installation320
- Seat Assemblies and Back Rests321
- Carpet327
- General Maintenance328
- Insulation (Foam and Headliner)328
- Emergency Equipment330
  - Emergency Locator Transmitter (ELT)330
  - Fire Extinguisher331
- Cargo Hook Installation333
Table of Contents349
- Description351
- Bladder Assembly353
  - Rollover Valves355
  - Sump Valve356
- Fuel Quantity357
- Fuel Valve369
  - Fuel Valve Control Rigging369
- Fuel Flow Check370
  - Bladder373
Page 32.I397
- Landing Gear Assembly399
- Cross Tubes401
- Skid Tubes407
- Fairing Assemblies409
- Maintenance409
- Pop-Out Floats Installation411
Table of Contents431
- Door Assembly433
- Chapter 52436
- Door Lock Replacement436
- Weather Seal (Door Assembly) Replacement436
- Door Vent Replacement439
- Gas Springs439
- Windshield Installation443
  - Standard (Acrylic) Windshield Installation443
  - Impact-Resistant (Polycarbonate) Windshield Installation446
Table of Contents451
- Cabin Assembly453
  - Repair453
- Fairings, Cowlings, and Panels455
- Frame Assemblies457
- Tailcone Assembly465
  - Inspection and Repair467
- Empennage Assembly469
Table of Contents475
- Main Rotor Blades477
  - Blade Boots482
- Main Rotor Hub483
  - Bearing Replacement485
  - Inspection and Repair487
- Main Rotor Assembly489
- Inspection of Main Rotor Blades500
- Repair of Main Rotor Blades511
  - Sealing, Filling, and Fairing511
  - Painting512
- Main Rotor Blade Tip Maintenance513
Table of Contents515
- Engine Shaft Weldment517
- Chapter 63518
- Engine Driveline) Forward Flex Plate Shimming518
- Clutch Assembly521
- Main Rotor Gearbox Assembly522
  - Yoke and Seal Replacement524
- Rotor Brake529
  - Pad Replacement530
- Rotor RPM530
Table of Contents531
- Tail Rotor Assembly533
  - Static Balance537
- Tail Rotor Blades540
- Tail Rotor Blade Inspection and Repair543
- Tail Rotor Hub549
  - Bearing Replacement549
  - Inspection549
Page 65.I551
- Description553
- Tail Rotor Drive Fan Shaft553
- Tail Rotor Drive Shaft Assembly555
  - Runout557
  - Damper Assembly559
- Tail Rotor Driveline) Intermediate Flex Plate Shimming560
- Tail Rotor Gearbox Assembly562
  - Output Shaft Seal Replacement563
  - Input Shaft Seal Replacement564
Table of Contents565
- Cyclic Controls567
- Collective Control572
  - Collective Stick Assembly572
  - Collective Friction574
- Jackshaft and Strut Assembly574
  - Jackshaft574
- Swashplate575
  - Swashplate Tilting Friction Adjustment577
  - Upper and Lower Scissor Assemblies577
- Tail Rotor Controls579
  - Pedals579
  - Pitch Control580
- Bellcranks581
Table of Contents585
- Description587
- Engine589
  - Preparing Engine for Rolls-Royce Maintenance Facility595
  - Preparing Engine for Helicopter Installation597
- Induction601
- Exhaust Weldment609
- Accessories610
Table of Contents627
- Chapter 79629
- Description629
- Scroll and Fanwheel Assemblies631
  - Fanwheel-To-Inlet Gaps631
- Oil Tank Assembly633
  - Oil Temperature Sender634
  - Sight Gage635
- Engine Oil Cooler635
- Engine Oil Filter635
- Engine Oil Line Assemblies and Fittings636
Table of Contents637
- Description639
- Police Version639
- C023-34 Tailcone Assembly643
- C060-3 Interior Light Installation643
- C069 Cyclic Control Assembly643
- C430-2 Five-Point Harness Installation (Optional)643
- C599 Airspeed Indicator643
- C813 Transceiver Installation (Optional)644
- C823-16 Audio Control Installation646
- C849-4 Blower Installation (Optional)647
- D301 Ballast Installation648
- F003-19 Seat Removal648
- F014-5 Landing Gear Installation648
- F036-3 Battery Installation648
- F051-1 Camera System Installation649
- F060 Intercom System Installation650
- F075-2 EFIS Installation651
  - C831-12, -13, & -14 (GTN XXX-Series) GPS/NAV/COM Installation651
  - G060-4 (Garmin G500H) Upper Console Assembly651
- F075-8 EFIS Installation652
  - F817-9 (Garmin G500H) GDU 1060 Display (R66 Police) Installation652
  - F818-11 (G070 Console) GTN 6XX-Series GPS/NAV/COM Installation652
  - G070-7 (8-Instrument, High) Upper Console Assembly652
- F079-1 Pa/Siren System Installation653
- F081 Searchlight Installation655
- F082-21 Fairing Installation656
- G415-1 DVR Installation (Optional)656
- G416 Monitor Installation657
- G423-1 Aux Electrical System Installation659
- G425-1 Wall Installation659
- G437-1 Lojack Installation660
- G460 Audio Control Installation661
- G608 GPS Mapping System Installation662
- G749-1 Console Installation665
- Wiring Schematics667
Table of Contents697
- A826-18 Transceiver Installation (FM1)701
- C023-24 Tailcone Assembly702
- C599-7 Airspeed Indicator702
- C720-1 Support Installation702
  - D097-36 HD Micro Camera Installation (Windshield Bow)703
  - D097-37 HD Micro Camera Installation (Aft-Center Cabin)704
  - D097-38 HD Micro Camera Installation (Tail)706
  - D097 HD Micro Camera Controller708
- F003-19 Seat Removal709
- F060 Remote Transmit Switch Installations709
- Landing Gear Assembly709
- F075-1 EFIS Installation710
- F082-21 Fairing Installation710
- F461-4 Cover Assembly710
- G197-13 Window710
- G425-1 Wall Installation711
- G445-2 Aux Circuit Breaker Panel Installation711
- G448 Aft Monitors Installation712
  - G448-1 10-Inch Monitor713
  - G448-1 Five-Inch Left Hand Monitor714
  - G448-2 Five-Inch Right Hand Monitor715
- G449 Forward Monitors Installation716
- G454-1 Camera System Installation717
  - D050-14 Gimbal Installation717
  - E002-2 Laptop Assembly723
  - E003-7 Aux Box Assembly724
- G456-1 Microwave System Installation725
  - ARC-CM-TX-RX-CR-01 Controller727
  - CMTX7-LITE Transmitter728
  - PA16-Series Pod Antenna729
  - GPS-1270FW Antenna732
- Antenna Installations733
  - G457-1 Antenna Installation (Transponder)733
  - G457-2 Antenna Installation (TV Tuner)734
  - G457-3 Antenna Installation (Scanner)735
- G470-1 Aft Console Installation736
- G487-1 FM Transceivers Installation736
- G489-1 Scanner Installation738
- G490-1 Talent Light Installation739
  - D553-1 (Forward Talent) Light Assembly739
  - ILED-MA (Aft Talent) Light740
- G491 TV Receiver Provision Installation740
  - Distribution Amp741
  - Digital TV Receiver742
- G492-1 Audio System Installation743
  - Forward Audio Panels744
  - Aft Console Audio Panels745
  - Digital Router746
- G493-1 Video Components Installation747
- G496-1 DVR Installation748
- Aux Electrical System Installation749
- D301 Ballast Installation749
- Wiring Diagrams751
92-290 Wiring Diagrams (Continued)769
- Pitot-Static System773
- Primary Instruments775
- Engine Gages784
- Additional Standard Indicating Equipment788
  - Outside Air Temperature (OAT) Gage/Voltmeter790
- Console Assemblies792
- Instrument Markings792
- Electronic Flight Displays795
Table of Contents803
- Lead-Acid Battery Installations807
- Lithium-Ion Battery Installation813
- External Power815
- Starter and Ignition System815
- Annunciator Panel816
- Lighting System816
- Audio System818
- Low Rotor RPM Warning Unit Adjustment818
- Engine Monitoring Unit (EMU)819
- Emergency Locator Transmitter (ELT)820
- Audio Alerts824
Table of Contents825
- Garmin G500H Electronic Flight Instrument System (EFIS) Installation827
- Radar Altimeter Installation835
- Garmin GTX 33 Transponder Installation838
- Garmin GDL 69A XM Receiver Installation841
- Avionics for R66 S/N 293, 520, 522 & Subsequent843
- Avionics Software855

Robinson R66 - Page 2

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