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RotorWay Exec 162F Maintenance Manual Download Page 88

RotorWay International

Exec 162F Maintenance Manual

88
Rev. 1  10/01

HOURLY SERVICE CHART  EXEC 162F

REFERENCE SECTION 19:  ROTOR HUB CONTINUED

PART NO. DESCRIPTION

25

50

100

200

250

500 1000 1500 2000

E49-4100

Cyclic Mount Bearing

I

R

E49-4110

Snap Ring, Cyclic Mount

I

R

E49-3531

Snap Ring, Rotating Swash Plate

I

R

E49-3210

Collective Slider Ball

I

R

E49-3220

Spherical Bushing

I

R

E49-1530

Slider Ball Clamp

I

R

E49-1520

Slider Ball O-ring

I

R

E49-3240

Snap Ring Slider Ball

I

R

E00-9302

Set Screw (10-32)

I

R

E49-4610

Swash Plate Scissor

I

R

E49-4710

Scissor Clevis

I

R

E49-4720

Male Rod End 5/16 x 3/8

I

R

E49-4810

Nylon Scissor Bushing

I

R

E49-4210

Collective Actuator Fork

I

R

E49-4310

Collective Scissor

I

R

E49-1380

Collective Scissor Mount

I

R

E14-6120

Control “T”

I

R

E14-1150

5/16 Male Rod End

I

R

E49-4510

Counter Balance

I

R

E15-1230

5/16 Male Rod End

I

R

E49-1410

Rod End Spacer

I

E49-1470

Spring Bracket

I

E49-1430

Tension Spring

I

R

E49-4800

Delrin Washer (Scissor)

I

R

E49-4830

Scissor Spacer 1-1/2"

I

R

E49-1180

Male Rod End 5/16"

I

R

E49-1510

Dust Boot

I

R

E49-1500

Rubber Shaft Protector

I

R

E49-1220

Main Thrust Bearing

I

R

E49-1230

Main Bearing Flange

I

R

E49-1260

Main Shaft Safety Spacer

I

R

E49-1251

Lower Main Shaft Bearing (Bearing Only)

I

R

E49-9100

Lower Main Shaft Bearing Weldment (Flange Only)

I

R

I

INSPECT

R

REPLACE

Summary of Contents for Exec 162F

Page 1: ...ANCE MANUAL The RotorWay EXEC 162F Maintenance Manual has been designed to provide the owner operator the lowest operating cost possible while maintaining the flight characteristics and safety of thei...

Page 2: ...g the clarity or correctness of the plans ease of construction or operation nor the safety of this aircraft or any part thereof Furthermore buyer and his heirs administrators and assigns releases and...

Page 3: ...ble its replacement before failure The R C O time represents the lifetime of a component as recommended by the manufacturer A phrase called on condition or O C is also utilized in this manual This mea...

Page 4: ...RotorWay International Exec 162F Maintenance Manual 4...

Page 5: ...e 21 Oil sump heat exchanger oil hoses oil filter SECTION 8 Cooling System Page 23 Radiator radiator cap hoses water pump assembly water pump pulley water pump alternator belt thermostat SECTION 9 Eng...

Page 6: ...g delrin shim stainless steel shim bolts main rotor drive pin thin washer snap rings thrust blocks thrust washer thrust block alignment bearing thrust block liner rod ends pitch link set screws pitch...

Page 7: ...greater than 62 inches 3 Removal of the two rear lower fiberglass body panels part no E32 7130 and E32 7140 will allow you access for a visual inspection of the Engine Mount Rubber Ring part no E13 3...

Page 8: ...RotorWay International Exec 162F Maintenance Manual 8...

Page 9: ...drill bit depending upon the size and head diameter of the rivet drill out the head of the rivet by rotating the drill in an elliptical manner This will remove the head without drilling through the ri...

Page 10: ...RotorWay International Exec 162F Maintenance Manual 10...

Page 11: ...ith acetone because of its high flammability Check to make sure that all metal parts protruding through the fiberglass have a minimum of 1 4 clearance If the clearance requires enlarging this process...

Page 12: ...appropriate size drill bit C If a cover is used while trailering make sure the cover has a soft inside lining and fits tight enough to the body to avoid flapping 3 Use any commercially available uphol...

Page 13: ...ure contact of the bearing to the snap ring When using a press press only on the outer race of the bearing and not the inner race Wipe off remaining Loctite J Install the second snap ring and let the...

Page 14: ...RotorWay International Exec 162F Maintenance Manual 14...

Page 15: ...scratch the inner surface of the tail rotor barrel E Grasp the pitch pin and pull it out of the barrel It may be necessary to insert a bolt in the tail rotor pin to lightly tap on for removal NOTE A s...

Page 16: ...k the nut with cotter pins for security 4 Every 50 hours add grease to the fitting on the tail rotor barrel until the grease comes out near the pitch horns and wipe off excess Drill a 3 16 inch hole i...

Page 17: ...ean grease lightly and reassemble Check clearance between head of bolt part no E16 2406 and front airframe tube There should be a minimum of 1 16 clearance If proper clearance cannot be obtained shim...

Page 18: ...d insert the bolt Torque and safety wire the bolt then pop rivet the bushing to the bracket 11 Refer to prints E49 2002 and E15 2001 A Remove the bolt part no E00 2516 that holds the rod end to the co...

Page 19: ...the bolt part no E00 2306 and the B control arm castings part no E15 5110 Slide the throttle shaft completely out of the pilot collective stick Place a small amount of grease on the throttle shaft par...

Page 20: ...RotorWay International Exec 162F Maintenance Manual 20...

Page 21: ...n the oil system should normally be replaced at 500 hours the specified number of years or on condition whichever comes first Shelf life or time before entering service is not included if the hoses ha...

Page 22: ...RotorWay International Exec 162F Maintenance Manual 22...

Page 23: ...recommended type of coolant NEVER use tap water or well water in the cooling system Failure to follow these guidelines could result in overheating and corrosion problems that may severely damage the...

Page 24: ...the water pump body in a vise and carefully tap out the seal assembly using a punch and hammer Be careful not to damage the shaft or water pump body I Before installing the new seal part no E29 1150...

Page 25: ...TION SERVICE REFERENCE INSPECTION INTERVAL R C O The RI 162F Engine has been designed specifically for the RotorWay Helicopter RotorWay International manufactures the entire engine Refer to the Engine...

Page 26: ...Y DO NOT CONTACT OR RUB ON ANYTHING ELSE CAUTION Teflon lined steel braided hoses have a tendency to set after being exposed to heat and pressure Attempting to change the curvature of a hose after it...

Page 27: ...ng 100 HR 100 HR OC 10 3 E23 1210 Main Drive Belts 50 HR 500 HR OC or 5 yrs 10 4 E23 7141 High Temp Fan 100 HR 2000 HR OC 10 5 E23 1170 Snap Ring 500 HR 2000 HR E23 3001 Fan Pulley Assembly 500 HR 200...

Page 28: ...0 hours of operation or at 5 years or on condition whichever comes first Shelf life or time before entering service is not included if the belts have not been exposed to the environment and have not b...

Page 29: ...e torch heat surrounding area where glue exists CAUTION Use only enough heat to pop the seal out with a screwdriver C Clean the lower oil bath pan with acetone and lightly sand any glue or uneven prot...

Page 30: ...RotorWay International Exec 162F Maintenance Manual 30...

Page 31: ...ak check To do this tighten all fittings turn on the fuel pumps and check carefully for leaks CAUTION The fuel system operates at a VERY high pressure When performing this check wear eye protection an...

Page 32: ...filter for any particles or debris that may have washed out of the fuel tanks Clean as necessary Every 500 hours disassemble clean and inspect the fuel shut off valve filter assembly Replace O rings a...

Page 33: ...the helicopter following the procedures in the Construction Manual and print E31 2000 2 New belts should be cleaned with acetone and properly tensioned following the procedures outlined in the Constru...

Page 34: ...RotorWay International Exec 162F Maintenance Manual 34...

Page 35: ...and low time pilot to sense Listed are some symptoms of blade fatigue A Change in blade droop while in its static position from previous inspection B Flight response controls seem sluggish and insens...

Page 36: ...0 hours or on condition Insert the tool into the bearing Pump the grease until it visibly comes out of the bearing purging out the old grease Wipe away the excess grease then rotate the inner race of...

Page 37: ...nd fuse 5 Check the toggle switch by first disconnecting the power leads from the battery terminals Then actuate the toggle switch on and off The switch should have a good solid snap action in both di...

Page 38: ...sary 9 To check the voltage regulator for normal operation monitor the voltage meter during a normal run up of the helicopter If the regulator is working a voltage jump will be noticed on the meter du...

Page 39: ...esistor of the appropriate value that you wish to check from the list above i e 615 ohms is 150 deg f D If sender lead goes to ground meter should peg full scale E If sender lead is open broken or sen...

Page 40: ...RotorWay International Exec 162F Maintenance Manual 40...

Page 41: ...mation If handling over rough ground reduce tire pressure to help absorb the shock being transmitted to the rotor system 2 Tire track is important for maintaining longevity of the rear landing gear If...

Page 42: ...RotorWay International Exec 162F Maintenance Manual 42...

Page 43: ...NOTES 1 CAUTION All weldments should be inspected thoroughly If a weldment fails and causes the ballast weight to depart the ship during flight the weight and balance of the helicopter could move out...

Page 44: ...RotorWay International Exec 162F Maintenance Manual 44...

Page 45: ...nufactured with a gel coat finish We recommend the use of a 2 part paint that will give you years of trouble free and very low maintenance operation NOTE The lighter the color of paint used the less h...

Page 46: ...RotorWay International Exec 162F Maintenance Manual 46...

Page 47: ...rews 1 4 x 5 8 100 HR 1000 HR Torque E00 9305 Set Screws 1 4 x 3 16 100 HR 1000 HR Torque E49 6310 Pitch Pin Outboard 100 HR 100 HR OC 19 7 E49 6320 Pitch Pin Inboard 100 HR 100 HR OC 19 7 E00 2417 NA...

Page 48: ...em DESCRIPTION SERVICE REFERENCE INSPECTION INTERVAL R C O SERVICE NOTES 1 Although the hub plate appears to be a very substantial and solid part it can be damaged CAUTION should be taken to prevent g...

Page 49: ...and thrust block liner C Remove the dust cap part no E49 1331 D Press the old bearing out of the thrust block with a small press CAUTION The inner steel sleeve not the outer aluminum block must be sup...

Page 50: ...o E49 1530 and on the lower ears of the collective slider ball part no E49 3210 Remove the set screw on the slider ball and add 2 shots of grease using a grease gun and the main drive pulley grease to...

Page 51: ...spans the distance across the teeter blocks and has 4 jaws minimum one rotor hub shimming fixture See page 59 in this manual for a drawing of the fixture with dimensions and specifications This fixtur...

Page 52: ...ion to the hub and the teeter blocks See photo 2 Photo 2 Mark the hub plate shaft and teeter blocks 6 Place the spring scale on the outboard pin and pull up or down until the hub plate starts to move...

Page 53: ...by feel so that you find the spot where the wrench will move the easiest Place a small amount of grease on the bolt threads and drive the bolts out through the hub plate with the hammer and punch CAUT...

Page 54: ...he block The bearing should come out with light pressure C Clean all mating bearing surfaces and place a small amount of Loctite 609 on both the outer race of the bearing and the inner hole of the tee...

Page 55: ...the outer surface of the shaft knuckle and on all shims 18 Place the steel and delrin shims on the main drive pin All shims should have a light coat of grease on every side Do this to shims on both s...

Page 56: ...pins and hold the fixture down on the 3 rivet point contacts located on the bottom Securely hold the fixture on the hub and rock the hub slightly back and forth until the needle on the indicator stop...

Page 57: ...RotorWay International Exec 162F Maintenance Manual 57 Photo 9 Hub alignment fixture Photo 10 Hub fixture located on hub Photo 11 Proper placement of hub fixture...

Page 58: ...ing towards the outside of the pin Refer to the Construction Manual Tail Rotor section for the correct snap ring procedures 29 After rocking the hub back and forth 10 to 15 times replace the 4 set scr...

Page 59: ...RotorWay International Exec 162F Maintenance Manual 59 HUB SHIMMING FIXTURE DRAWING...

Page 60: ...swash plate at a relative perpendicular angle to the shaft Loosen the two set screws part no E00 9302 Ref 16 on print E49 2002 three full turns With your fingers loosen the adjustment collar approxim...

Page 61: ...t rather than too loose If feedback through the cyclic continues you may back off the adjustment collar another 1 4 for a total 3 4 maximum from the starting index mark If an undesirable condition sti...

Page 62: ...RotorWay International Exec 162F Maintenance Manual 62...

Page 63: ...me off in flight serious damage could occur to the helicopter INSPECTION CHART PART NO E41 7120 Door Pilot 100 HR OC E41 7130 Door Passenger 100 HR OC E41 7140 Door Stiffener 100 HR OC E41 7150 Door S...

Page 64: ...RotorWay International Exec 162F Maintenance Manual 64...

Page 65: ...00 2800 Main Rotor Blade Retention Bolts 9 16 x 4 1 4 70 ft lbs Construction Manual Sec 24 Maintenance Manual p 35 E00 2522 Main Rotor Blade Strap Bolts 5 16 x 3 14 ft lbs Construction Manual Sec 24 P...

Page 66: ...RotorWay International Exec 162F Maintenance Manual 66...

Page 67: ...quired in the event of a blade strike or swash plate stoppage 4 SECONDARY DRIVE If a roll over accident or blade strike occurs the secondary unit should be returned to the factory The secondary unit i...

Page 68: ...RotorWay International Exec 162F Maintenance Manual 68...

Page 69: ...DESCRIPTION 25 50 100 200 250 500 1000 1500 2000 E10 1001 EXEC 162F Airframe I R E00 2415 AN4 24A 1 4 x 2 1 2 Bolt I R E00 2601 AN6 10A 3 8 x 1 Bolt I R E11 9010 Rear Landing Gear I R E13 3121 Engine...

Page 70: ...im Fins I R E09 3252 Vertical Trim Fin Bracket I R E00 2300 AN3 4A 3 16 x 1 2 Bolt I R E00 2301 AN3 5A 3 16 x 5 8 Bolt I R E00 2303 AN3 6A 3 16 x 3 4 Bolt I R E00 2305 AN3 11A 3 16 x 1 1 8 Bolt I R E0...

Page 71: ...screen I E32 1301 Seat Upholstery I Skid Pants I E32 1111 Cyclic Boot I E32 3131 Floor Pan Instrument Pod I E32 6111 Seat Bulkhead I E32 7102 Bottom Tub I E32 7111 Fuselage Right Front I E32 7113 Fuse...

Page 72: ...0 100 200 250 500 1000 1500 2000 E18 6130 Idler Pulley Mounting Scissors I R E18 1131 Idler Pulley Bearing Assembly R E18 2012 Tail Rotor Idler Pulley I R E18 1150 Tail Rotor Belt 1 R E18 1160 Tail Ro...

Page 73: ...arriage Slider Bearing I R E17 1210 Rod End 5 16 Teflon I R E17 6000 Tail Rotor Blade Assembly I R E17 5120 Pitch Actuator Arm Pivot Casting I R E17 1340 Bearing Assembly I R E17 5110 Pitch Horn I R E...

Page 74: ...End I R E16 1212 Directional Control Cable I R E14 6131 Cross Shaft Bushing I R E14 1241 Nylon Bushing I R E14 1150 5 16 Male Rod End I R E14 1211 Cyclic Control Cable I R E14 1221 Cyclic Control Cab...

Page 75: ...E SECTION 7 OIL SYSTEM PART NO DESCRIPTION 25 50 100 200 250 500 1000 1500 2000 E28 7150 Oil Sump Heat Exchanger I E28 1192 Valve Cover Drain Hose I R E28 1230 Main Oil Drain Hose I R E28 1110 Oil Fil...

Page 76: ...500 1000 1500 2000 E30 1161 Radiator I R E34 1180 Radiator Cap I R E34 1300 Hose I R E34 1310 Hose I R E34 1320 Hose I R E34 1330 Hose I R E34 1340 Hose I R E34 1350 Hose I R E34 1360 Hose I R E34 13...

Page 77: ...rt I R E27 9000 Torque Link Weldment I R A24 162F R I 162F Engine I E24 9950 Spark Plug Wires I R E24 9948 Spk Plug Wire Separator I R E24 9740 Spark Plug I R E24 7560 Air Filter W Clamp I A24 1600 En...

Page 78: ...25 Secondary Shaft I R E23 2552 Lower Bearing I R E23 1210 Main Drive Belts I R E23 7141 High Temp Fan I R E23 1170 Snap Ring I R E23 3001 Fan Pulley Assembly I R E23 1221 Fan Pulley Bearing R E23 619...

Page 79: ...1 Hose Assembly I R E25 4071 Hose Assembly I R E25 4080 Hose Assembly I R E25 4110 Hose Assembly I R E25 4121 Hose Assembly I R E25 4570 Fuel Valve Cable I R E25 4600 Fuel Pump I R E25 4630 Fuel Filte...

Page 80: ...CE CHART EXEC 162F REFERENCE SECTION 12 FAN DRIVE PART NO DESCRIPTION 25 50 100 200 250 500 1000 1500 2000 E31 1120 Bearings I R E31 1130 Belt Upper I R E31 1141 Belt Lower I R E31 5100 Pulley Upper I...

Page 81: ...NAS1309 54 9 16 x 4 1 4 Bolt I R E00 3800 AN365 918A 9 16 18 Fiberlock Nut I R E20 1400 Elastomeric Thrust Bearing I E20 1401 Elastomeric Thrust Bearing I E20 3170 Tip Weight I R E20 6000 Aligner Blo...

Page 82: ...dule I R E35 4060 Man Baro Pressure Sensor I R E35 4080 9 Pin Cable I R E35 8231 Fuse Holder I R E35 8240 Toggle Switch I R E35 8321 Fuses I R E35 8410 Battery Terminal Eyelet I R E35 8520 Starter Rel...

Page 83: ...sure Sender I E36 1220 Volt Meter I E36 3002 Dual Engine Rotor Tach I E36 4010 Altimeter I E36 4020 Vertical Speed Indicator I E36 4030 Air Speed Indicator I E36 4040 Compass I E36 4050 Manifold Press...

Page 84: ...xec 162F Maintenance Manual 84 HOURLY SERVICE CHART EXEC 162F REFERENCE SECTION 16 GROUND HANDLING WHEELS PART NO DESCRIPTION 25 50 100 200 250 500 1000 1500 2000 E37 4090 Wheel and Tire I R Tire Trac...

Page 85: ...EC 162F REFERENCE SECTION 17 BALLAST WEIGHT PART NO DESCRIPTION 25 50 100 200 250 500 1000 1500 2000 E22 9000 Support Tube Weldment I R E22 9010 Mount Tube Weldment I R E22 9020 Ballast Weight Tube I...

Page 86: ...RotorWay International Exec 162F Maintenance Manual 86 HOURLY SERVICE CHART EXEC 162F REFERENCE SECTION 18 PAINT PART NO DESCRIPTION 25 50 100 200 250 500 1000 1500 2000 Paint I I INSPECT R REPLACE...

Page 87: ...49 1340 Thrust Blk Align Bearing R E49 1360 Thrust Block Liner I R E49 1170 Rod End Left Hand I R E49 1190 M R Blade Pitch Link I R E00 9300 Set Screws 1 4 x 1 4 I R E00 9301 Set Screws 1 4 x 5 8 I R...

Page 88: ...49 4720 Male Rod End 5 16 x 3 8 I R E49 4810 Nylon Scissor Bushing I R E49 4210 Collective Actuator Fork I R E49 4310 Collective Scissor I R E49 1380 Collective Scissor Mount I R E14 6120 Control T I...

Page 89: ...50 100 200 250 500 1000 1500 2000 E41 7120 Door Pilot I E41 7130 Door Passenger I E41 7140 Door Stiffener I E41 7150 Door Stiffener I E41 3110 Door Hinge I E41 3120 Body Hinge I E00 2300 AN3 4A 3 16 x...

Page 90: ...RotorWay International Exec 162F Maintenance Manual 90...

Page 91: ...n The approximate shot dimension is 25 inch diameter by 1 5 inches long To facilitate maintenance some parts of the helicopter are equipped with grease fittings listed below Please consult the service...

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