CHAPTER 10

RIGGING, TRACK AND

BALANCE

Section Title Page

10.0 Rigging, Track and Balance..................................................10.1
10.1 Introduction..............................................................10.1
10.2 Rod End Adjustment Procedure....................................10.1
10.100 Rigging.............................................................................10.2
10.110 Main Rotor Flight Controls............................................10.2
10.111 Cyclic Controls...................................................10.2
10.112 Swashplate.......................................................10.4
10.113 Collective Control...............................................10.4
10.120 Main Rotor................................................................10.4
10.121 Cyclic Travel Rigging...........................................10.7
10.122 Collective Travel Rigging.....................................10.10
10.130 Tail Rotor Flight Controls.............................................10.11
10.131 Pedals..............................................................10.11
10.132 C316 Bell Crank.................................................10.12
10.133 A120-3 Bell Crank..............................................10.12
10.134 Tail Rotor Pitch Links..........................................10.12
10.140 Tail Rotor Rigging.......................................................10.12
10.150 Throttle Correlation Rigging.........................................10.19
10.160 Actuator Rigging........................................................10.19
10.200 Track and Balance..............................................................10.19
10.210 Equipment Requirements.............................................10.20
10.220 Equipment Installation................................................10.20
10.221 Main Rotor Equipment Installation........................10.20
10.222 Tail Rotor Equipment Installation..........................10.24
10.230 Main Rotor Track and Balance Procedure........................10.27
10.231 Main Rotor Balance Adjustments..........................10.28
10.232 Main Rotor Pitch Link Adjustment.........................10.28
10.233 Main Rotor Blade Trim Tab Adjustment..................10.32
10.234 Main Rotor Track and Balance Trouble-Shooting.....10.33
DEC Page
2011 10.i
 CHAPTER 10

RIGGING, TRACK AND BALANCE

(Continued)

Section Title Page

10.240 Tail Rotor Balance Procedures...........................................10.34
10.250 Autorotational RPM Adjustment.........................................10.36

Page DEC
10.ii 2011
 CHAPTER 10

RIGGING, TRACK AND

BALANCE

10.000 Rigging, Track and Balance

10.001 Introduction
This section contains procedures necessary to rig the main rotor flight controls,
tail rotor flight controls and throttle correlation. The track and balance
procedures in this section are to be used in conjunction with Chadwick-Helmuth
balancing equipment instructions.

WARNING
A rotor which is smooth after balancing but then goes out
of balance again within a few flights is suspect and must be
examined by a RHC-authorized component overhaul facility
before further flight.
10.002 Rod End Adjustment Procedures

The following procedure is standard for adjustment of rod ends:

1. Loosen palnut and jam nut on rod end shank.

2. Screw rod end in or out of push-pull tube or pitch link as required to obtain
proper rigging adjustment.
3. After any rod end adjustment, verify rod end threaded shank blocks passage
of
0.020 inch diameter wire thru the witness hole in the push-pull tube or pitch
link as shown in Figure 2-1. When no witness hole is provided, refer to
Figure 2-1 for maximum rod end extension.

4. Position rod ends to allow as much push-pull tube or pitch link rotation as
possible without binding. Refer to Figure 2-1A.

5. C258-1 main rotor pitch links may require adjustment during rigging or tracking.
For collective adjustments, both pitch links must be adjusted exactly the
same.

Each main rotor pitch link has coarse, medium, and fine length adjustments:
a. Coarse length adjustments are made by rotating coarse-threaded section of
pitch link. Disconnect upper rod end from blade and loosen jam nut in
middle of pitch link only. Increase blade angle by unscrewing C258-2
fitting from lower pitch link. Decrease angle by screwing fitting into lower
pitch link. One full turn changes blade angle by approximately 0.88º.

b. Medium length adjustments are made by rotating upper rod end only.
Disconnect rod ends from blade and loosen rod end jam nuts. Increase
blade angle by unscrewing rod end from pitch link. Decrease angle by
DEC Page
2011 10.1
 screwing rod end into pitch link. One full rod end turn changes blade
angle by approximately 0.48º.

DEC Page
2011 10.1
 10.002 Rod End Adjustment Procedures (cont’d)
c. Fine length adjustments are made by rotating only the C258-2 fitting. Upper
and lower rod ends remain connected. Loosen jam nuts at upper rod end
and in the middle of pitch link. Increase blade angle by screwing fitting
out of lower pitch link. Decrease blade angle by screwing fitting into lower
pitch link. One full turn of fitting changes blade angle approximately
0.40º.

6. Torque jam nuts and palnuts per Section 1.320 and torque stripe per Figure

2-1. 10.100 Rigging

10.110 Main Rotor Flight

Controls 10.111 Cyclic

Controls
The cyclic control travel is non-adjustable and is controlled by the A211-3 stop
plate attached to cyclic box assembly.

NOTE
ll tube assemblies and fork assembly between the keel panels are to be adjusted to the noted center-

C121-1= 51.03 ± 0.03 inches

C121-3 = 32.54 ± 0.03 inches
C121-19= A205-3, -5 =
31.38 ± 0.03 inches
03.80 ± 0.03 inches

a) Refer to Figure 10-1. Place cyclic control in neutral position. Cyclic neutral
position is 7.0 inches to the right of full-left travel and at mid-point of
total fore and aft travel or use MT559-1 rigging blocks. Place collective
control full down.

b) Apply full cyclic and collective friction.

NOTE
Care must be taken not to move cyclic control from
neutral position.

Page DEC
10.2 2011
 7.0 in.

VIEW LOOKING FWD

CYCLIC CONTROL LATERAL
NEUTRAL POSITION

FULL LEFT
NEUTRAL

TOTAL TRAVEL
MID P0IMT OF TOTAL TRAVEL

CYCLIC CONTROL

LONGITUDINAL
NEUTRAL POSITION

FULL FORWARD FULL AFT

-

—NEUTRAL

FIGURE 10-1 CYCLIC CONTROL STICK NEUTRAL POSITION

Change 2: 12 Dec 94 Page 10.3

 10.112 Swashplate
With the cyclic and collective controls locked in position per Section 10.111,
adjust the C121-7 and C121-5 push-pull tubes to obtain a constant clearance
from the flange of the C281-1 fitting of 1.069 (see Figure 10-2). MT146-2
swashplate rigging blocks may be used as a spacer to set the 1.069 inch
dimension.
10.113 Collective Control
Since the collective slider stop is non-adjustable, this check is to ensure full
control travel is obtained and does not interfere with the swashplate travel.
a) Lift the swashplate boot so the uniball and slider tube may be observed.
b) Pull the collective control full up. The uniball must be flush with the top
of the slider tube within 0.03 inches. If this does not occur, turn the upper
rod ends of the C121-5 and C121-7 push-pull tubes in or out equally to
raise or lower the swashplate.

10.120 Main Rotor

The main rotor is rigged by determining the average blade angle. Blade angle
measurements are taken at the 0.75 radius of the main rotor (or 49.5 inches in from
the blade tip).
The main rotor blade angles are measured using the MT525-1 rigging fixture and
a Kell-Strom KS113 propeller protractor or a comparable protractor (see Figure 10-4).
Use the following procedure to set up for rigging:

a) Verify that the A2O5-5 forks at the swashplate are set to the proper length
(see Figure 10-3). Measuring to bolt center lines, the lower fork assembly
should be 3.70 z 0.03 inches and the upper fork assembly should be 3.85
z 0.03 inches.
b) Level the rotorcraft per Section 1.220 (Method 2, Main Rotor Hub).

c) Place a tracking stick at the end of one rotor blade and mark the height of
the blade tip. Rotate the rotor 180° and mark the height of the opposite
blade tip. Teeter the main rotor as necessary to obtain a main rotor track of
e 1 inch.
d) Zero the propeller protractor to the main rotor hub at the location marked
"Level Here". The protractor must be placed parallel to the teeter hinge
bolt.

Page 10.4 Change 2: 12 Dec 94

 MODEL RF•4

TOP OF BALL FLUSH WITH TUBE WITHIN

0.03O1NCH AT FULL-UP COLLECTIVE

TUBE

LOWER, NON-ROTATING
SWASHPLATE

I
I

C 28 1 -1 I
FITTING
SWASHPLAT E RIGGING BLOCKS
(2 Req’d)

MT146-2 (use with C017-2 S vv ashplate) 1.069 INCHES high

MT146-3 (use with CO 17-4 S vvashplate) 0.969 INCH high

FIGURE 10-2 LOWER SWASHPLATE CLEARANCE

3.B 5 * 0. 03 INC HES - UPPER (Rotating)

3.70 + 0.03 INCHES - LOWER (Non- Rotating)

FIGURE 10-3 A 205-5 FORK DIMENSIONS FOR

SWASHPLATE SCISSORS

Change 14: JUL 2008 Page 10.5

 MOOEL R•4•4

PROPELLER PRO T RAC TO R

MT 52 5-1 MAIN ROTO R

RIGG ING FIXTURE
MAIN ROTO R BLADE

49. 5 IN . FRO M END OF MAIN ROTO R BLAD E

TAPE STRIP (HANG FRO M ONLY ONE BLAD E TIP)

FIGURE 10-4 PLACEMENT OF PROTRACTOR

Page 10.6 Change 14: JUL 2008

 MAINTENANUEMANMAL MC2£2EL RHH

10.1 20 Main Rotor (cont‘d)

When zeroing th
facing one of the
tape. When maki
protractor must al

e) Measure in
from the tip
of each
main rotor
blade 49.5
inches and
place a
piece of 1
-inch
masking
tape
chordwise
across
each blade
with the
center of
the tape
over the
mark.

WARNING

Do not mark the rotor blades with a ball point pen or other
sharp instrument. Use a grease pencil or soft marker. Sharp
instruments can scratch the blades skins, causing cracks and
fatigue failure of the blade.

f) Mark each
rotor blade
with a
different
color
designation
such as red
or blue.
This will be
used in
recording
blade
Change 1 4: .IUL 2008 Page 1O.7
 angles.

10.1 21 Cyclic Travel Rigging

NOTE

Adjust collective travel rigging before cyclic travel rigging.

Hydraulic flight controls must be pressurized prior to measuring
blade angles.

a) Place the collective control full down.

Place the cyclic control in the neutral
position laterally (7.0 inches to the right
of full left travel) and hold against the
forward stop.

NOTE

Sand bags may be used to secure cyclic stick against stops to

ensure it will not move.

b) Rotate the blades so the pitch links are

aligned with the longitudinal axis of the
helicopter. Place the tracking stick at one
of the blade tips for reference when
rotating the rotor.

Change 1 4: .IUL 2008 Page 1O.7

 10.121 Cyclic Travel Rigging (cont’d)
c) Forward longitudinal cyclic:
1) Measure the blade angles and record below. Rotate the rotor 180” and
record the blade angles below.

Blue Blade Position Cyclic Full Forward

Pitch horn aft ” nose up
Pitch horn ° nose down
forward ° —2 = °
(1 4.25/13.50 degrees required)

Cyclic Full Forward

Red Blade
Position
Pitch horn aft ° nose up
Pitch horn forward ° nose down
° —2 = °
(14.25/13.50 degrees required)
2) Adjust the aft swashplate push-pull tube as required (one full turn =
0.44”) to obtain blade angle averages between 13.50° and 14.25°.
Additional coarse adjustment is available by simultaneously adjusting the
two forward push-pull tubes but they both must be adjusted exactly the
same amount.

d) Aft longitudinal cyclic:

1) Place the cyclic control in the neutral position laterally and hold against
the aft stop.
2) Measure the blade angles and record below. Rotate the rotor 180° and record
the blade angles below.

Blue Blade Cyclic Full Aft

Position Pitch ° nose down
horn aft Pitch ° nose up
horn forward ° —2 = °
(14.25/13.50 degrees required)

Cyclic Full Aft

Red Blade ° nose down
Position Pitch ° nose up
horn aft Pitch horn ° —2 = °
forward
(1 4.25/ 13.50 degrees required)

Page 10.8 Change 9: FEB 2003

 MODEL R•4•4

10. 121 Cyclic Travel Rigging (cont’d)

3) Adjust the aft swashplate push-pull tube as required (one full turn - 0.44”) to
obtain blade angle averages between 13.50 o and 14.25°. Additional coarse
adjustment is available by simultaneously adjusting the two forward push-pull tubes,
but they both must be adjusted exactly the same amount.

NOTE

If adjustment is required to obtain aft cyclic control blade angles,

the forward cyclic must be rechecked.

e) Left Lateral Cyclic:

1) Place the cyclic control in the neutral position longitudinally (mid travel) and
hold the cyclic against the left stop.

2) Rotate the rotor until the pitch links are aligned with the lateral axis of the helicopter.
Place the tracking stick at the end of one blade fo r reference.

3) Measure the blade angles and record below. Rotate the rotor 180 ” and record
the blade angles below:

Blue Blade Position Cyclic Full Left

Pitch horn right nose up
Pitch ho rn left nose d own
— 2 = ” Average
(8.5/7.5 degrees required)

Red Blade Position Cyclic Full Left

Pitch horn right nose up
Pitch horn left nose down
— 2 = ” Average
(8.5/7.5 degrees required)

4) Adjust either of the two forward push-pull tubes as required (one full turn = 0.6
degree) to obtain blade angle averages between 7.5 o and 8.5 °.

I) Right lateral cyclic:

1) ) Place the cyclic control in the neutral position longitudinally (mid travel) and
hold the cyclic against the right stop.

Change 13: OCT 2006 Page 1 0.

9
 10.121 Cyclic Travel Rigging (cont’d)

2) Measure the blade angles and record below. Rotate the rotor 180 o and
record the blade angles below:

Blue Blade Position Cyclic Full Right

Pitch horn right nose down
Pitch horn left nose up
o
—2= Average
(7.0/6.0 degrees required)

Red Blade Position Cyclic Full Right

Pitch horn right nose down
Pitch horn left nose up
—2= o
Average
(7.0/6.0 degrees required)

3) Adjust either of the two forward push-pull tubes as required (one full turn 0.6
degree) to obtain blade angle averages between 6.0 o and 7.0 o .

NOTE

If adjustment is required to obtain right cyclic control blade

angles, the left cyclic must be rechecked.

10.122 Collective Travel Rigpinp

a) Place the cyclic control in the neutral position (see Figure 10-1). Place the
collective control full down. Apply full cyclic and collective friction.

b) Rotate the main rotor to align pitch links with the longitudinal axis of the
helicopter. Place the tracking stick at the end of one blade for reference.

c) Measure the blade angles using the MT525-1 rigging fixture and propeller
protractor.

Page 1O. 10 Change 9: FEB 2003

 10.122 Collective Travel Rigqinq (cont’d)

NOTE
The MT525-1 fixture is placed on top of the blade at 49.5 inches
from blade tip. The fixture must be held tightly against the leading
edge to ensure accurate readings. All measurements must be
taken with protractor facing marked blade.
Record blade angles, then rotate rotor 180 o and again record angles. Adjust the pitch
link of each blade until the two blade angles are within 0.2 degrees of each other when the
blade pitch horn is in the forward position. Check the blade angles with each blade pitch
horn aft. Average of these angles must be within 0.2 degrees also.

COLLECTIVE FULL DOWN

Blue Blade Red Blade

o
Pitch horn forward nose up ° nose up
Pitch horn aft + ° nose up O
nose up
O
° —2 = ° ° —2 =
(1.0/2.0 degrees required)

d) Raise collective control to the full up position. Apply full collective friction.
Measure the blade angles per Step c) above and record averages below.

Blue Blade Red Blade

Pitch horn forward ” nose up ” nose up

Pitch horn aft + ” nose up ” nose up
° —2 = ° ° —2 = 0

(Average 12.5 °/13.5 ” degrees above collective-down required for rigging;

autorotation rpm adjustment will determine final angle)

e) Track and balance main rotor per Section 10.200.

10.130 Tail Rotor Flight Controls

10.131 Pedals (See Figure 10-5)

Pedal rigging is accomplished as follows:

a) Insert a 3/16-inch diameter rigging pin through the hole in the right-hand keel
panel and the rigging pin holes in the C317-1 bellcrank.
b) Adjust the C121-9 push-pull tubes as required to obtain a dimension of 2.90
* 0.03 inches from the pedal to the right hand stop located on the side of the
forward console (does not apply to helicopters without stop on lower console).

Change 14: JUL 2008 Page 10.11

 10.122 Collective Travel Rigqinq (cont’d)

Change 14: JUL 2008 Page 10.11

 10.132 C3 16 Bellcran k (See Figure 1 0-5)

Remove rigging pin and place left pedal against its stop. Adjust C343-1 push-pull
tube to obtain 0.10 0.20 inches between C316-1 rod end and bulkhead (0.3 - 0.5
for helicopters without pedal stop on lower console).

10.133 A1 20-3 Bellcrank

With left pedal at stop, adjust the C 121-17 push-pull tube length as required to
obtain O. 35 * 0.03 inch between two faces of pitch control assembly and the
housing. (See Figure 10-7).

10.134 Tail Rotor Pitch Links

Adjust the pitch links to a dimension of 2.620 + 0.010 inches between rod end
centers (see Section 8.570).

10.140 Tail Rotor Rigging

1) Set up:

a) Level the rotorcraft per Section 1.220 (Method 2, Main Rotor Hub).

b) Rotate the tail rotor until the blades are parallel to the tailcone.

c) Tape a tracking stick to the tailcone at the tip of the fwd blade.

NOTE
A tracking stick can be made using a 1 ” x 12” strip of aluminum
with a 90” bend 2 inches from one end.
d) Visually align the tail rotor to a zero teeter position and mark the tracking stick
where the tip of the tail rotor blade passes.
e) Rotate the tail rotor 180°, using the forward flex coupling so teeter angle is
not disturbed, until the opposite blade tip is aligned with tracking stick. Mark
the stick.

f) Teeter the tail rotor to position the blade tip to the mid point between the
marks. Rotate the tail rotor and check that the blades track. Repeat the
above procedure as necessary to track the tail rotor.
g) Place the left pedal against its stop. Mark the tracking stick where the blade
tip passes the stick. Place the right pedal against its stop and mark the
tracking stick.

Page 10.1 2 Change 1 4: JUL 2008

 TAIL ROTOR CONTROLS

C3t7-1
BELL CRANK

RIGGING PIN HOLE

0. 10 - 0.20n.
(Left pedal against
StOP)
PEDAL STOP
2. 90 in.
KEEL FANEL C316 -1 BEL L CRAflk

FLOOR
CI21-9 PUSH-PULL TUBE

FIGURE 10-5 TAIL ROTOR CONTROL

P£DâL RIGGING

Issued: 11 Jun 93 Page 10.13

 C121-17
PUSH-PULL
l TUBE

A120-3
BELL CRANK

0.35 n. (Left pedal at stop)

C031-1
FITCH CONTROL
ASSEMBLY

FI SURE 10-6 A120-3 BELL CRACK RIGGI VG

Page 10.14 Issued: 11 Jun 93

 AFT MACHINED FAC E
C 148-1 TA ILCONE
CLOSURE BULKH EAD

,
” , .’.’ A1 20-3 BELLCRAN K

' '***“ " ” PROPELLER

- , PROTRACTOR

C 12 1 -1 7 PUSH- PULL TUBE Oj

MT525-2
TAIL ROTO R ASSEMBLY “) RIGG
ING
FIXTURE

7.25
INCH ES

DISTANCE FROM TIP

OF TAIL ROTO R BLADE
DISTANC E 7. 25
FROM TIP O F ACHES
TAIL ROTO R
BLADE

PROPELLER
PROTRACTOR

MT 525-2
RIGG
ING
FIXTURE

FIGURE 10-7 TAIL ROTOR RIGGING

Change 13: OCT 2006 Page 10.15
 10.140 Tail Rotor Rigging
(cont’d)
2) Measure the tail rotor blade angles as follows:

a) Using a soft marker or grease pencil mark each blade as red or blue.

b) Measure in from each blade tip 7.25 inches and place 3/4 inch masking tape
chordwise on each blade at this point.

c) Have someone hold one blade tip at left pedal track mark with left pedal
against its stop.

d) Place MT525-2 rigging fixture on aft blade inboard side.

NOTE

MT525-2 fixture must straddle masking tape.

e) Using a propeller protractor measure blade angle and record below. Rotate tail
rotor 180 degrees and record opposite blade angle.

Pedals Full Left

Blue Blade ° nose right

Red Blade + ” nose right

° — 2=
(18.5/19.0 degrees required)

CAUTION

For acceptable track, differences between Blue and Red blade

angles must not exceed 0.4 degree. If blade angles cannot be
adjusted to within 0.4 degree of each other using adjustable
pitch links then remove tail rotor assembly and rotate it one-half
revolution, reinstall and repeat above procedure. If blade angles
still cannot be adjusted to within 0.4 degree of each other then
replace blade(s). Contact factory for blade matching assistance.

NOTE

Adjustable pitch link jam nuts must be tight to ensure

accurate blade angle measurements.

Page 1 0.16 Change 1 4: JUL 2008

 10.140 Tail Rotor Rigging (cont’d)

WARNING

Both pitch links must be same part number (same type and
material). Mixing one-piece with adjustable-length pitch links is
prohibited. Mixing steel one-piece with aluminum one-piece pitch
links is prohibited.

f. Adjustment of blade angles is made using rod ends of C121-17 push-pull tube.
One full turn of rod end will change blade angles 0.33 degrees. Adjust rod end
as necessary to obtain 18.5 to 19.0 degrees.

g. Place right pedal against its stop. Measure blade angles and record below
using right pedal track mark.

Pedals Full Right

Blue Blade ” nose left

Red Blade + ° nose left

° — 2 =
(15.5/16.5 degrees required)

h. Adjust C 121-17 push-pull tube as necessary to obtain blade angles of 15.5 to

16.5 degrees.

NOTE

If adjustment is required to obtain right pedal blade angles, left

pedal angles must be rechecked.

i. If blade angle range, for left and right pedal settings, cannot be obtained using
above procedure, this indicates pedal travel is either too great or too small.
Use following procedure to check and adjust pedal travel:

1) Add right and left pedal angles together. If total is less than 34.0° pedal
total travel is too small. If total is greater than 35.5” total travel is too
great.

2) If total travel is too small, first increase right pedal travel by increasing
length of C121-9 push-pull tube. To increase left pedal travel, decrease
length of C343-3 push-pull tube.

Change 14: JUL 2008 Page 10.17

 CO LLECTI V E

PUSH-PULL C336
TUBE USH-
I PULL
OVERTRAVEL TUBE
FORWARD SPRING
ASSEMBLY

3.00 INCHES WITH FULL-UP

COLLECTIVE AND THROTTLE
FULLY CLOSED

IDLE RPM
ADJUSTMENT
SCREW TO RQUE NUT 20-60
INCH POUNDS
THROTTLE MS 24665-132 COTTE R PIN
LEVER

•’“ I BURETO R

C336
PUSH - 0. 01 0 - 0.030 INCH
PULL TUBE THROTTLE LEVER POSITION
CARB FULL OPEN
27.5°i7.5°

CARB

FIGURE 10-8 THROTTLE CORRELATION RIGGING

(CARBURETED SHIPS)

Page 10.18 Change 14: JUL 2008

 COLLECTIVE

FORWARD

FUEL CONTROL
A 336
PUSH-PULL PU SH-
LINKAGE TUBE PULL TUBE
BALANC
E SPRING
OVERTRAVEL
SPRING
ASSEMBLY

3.00 IN CHES WITH FULL-

UP COLLECTIVE AND
THROTTLE FULLY CLOSED A 336

TU
INTAK E MANIFO LD
BE

FU EL CONTROL
STOP

0.0 10 - 0.030 INCH

IDLE RPM
A DJUSTM ENT
SC REW

VIEW "A"
(VIEW LOO KING AFTI

FIGURE 10-8A THROTTLE CORRELATION RIGGING

(FUEL INJECTED SHIPS)
Change 1 4: JUL 2008 Page 10.18A
 Intentionally blank

Page 1 Change 14: JUL 2008

0.18B
 10.140 Tail Rotor Rigging (cont’d)

3) To decrease the total travel, shorten the C1 21-9 push-pull tube for right pedal
travel and increase the length of C343-3 or C343-9 push-pull tube for left I
pedal travel.

4) Recheck the tail rotor blade angles per steps e) through h) above.

j) Ensure all rod ends are installed properly by checking the push-pull tube
witness holes. Tighten all rod end palnuts and jam nuts. Torque stripe all
nuts.
k) Balance tail rotor per Section 10.240.
10.150 Throttle Correlation Ripping (see Figure 10-
8) For in-service check and adjustment:
1. Verify idle rpm is correct with engine warm, clutch fully engaged, and throttle closed.
Adjust 0-540 idle to 53-57% and IO-540 idle to 58-62%.

2. Shut down helicopter.

3. Rotate twist-grip throttle fully closed through overtravel spring pressure to
positive stop. Holding throttle tight against stop, raise collective full up while
observing throttle arm on carburetor or fuel control, as applicable. Throttle arm
should move 0.010-0.030 inch off of idle stop screw when collective up-stop is
reached.
4. If necessary, adjust length of throttle push-pull tube at carburetor or fuel control,
as applicable.
5. Standard torque jam nut(s) per Section 1.320, check witness holes, and torque
stripe per Figure 2-1.
1 0.160 Actuator Rigging

No field adjustment of actuator-engaged belt tension is permitted. Adjust actuator’s down-

limit stop screw so there is a delay of less than 5 seconds before rotor starts turning when
actuator is engaged at start up.

10.200 TRACK AND BALANCE

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 tracking checks.

Change 1 4: JUL 2008 Page 10.19

 10.210 Equipment Requirements
The following list of equipment may be used on the R44 for track and balance:
a) Balancers
Chadwick-Helmuth 177M05
Model Number 1 77M-
6
177M-6A
177M-7
177M-7A
8350 series
M1 92 series
or equivalent equipment
b) Strobex
Chadwick-Helmuth 135M-10*
Model Number 135M-1 OA*, B” and C*
135M-11
or equivalent equipment
* When tracking the main rotor using the 135M-10 series Strobex a double
interrupter must be used.
c) Cables, accelerometers/velocimeters, pickups, and targets” *
Chadwick-Helmuth 3140 D.C. Adapter Cable
Model Number 3030 Magnetic pickup
3319-1 or 10808-25 Magnetic pickup cable
4177 Accelerometer
4296-1 and -2 Accelerometer Cable
3300 Target Patches
4270 Target Patches
7310 Velocimeter
11210-20/-50 Velocimeter Cable
d) Brackets* ”
Robinson MT121-1 Magnetic Pickup Bracket
e) Charts” *
Robinson Main Rotor Chart
Tail Rotor Chart
” ” As required by the balancing equipment being used.
10.220 Equipment Installation
10.221 Main Rotor Equipment Installation (see Figure 1 0-9A)
Refer to specific manufacturer’s installation instructions when using balancing
equipment other than Chadwick-Helmuth. Install Chadwick-Helmuth equipment as
follows:
a) Install the accelerometer/velocimeter under the upper console left-side
attachment screw with cable connector pointing outboard.

Page Change 9: FEB 2003

10.20
 TARGET WIDTH

CHORDXISE TARGE’
LEMGTH

4270 M.R. TARGET PATCH LOCATION

FIGURE 10-9 MAIN ROTOR TARGET PATCH LOCATION

Change 2: 12 Dec 94 Page 10.21

 BALANCER

DUCT TAPE

3030
MAGMETIC ii
PICKUP

NT121-1
BRACKET
4177
ACCELEROXETER

CONSOLE
DUCT
TAPE

FIGURE 10-9AMAIN ROTOR BALANCING

EQUIPMENT INSTALLATION

Page 10.22 Change 6: 18 MAR 99

 10.221 Main Rotor Equipment Installation (cont’d)
bl Install MT121-1 Bracket onto the lower right-hand side of the
swashplate.

WARNING
Ensure attachment bolts are torqued to 200
in.-lb plus nut drag. The MT121-1 Bracket
will remain installed for in-flight track and
balance.

cl Install the 3030 magnetic pickup onto the MT121-1 Bracket. Set
the interrupter pickup gap to 0.030" e 0.010".
d) Attach the cable to the magnetic pickup. Pull collective stick full
up and cyclic stick full left. Secure the cable to the mast fairing with
duct tape. Route the cable to the lower front of the left door
frame. Secure the cable every 12 inches with duct tape.

CAUTION
Security of the cable is essential as the
helicopter will be flown at Vne.

e) Attach the cable to the accelerometer/velocimeter mounted on the

left forward hold down screw of the console. Secure with duct
tape.

CAUTION
Ensure the cable cannot become entangled
with tail rotor pedals.

f) Attach the cables to the balancer and secure excess cable to the
bracket in front of the left seat.
g) Apply the 4270 target tapes to the main rotor blades per
Figure 10-9.

Change 1: 2 Jul 93 Page 10.23

 10.222 Tail Rotor Equipment Installation (see Figures 10-9C and 10-9D)

NOTE
Prior to installing balancing equipment, verify blades are clean
and smooth, no debris under tip covers (square tip blades),
rod end and spherical bearing play are within limits, and
elastomeric bearings (if applicable) are satisfactory.
1. Install accelerometer/velocimeter bracket under upper forward tail rotor
gearbox output seal housing attachment bolt. Connector end of
accelerometer/velocimeter must point up.
2. If using a Vibrex 2000-series balancer with photocell, install photocell bracket
between velocimeter and velocimeter bracket as shown in Figure 10-9C.
3. If using Strobex to obtain clock angle, install a target tape spanwise facing
outboard on one arm of tail rotor hub. If using photocell to obtain clock
angle, install a target tape spanwise facing inboard on one arm of tail rotor
hub.
4. Connect cable(s) to accelerometer/velocimeter and photocell (if used). Route
cable(s) forward and wrap around tailcone several times. Secure with duct
tape.

WARNING
Ensure cable(s) cannot entangle tail rotor.
5. If using Strobex to obtain clock angle, route cable to a position located
approximately 20 feet to left of tail rotor. Place sandbags (or similar) on
cable to prevent cable movement. If using photocell to obtain clock angle,
cables may be routed into cabin and secured with duct tape to prevent
cable movement.
6. Connect cable(s) to balancer.

Page 10.24 Change 9: FEB 2003

 DUCT TAPE

CABLE(S)

BALANCER STROBEX

OPTIONAL CABLE ROUTING

WHEN USING PHOTOCELL
SAND
BAGS

CABLE
ACCELEROMETER/VELOCIMETER

PHOTOCELL
(IF USED)

TARGET TAPE
(INSTALL AS SHOWN
WHEN USING
STR0- BEX
INSTALL
ON INBOARD SIDE
PER FIGURE 10-
9D WHEN USING
PHOTOCELL.)

FIGURE 10-9C
TAIL ROTOR BALANCING EQUIPMENT INSTALLATION

Change 9: FEB 2003 Page 1O. 25

 ENSURE TARGET
TAPE IS IN PATH
OF PHOTOCELL BEAM PHOTOCELL

(VIEW LOOKING FORWARD)

FIGURE 10-9D
TAIL ROTOR PHOTOCELL INSTALLATION

Page 10.26 Change 9: FEB 2003

 10.230 Main Rotor Track and Balance
Procedure
NOTE
Prior to installing balancing equipment, verify blades are clean
and smooth, rod ends and spherical bearings play are within
limits, correct swashplate tilting friction, and correct teeter and
coning hinge frictions.
In-flight track and balance is accomplished using the following testing and adjustment
sequence:
1. Check main rotor track in a hover. When using Vibrex 177- or 8350-series
equipment, place Function knob in track position, RPM (flash rate) on Strobex to
326. Adjust track by shortening high blade pitch link per Section 10.232 to bring
I track within 0.25 inch.
2. Check main rotor balance in a hover. For Vibrex 177- or 8350-series equipment,
place Function knob in “A” position, RPM on Phazor to 408. Adjust balance as
indicated by main rotor balance chart (maximum 0.2 IPS).
3. Fly the helicopter at 50, 60, 70, 80, 90, 100, 110, 120, and 130 knots. Check
track at each airspeed and record.

WARNING
Do not exceed Vne of helicopter when checking track.
4. Make slight tab adjustment to correct for a climbing blade by bending trim tab
down per Section 10.233.

WARNING
Blades with two trim tabs are obsolete and must be removed
from service.
5. Repeat Steps 3 & 4 as required until track will remain on at all airspeeds within
3/8 inch.
6. Readjust main rotor balance in a hover (maximum 0.2 IPS).
7. Check autorotational RPM per Section 10.250. Adjust as required.
8. Evaluate collective trim and adjust as required (non-hydraulic aircraft only).
9. Check main rotor balance in a hover. Adjust as required.

Change 14: JUL 2008 Page

10.27
 10.230 Main Rotor Track and Balance Procedure (cont’d)

10.231 Main Rotor Balance Adjustments

Spanwise balance adjustments are made by adding or subtracting weight as indicated

by the balance chart. Weight is changed by removing the blade tip cover and changing
C298 tip weights. Fine adjustments may be made with AN96O-10 or -10L washers
and also by trimming washers.

Coarse adjustment of chordwise balance is accomplished by shifting rotor hub (see

Section 9.1 24) as indicated on balance chart. Fine adjustment of chordwise balance
is accomplished by adding or subtracting A 255-1 or -2 chord weights or AN97O-4
washers as indicated by balance chart. A maximum of four A 255-2 weights (four A255-
2 weights equal twelve A 255-1 weights) may be installed.

Three A25 5-1 Weights = One A25 5-2 Weight

Eight AN970-4 Washers = A25 5-1 Weight

10.232 Main Rotor Pitch Link Adjustment

Two length adjustments can be made on the main rotor pitch link. Coarse adjustment
is made by loosening upper rod end jam nut, disconnecting rod end from blade
pitch horn and turning rod end up or down (one-half turn of rod end changes track
approximately 0.25 inch).

Fine adjustment is made by leaving rod end connected to pitch horn and loosening
rod end jam nut, loosening barrel jam nut, and then screwing barrel up or down. One
barrel revolution is equivalent to one-half turn of rod end. Partial turns of barrel can
be made by counting number of hex flats rotated (see Figure 10-11).

CAUTION

After adjusting pitch link, verify 0.020 inch diameter safety wire
cannot pass through witness holes.

Page 1 0.28 Change 14: JUL 2008

 MAIN ROTOR , yE
SHIP S/5
TRACK AND BALANCE CHART !*090
Page of Page
. HEAD
030
2 .ONO
MOUNT ACCELEROMETER ON
LEFT SIDE OF CONSOLE
POINTED LEFT

FORWARD
BLADE
4

I
N
T
CH E
OR R
D R
AR U
P
M T
E
W AF R
E T
I B O
G L N
H A
T D I
N
E S
I
D
E

L
E
A
D

A
R
M
OF
SWA
SHP
LAT
E

MAG
PICK-UP

SPA
WIS
WEI

HTS
(2)AIJ960-
10L
Change 6: 18 MAR 99 Page
70.29
 W ( 0 WASHERS = (1)C298-2
AS
HE 5 WEIGHT
RS ) (11)AN960-10
=
A WASHERS=(1)CZ98-3
1) WEIGHT
N
AX WASHERS=(1)A255-1
96 9
0- WEIGHT (4)C298-3
6
10 WE1GHTS=(1)C298-4
W 0 t4EIGHT
AS -
HE WEIGHTS=(l)A255-2
R 1 WEIGHT

BALANCE TRACK (KNOTS)

CLOCK IPS HOVER CLIMB 50 60 70 80 90 100 110 120 130

CIJANGE
NADE :

CHANGE
MADE:

CNAIJGE
MADE:

Change 6: 18 MAR 99 Page

70.29
 UPPER ROD EMD

BARREL

JAM NUTS
WITNESS HOLES

FIGURE 10-11 MAIN ROTOR PITCH LINK

MAIM ROTOR BLADE

MT526-I TAB BEMDER

BEMD DOWN
MOTE DIFFERENCE

FIGURE 10-12 MAIN ROTOR

TRIM TAB ADJUSTMEMT
BEND UP

Page 10.30 Change 5: 15 Jun 98

 MOOELR' A

MT3 52-1 TRIM TAB GAGE DIAL INDICATO R SPINDLE

1TOR BLADE

MT352—1 TRIM TAB GAGE

TAB”
Tool bottom edge must contact try m tab trailing edge.
M EASU RE HERE

3 MEASURING POINTS, EQUALLY SPACED *'

FIGURE 10-13 MAIN ROTOR TRIM TAB MEASUREMENT

Change 14: JUL 2008 Page 10.31

 10.233 Main Rotor Blade Trim Tab Adjustment

Main rotor blade trim tab adjustments are made using the MT526-1 tab bender and
the MT352-1 trim tab gage. Refer to Figure 10-13. Using a felt marker, draw a line
across top of trim tab aligned with blade trailing edge. Mark line with three equally
spaced measuring points. Place trim tab gage chordwise across upper surface of blade
and trim tab trailing edge with dial indicator stylus resting on a marked measuring
point. Set dial indicator scale to zero. Similarly measure both remaining measuring
points and verify they are within 0.005 inch of first.

CAUTION

MT352-1 gage must contact trim tab trailing edge. Space

between edge of gage and trailing edge of trim tab indicates
trim tab bent beyond limit.

To bend trim tab, loosen bolt on MT526-1 tab bender and slide tab bender over trim
tab trailing edge as far toward leading edge as possible. Ensure single-rib side of tool
contacts blade bottom surface to bend tab down and vice-versa. Tighten bolt to bend
tab. Clamping action of tool is sufficient to bend tab; do not use tool like a lever.
Refer to Figure 10-1 2. Make very slight bends downward on trim tab. Do not bend
trim tab upward unless absolutely necessary; bending trim tab upward can increase
cyclic stick shake. A trim tab bend of approximately 0.015 inch will move tip of main
rotor blade approximately 0.2 inch. Remeasure trim tab with MT352-1 gage. Adjust
bend in trim tab as required to keep three measuring points within 0.005 inch.

CAUTION

Do not use main rotor blade trim tab bending tools

manufactured by other helicopter manufacturers. Use of these
tools will damage main rotor blade.

Page 1 0.32 Change 1 4: JUL 2008

 10.234 Main Rotor Track and Balance Troubleshooting

Symptom Probable Cause Correction

1. Excessive Cyclic
Rough or binding A205-5 Replace or refer to Section 8.6.
or Stick Shake
fork assembly (upper
swashplate).
Send blade(s) to RHC or Service
Brinelled spindle bearing Center for spindle bearing
(rough movement). replacement.
Rough blade surface (chipped paint). Repair blades per Section
9.130. Rough or binding pitch links. Replace pitch link rod ends
MR blade boot misaligned. Realign or replace boot per Sections
9.113 & 9.114.
MR teeter or coning hinge binding. Replace bearings per Section 9.126.
MR blade trim tabs bent upward. Bend trim tabs evenly down per
Section
10.233.
Blade mismatch. Send blade(s) to RHC for replacement.

2. Excessive
MR out of track and balance. Track and balance per Section
Ship
Vibration 10.230. MR teeter or coning hinge friction. Adjust hinge friction per
Section 9.124. MR teeter or coning hinge binding. Replace bearings per
Section 9.126.
Brinelled spindle bearing Send blade(s) to RHC or Service
(rough movement). Center for spindle bearing
replacement.
MR teeter hinge bearings worn. Replace bearings per Section 9.126.

3. Excessive Cyclic Brinelled spindle bearing Send blade(s) to RHC or Service

Stick Forces (rough movement). Center for spindle bearing
replacement.

4. Intermittent
MR teeter or coning hinge friction Adjust hinge friction per Section
Blade
Track 9.124. MR coning hinge binding. Replace bearings per Section 9.126.
Picture
MR teeter hinge not "broken-in." Track and balance per Section 10.230.
Adjust track to minimize error.
Brinelled spindle bearing
Send blade(s) to RHC or Service
(rough movement).
Center for spindle bearing
replacement.

5. Radical Changes MR teeter hinge bearings worn. Replace bearings per Section 9.126.
to Cyclic Trim 6. Lateral Vibration
Intermittent Ship

DEC Page
2011 10.33
Brinelled spindle malfunction in spark plugs,
Send blade(s) to RHC for
bearing (rough ignition leads, magneto, or engine
spindle bearing replacement.
movement). not “broken-in.”
Refer to Textron-Lycoming Maintenance
Engine misfiring due to
Instructions.

7. 4 per second Aircraft CG out of limits. Operate aircraft within CG envelope.

Fore/Aft
Deteriorated / contaminated main Replace main gearbox mounts.
Oscillation
gearbox rubber mount(s).

DEC Page
2011 10.33
 10.240 Tail Rotor Balance Procedure
Refer to specific manufacturer’s installation instructions when using balancing
equipment other than Chadwick-Helmuth Vibrex system.

Install Chadwick-Helmuth equipment per Section 10.222. Set Function Knob on

Balancer to appropriate channel. Set balancer RPM Range knob to X10 and set
RPM to 231. With helicopter running with governor ON, view tail rotor assembly
with Strobex. Tune Balancer while viewing target tape and adjusting RPM dial on
Balancer. Record clock angle and IPS on tail rotor balance chart. Adjust as
required until balance is less than
0.2 IPS.
Spanwise balance adjustments for C029-1 square-tip blades are made by
adding, subtracting, or exchanging weights under the removable tip cover. Use
C134-1 or -2 tip weights or AN960-8 or -8L washers. -8L washers may be
trimmed as a very fine adjustment.

Spanwise balance adjustments for C029-2 and C029-3 round-tip blades are made
by exchanging different diameter washers under nut securing blade’s outboard
retaining bolt. The bolt has sufficient length to allow necessary spanwise weight
changes; verify 2-4 threads protruding past nut after torquing per Section
1.320.

Chordwise balance is adjusted by adding, subtracting, or exchanging A141-14,

A214-3, NAS1149F0463P/F0432P, or NAS1149D0463J/D0432J washers under
nut securing blade’s pitch link attaching bolt. Change pitch link attaching bolt
length as required for proper thread engagement (see Section 1.310, refer to
IPC for allowable lengths).

Page DEC
10.34 2011
 DATE SERIAL NO. C008-9 TAIL ROTOR ASSEMBLY
PAGE

CHORDWISE WEIGHTS SPANWISE WEIGHTS

(1) NAS1149F0463P Washer = (2) NAS1149F0432P Washers (1) C141-23 Washer = (3.5) NAS1149F0663P Washers
(1) A214-3 Washer = (3.5) NAS1149F0432P Washers (1) C141-24 Washer = (7) NAS1149F0663P Washers
(1) A141-14 Washer = (5) NAS1149F0432P Washers (2) NAS1149F0632P (1) NAS1149F0663P Washer

BALANCE
CLOCK IPS

ADJUSTMENT:
CLOCK IPS

ADJUSTMENT:
CLOCK IPS

ADJUSTMENT:
CLOCK IPS

ADJUSTMENT:

FIGURE 10-14 C008-9 TAIL ROTOR ASSEMBLY DYNAMIC BALANCE CHART

DEC Page
2011 10.34A
 DATE SERIAL NO. C008-4 TAIL ROTOR ASSEMBLY
PAGE

CHORDWISE WEIGHTS SPANWISE WEIGHTS

(1) NAS1149F0463P Washer = (2) NAS1149F0432P Washers (1) C141-20 Washer = (5) NAS1149F0563P Washers
(1) A214-3 Washer = (3.5) NAS1149F0432P Washers (1) AN970-5 Washer = (13) NAS1149F0563P Washers
(1) A141-14 Washer = (5) NAS1149F0432P Washers

BALANCE
CLOCK IPS

ADJUSTMENT:
CLOCK IPS

ADJUSTMENT:
CLOCK IPS

ADJUSTMENT:
CLOCK IPS

ADJUSTMENT:

FIGURE 10-15 C008-4 TAIL ROTOR ASSEMBLY DYNAMIC BALANCE CHART

Page 10.34B DEC

2011
DATE SERIAL NO. C008-2 TAIL ROTOR ASSEMBLY
PAGE

CHORDWISE WEIGHTS SPANWISE WEIGHTS

(1) NAS1149F0463P Washer = (2) NAS1149F0432P Washers (1) NAS1149FN832P = (2) NAS1149FN816P Washers
(1) A141-14 Washer = (5) NAS1149F0432P Washers (1) C134-1 Weight = (14) NAS1149FN816P Washers

BALANCE
CLOCK IPS

ADJUSTMENT:
CLOCK IPS

ADJUSTMENT:
CLOCK IPS

ADJUSTMENT:
CLOCK IPS

ADJUSTMENT:

FIGURE 10-16 C008-2 TAIL ROTOR ASSEMBLY DYNAMIC BALANCE CHART

DEC Page
2011 10.35
 Intentionally Blank

Page DEC
10.35A 2011
 INTENTIONALLY BLANK

Change 9: FEB 2003 Page 10.35B

 D

tfl B
0
0
z
1g.250 Autprota ional RPM Agjuytmpnt
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.

a) Perform autorotation RPM check at less than 1900 lb gross weight.

Calculate the takeoff gross weight of the helicopter. Record the time on
the hour meter.

Take-Off gross weight

Take-Off hourmeter reading

b) 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
over- speeding the rotor.
Take at least 3 RPM readings at SOO to 1000 foot altitude intervals.
Record the following in-flight data:
Hourmeter Pressure Test
Test # Reading OAT Altitude %RPM
1

Page 10.36 Change 3: 5 May 95

 10.250 Autorotational RPM Adjustment (cont'd)
c) After test flight, refer to Figure 1 0-15 chart and determine following:
C lbs of Fuel Test % RPM
Test # Elapsed Time Test Gross Test Chart % RPM
h1 (in-flight Consumed Weight (take- Longitudinal RPM (from in- Correction
an hourmeter (elapsed time off gross Center of flight data) (chart %
O reading minus x 93 lb/hr) weight minus Gravity RPM minus
take-off hour- fuel consumed) Test % RPM)
g:
meter reading)

2 1
0 2
0 3
4
5

“ Chart Instructions:

1. Start at outside air temperature, and draw a vertical line up to pressure altitude.

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

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

Notes:

i. Increase rotor RPM 0.75 % for every inch that CG is forward of FS 100.0.

ii. Decrease rotor RPM 2 % for model R44 O.

d) 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
3 1/2 %. Adjust both pitch links exactly the same so track will not be affected.

e) Repeat steps (a) through (d) as required until the RPM correction is + 1% of chart RPM.
 AUTOROTATION RPM
COLLECTIVE FULL DOWN
50 KIAS
(One full turn of rod ends = approximately 3 % RPM change)
(One full turn of rod end = 1 turns of barrel)

NOTES:
1. Increase Rotor RPM 0.75% for every inch that CG is forward of FS 100.0.
2. Decrease Rotor RPM 2% for Model R44 II.

Example: R44 II, OAT = 25° C, Hp = 2000 ft, GW = 1900 lb, CG = FS 98.0
Design RPM = 104% — 2% + (2 x 0.75%) = 103.5%

FI
G
U
R
E
10

-4 0 -30 -2 0 -10 0 10 20 30 40 90 92 94 96 98 100 10 2 106 106 1 08 l1 0

TE MP E RA T UR E , DE G R E ES C
% Rotor RPM
-40 -Z0 0 20 40 60 80 1 00
TEMEERATUP E, DEGREES E