Robinson R22 RTR 060 Maintenance Manual & Continued Airworthiness – April 2012 PDF
The Robinson R22 RTR 060 Maintenance Manual & Continued Airworthiness – April 2012 PDF is a comprehensive maintenance reference for the Robinson R22 helicopter family. Issued by Robinson Helicopter Company as RTR 060, it brings together servicing instructions, inspection requirements, structural and mechanical maintenance procedures, component life information, rigging data, system servicing, troubleshooting-oriented checks, and continued-airworthiness material across the aircraft. The manual is written for maintenance use and repeatedly directs technicians to follow the specified procedures, warnings, cautions, torque requirements, inspection limits, and related R22 technical publications before beginning work.
Maintenance and Inspection Scope
This manual goes well beyond routine servicing. Early sections cover scheduled maintenance, lubrication, chip-detector cleaning, main and tail rotor gearbox drain-and-flush procedures, defueling, storage, ground handling, jacking, hoisting, leveling, weighing, center-of-gravity calculations, standard and special torque requirements, approved materials, lubricants, sealants, paints, part interchangeability, and instructions for uncrating, reassembly, and flight testing. These sections establish the practical workshop foundation used throughout the rest of the manual.
Inspection coverage is especially detailed. The R22 inspection section includes general inspection procedures for bearings, push-pull tubes, rod ends and spherical bearings, elastomeric bearings, and temperature indicators, followed by ground and flight checks used with 100-hour or annual inspections. The manual includes a structured 100-hour/annual airframe inspection checklist that works through access panels and major helicopter areas, with checks for wiring, controls, fuel lines, gearbox condition, rotor brake components, drive-system items, tailcone and empennage, rotor hub and blades, cabin, and landing gear. Special inspection procedures address conditions such as clutch-actuator bearing concerns, V-belt discrepancies, tail-skid and tail-rotor strikes, main-rotor strikes, rotor or engine overspeed, hard landings, steel-tube-frame corrosion, main-rotor-blade inspection, float inspection and testing, and windshield inspection.
Life Limits, Overhaul and Airworthiness Information
A major part of the Robinson R22 RTR 060 Maintenance Manual & Continued Airworthiness – April 2012 PDF is the continued-airworthiness content. Section 3 identifies life-limited components, time-in-service record requirements, inspection and overhaul requirements, and the FAA-approved Airworthiness Limitations material. The manual lists fatigue life-limited parts and maximum service lives, including main rotor blades, frame components, tailcone and tail rotor components, gearbox parts, rotor hub and spindle parts, and specified attachment hardware. It also explains how recorded time is applied for service-life purposes.
The inspection material further covers 12-year inspection and limited-overhaul requirements and 2200-hour overhaul requirements. These procedures identify assemblies to be inspected, overhauled, replaced, or returned for authorized component work, and they include post-maintenance actions such as inspection, ground checks, run-up, rotor balancing, main-rotor tracking and balancing, flight checks, gearbox servicing, and weight-and-balance updates where required. This makes the manual useful not only for routine periodic work but also for planning major maintenance events and understanding the relationship between calendar limits, time-in-service limits, inspections, and component replacement.
R22 Variants and Technical Coverage
The manual contains version descriptions for multiple R22 configurations, including R22 Standard, R22 HP, R22 Alpha, R22 Beta, R22 Beta II, R22 Mariner, and R22 Mariner II, along with Instrument Trainer and Police Helicopter configurations. It also references Lycoming O-320-series and O-360-series engine publications for engine-specific maintenance information. Dimensional illustrations show external dimensions for standard/HP, Alpha/Beta/Beta II, and Mariner/Mariner II configurations, while other pages document model differences, equipment changes, and configuration-specific inspection or service requirements.
The manual also includes the Type Certificate Data Sheet material for R22 variants, with approved-model information, weights, capacities, operating limitations, eligible serial ranges, and configuration data. These pages supplement the maintenance procedures by giving technicians a regulatory and configuration reference for the aircraft models covered by the manual.
File Details
- Manual type: Maintenance Manual and Instructions for Continued Airworthiness
- Brand/model: Robinson R22
- Publication number: RTR 060
- Issue date: April 2012
- Type Certificate: H10WE
- Language: English
- Page count: 634
- File format: PDF
Chapters Covered
- Introduction
- Section 1 – General
- Manual information and revisions
- Maintenance authorization and customer support
- Helicopter servicing and scheduled maintenance
- Handling, jacking, hoisting, leveling, weighing and CG calculation
- Fastener torque requirements
- Approved materials, lubricants, adhesives and sealants
- Part interchangeability
- Uncrating, reassembly and flight testing
- Section 2 – Inspection
- General inspection procedures
- Ground and flight check for 100-hour/annual inspection
- 100-hour/annual airframe inspection
- Special inspections
- 12-year inspection and limited-overhaul requirements
- 2200-hour overhaul requirements
- Section 3 – Life-Limited Components
- Time-in-service records
- Fatigue life-limited parts
- Inspection and overhaul requirements
- Airworthiness limitations
- Section 4 – Airframe
- Fuselage and cabin components
- Windshield and door work
- Welded steel tube frame assemblies
- Tailcone and empennage
- Section 5 – Landing Gear
- Section 6 – Powerplant
- Section 7 – Drive Train
- Section 8 – Flight Controls
- Section 9 – Rotor Systems
- Section 10 – Rigging, Track and Balance
- Section 11 – Heating and Ventilation
- Section 12 – Fuel System
- Section 13 – Instruments
- Section 14 – Electrical and Avionics Systems
- Section 15 – Furnishings
- Section 16 – Special Tools
- Section 17 – Revision Log
Taken as a whole, the manual gives a technician a system-by-system path through the R22: how to inspect the aircraft, recognize limits and discrepancies, remove and install airframe and mechanical components, service drivetrain and rotor-system items, perform rigging and balance work, handle fuel and electrical-system maintenance, and confirm the helicopter after major work through ground, run-up, and flight checks. The combination of procedures, drawings, inspection checklists, torque information, service-life data, warnings, and component-specific limits makes it a substantial maintenance reference rather than a brief owner’s guide.
Complete PDF Bookmark Tree
Complete Bookmarks
The complete bookmarks in the “Robinson R22 RTR 060 Maintenance Manual & Continued Airworthiness – April 2012 PDF” are as follows:
+R22MM_Introp. 1
+R22 Maintenanance Manual – Introductionp. 1
Cover Pagep. 1
Subscription Formp. 2
Section Listp. 3
Recommended Change Reportp. 4
Limited Aircraft Warrantyp. 5
Limited Parts Warrantyp. 6
+R22MM_1p. 7
+R22 Maintenance Manual – Section 1 Generalp. 7
Contentsp. 7
+1.000 Introductionp. 9
1.001 Manual Notationsp. 9
1.002 Manual Revisionsp. 9
1.003 Maintenance Authorizationp. 9
1.004 Overhaul Authorizationp. 10
1.005 Customer Supportp. 10
1.006 External Dimensionsp. 11
1.007 Version Descriptionp. 14
+1.100 Helicopter Servicingp. 16
1.101 Scheduled Maintenance and Inspectionsp. 16
1.105 Calibration of Toolsp. 17
1.110 Lubrication – Generalp. 17
1.115 Chip Detector Cleaningp. 17
1.120 Main Rotor Gearbox Drain and Flushp. 18
1.130 Tail Rotor Gearbox Drain and Flushp. 20
1.140 A184 Upper Bearing Lubricationp. 21
1.150 Defuelingp. 21
1.160 Storagep. 22
+1.200 Handling, Jacking, Hoisting, Leveling, and Weighingp. 23
+1.210 Ground Handlingp. 23
1.211 Ground Handling Wheels – Skid Landing Gearp. 23
1.212 Ground Handling Wheels – Float Landing Gearp. 24
1.213 Moving Helicopter on Ground Handling Wheelsp. 26
1.214 Main Rotor Blade Tie-Downsp. 26
1.215 Parkingp. 28
1.216 Traileringp. 28
1.220 Jacking, Hoisting, and Levelingp. 29
1.230 Weighing and CG Calculationp. 32
1.240 Ballast Installationp. 35
+1.300 Fastener Torque Requirementsp. 36
1.310 Generalp. 36
1.320 Standard Torquesp. 38
1.330 Special Torquesp. 40
+1.400 Approved Materials Listp. 43
1.410 Paint Strippersp. 43
1.420 Solvents and Cleanersp. 44
1.430 Fillers and Puttyp. 44
1.440 Torque Sealp. 44
1.450 Primersp. 45
1.455 Power Coatp. 45
1.460 Paintsp. 46
1.470 Lubricantsp. 48
1.480 Adhesives and Sealantsp. 50
1.490 Storage Limitsp. 52
1.500 Part Interchangeabilityp. 53
1.600 Instructions for Uncrating, Reassembling, and Flight Testing R22 Series Helicoptersp. 54
1.700 Replacement Component Identification (Data) Platesp. 56
+R22MM_2p. 57
+R22 Maintenance Manual – Section 2 Inspectionp. 57
Contentsp. 57
2.000 Introductionp. 59
+2.100 General Proceduresp. 59
2.110 Ball and Roller Bearingsp. 59
+2.120 Push-Pull Tubes, Rod Ends, and Spherical Bearingsp. 59
2.121 Push-Pull Tubesp. 59
2.122 Rod Ends and Spherical Bearingsp. 60
2.125 Elastomeric Bearingsp. 62
2.130 Telatemp Indicatorsp. 64
+2.200 Ground and Flight Check for 100-Hour/Annual Inspectionp. 65
2.205 Ground Checkp. 65
2.210 Run Upp. 67
2.220 Flight Checkp. 68
2.300 Airframe Preparation for 100-Hour/Annual Inspectionp. 68
+2.400 100-Hour/Annual Airframe Inspectionp. 69
2.410 Inspection Procedures and Checklistp. 69
+2.500 Special Inspectionsp. 99
2.501 Clutch Actuator Upper and Lower Bearings Inspection and Lubricationp. 99
2.502 A181-4 Actuator Lower Bearing Inspection and Lubricationp. 99
2.503 A184 Actuator Upper Bearing Inspection and Lubricationp. 100
2.507 V-Belt Inspectionp. 101
2.508 Lower Sheave V-Belt Wear Pattern Inspectionp. 103
2.510 Tail Skid Strikep. 104
2.520 Tail Rotor Strikep. 105
2.530 Main Rotor Strikep. 106
2.540 Rotor/Engine Overspeedp. 107
2.550 Hard Landingp. 109
2.560 Steel Tube Frame Corrosionp. 111
+2.570 Main Rotor Blade Detail Inspectionp. 112
2.571 Spar Cover Adhesive Damage (A016-2 Main Rotor Blade Only)p. 112
2.572 Main Rotor Blade Sealant and Filler Crackingp. 114
2.573 Visual Inspection of Main Rotor Blade Root Areap. 115
2.580 Float Inspection and Testingp. 116
2.590 Windshield Inspectionp. 117
+2.600 12-Year Inspection and Limited Overhaul Requirementsp. 118
2.610 Inspection Procedurep. 118
2.620 Additional Parts Requiring Replacement on Some R22sp. 120
2.630 Component Inspection Procedurep. 121
+2.700 2200-Hour Overhaul Requirementsp. 122
2.710 Inspection Procedurep. 122
2.720 Additional Parts Requiring Replacement on Some R22sp. 124
+R22MM_3p. 125
+R22 Maintenance Manual – Section 3 Life-Limited Componentsp. 125
Contentsp. 125
+3.000 Life-Limited Componentsp. 127
3.001 Introductionp. 127
3.002 Time-In-Service Recordsp. 127
3.003 Fatigue Life-Limited Partsp. 127
+3.100 Inspection and Overhaul Requirementsp. 128
3.110 Powerplant Overhaul Requirementsp. 128
3.120 Aircraft Overhaul Requirementsp. 128
3.130 12-Year Inspection and Limited Overhaul Requirementsp. 128
3.200 Additional Bearing Replacement Requirementsp. 128
3.300 Airworthiness Limitationsp. 129
Type Certificate Data Sheetp. 131
+R22MM_4p. 141
+R22 Maintenance Manual – Section 4 Airframep. 141
Contentsp. 141
+4.000 Airframep. 143
4.001 Introductionp. 143
4.002 Descriptionp. 143
+4.100 Fuselagep. 143
4.110 Cabin Assemblyp. 143
+4.120 Windshield Assemblyp. 144
4.121 Windshield Removalp. 144
4.122 Windshield Installationp. 144
4.123 Windshield Replacementp. 145
4.130 Door Removal and Installationp. 146
+4.140 Fairing, Cowling and Inspection Panelsp. 146
4.141 Side Skirtsp. 146
4.142 Mast Fairingp. 148
4.143 Aft Cowlingp. 148
4.144 Cabin Inspection Panelsp. 148
4.200 Welded Steel Tube Frame Assembliesp. 149
+4.210 Left-Hand Frame Assemblyp. 150
4.211 Removalp. 150
4.212 Left-Hand Frame Assembly Installationp. 150
+4.220 Right-Hand Frame Assemblyp. 151
4.221 Right-Hand Frame Removalp. 151
4.222 Right-Hand Frame Installationp. 154
+4.230 Upper Frame Assemblyp. 155
4.231 Upper Frame Removalp. 155
4.232 Upper Frame Installationp. 156
4.240 Strut Assembly Removal and Installationp. 157
4.300 Tailcone and Empennagep. 158
+4.310 Tailconep. 158
4.311 Tailcone Removalp. 158
4.312 Tailcone Installationp. 158
4.313 Tailcone Replacementp. 159
4.314 Tailcone Repairp. 164
+4.320 Empennage Assemblyp. 164
4.321 Empennage Removalp. 164
4.322 Empennage Installationp. 165
4.323 Upper Stabilizer Replacementp. 165
4.324 Lower Stabilizer Replacementp. 165
4.325 Horizontal Stabilizer Replacementp. 166
+R22MM_5p. 169
+R22 Maintenance Manual – Section 5 Landing Gearp. 169
Contentsp. 169
+5.000 Landing Gearp. 171
5.001 Introductionp. 171
5.002 Descriptionp. 171
+5.100 Landing Gear Assemblyp. 171
5.110 Landing Gear Removalp. 171
5.120 Landing Gear Installationp. 173
+5.200 Cross Tubesp. 173
5.210 Cross Tube Removalp. 173
5.220 Cross Tube Installationp. 176
+5.300 Skid Tubesp. 176
5.310 Skid Tube Removalp. 176
5.320 Skid Tube Installationp. 176
5.330 Skid Shoe Removal and Replacementp. 176
5.340 Removal and Replacement of Ground Handling Wheel Supportp. 178
5.400 Preventative Maintenancep. 178
+5.500 Float Ship Landing Gearp. 179
5.510 Float Landing Gear Removalp. 179
5.520 Float Gear Installationp. 180
5.530 Float Tube Removalp. 181
5.540 Float Tube Installationp. 181
5.550 Float Tube Repairp. 183
+R22MM_6p. 185
+R22 Maintenance Manual – Section 6 Powerplant and Related Systemsp. 185
Contentsp. 185
+6.000 Powerplant and Related Systemsp. 187
6.001 Introductionp. 187
6.002 Descriptionp. 187
+6.100 Powerplantp. 188
6.110 Engine Removalp. 188
6.120 Engine Installationp. 190
6.130 Engine Shimmingp. 192
+6.200 Cooling Systemp. 195
6.210 Fanwheel Removalp. 195
6.220 Fanwheel Installationp. 198
6.230 Reservedp. 199
6.240 Balancing Fanwheelp. 199
6.250 Cooling Scroll Replacementp. 203
+6.300 Lubrication Systemp. 208
6.310 Oil Cooler Removalp. 208
6.320 Oil Cooler Installationp. 208
+6.400 Induction Systemp. 208
6.410 Carburetor Removalp. 208
6.420 Air Box Removalp. 209
6.430 Air Box Installationp. 209
6.440 Carburetor Installationp. 211
6.450 Carburetor Heat Scoop Removalp. 211
6.460 Carburetor Heat Scoop Installationp. 211
+6.500 Exhaust Systemp. 212
6.510 Exhaust System Removalp. 212
6.520 Exhaust System Installationp. 212
6.610 Low-Power Checklistp. 213
+6.700 Throttle Control and Carburetor Heat Assistp. 215
+6.710 Overtravel Springp. 215
6.711 Overtravel Spring Removalp. 215
6.712 Overtravel Spring Installationp. 215
6.720 Reservedp. 215
+6.730 Throttle Push-Pull Tube Assemblyp. 216
6.731 Throttle Push-Pull Tube Assembly Removalp. 216
6.732 Throttle Push-Pull Tube Assembly Installationp. 216
+6.740 Carburetor Heat Assistp. 216
6.741 Carburetor Heat Control Removalp. 216
6.742 Carburetor Heat Control Cable Installationp. 217
6.743 D334-5 Carburetor Heat Assist Bellcrank Assembly Removalp. 217
6.744 D334-5 Carburetor Heat Assist Bellcrank Assembly Installationp. 217
6.745 D334-5 Bellcrank Friction Adjustmentp. 219
+R22MM_7p. 221
+R22 Maintenance Manual – Section 7 Drive Trainp. 221
Contentsp. 221
+7.000 Drive Trainp. 225
7.001 Introductionp. 225
7.002 Descriptionp. 225
+7.100 Main Rotor Gearboxp. 225
7.110 Main Rotor Gearbox Removalp. 225
7.120 Main Rotor Gearbox Installationp. 227
7.130 Leveling Main Rotor Gearboxp. 229
7.140 A006-5 or A908-4 Yoke Removal and Installationp. 231
+7.150 Replacement of Main Rotor Gearbox Pinion Sealp. 231
7.155 Replacement of Main Rotor Gearbox (MRGB) Sump O-Ringp. 233
7.160 Main Rotor Gearbox Overtemp Inspectionp. 234
7.170 Main Rotor Gearbox Chip Light Indicatorp. 235
7.180 Reservedp. 235
+7.200 Clutch Assemblyp. 236
+7.210 Clutch Assembly Removalp. 236
7.211 A184 Bearing Removalp. 238
7.212 A184 Bearing Installationp. 240
7.213 Clutch Assembly Seal Replacementp. 241
7.220 Clutch Assembly Installationp. 245
7.230 Clutch Sheave Alignmentp. 248
7.240 Clutch Shaft Anglep. 250
7.250 Clutch Lateral Centeringp. 250
7.260 A907 Yoke Removal and Installationp. 252
7.270 A195 Yoke Removal and Installationp. 252
+7.280 V-Beltsp. 253
7.281 V-Belt Removalp. 253
7.282 V-Belt Installationp. 259
7.283 V-Belt Tensionp. 262
+7.290 A007-3 & -5 Fanshaft and Bearing Assembly, Starter Ring Gear Support, Lower Sheave and Alternator Belt Replacementp. 264
7.291 Removalp. 264
7.292 Installationp. 264
+7.300 Tail Rotor Driveshaftp. 266
7.310 Tail Rotor Driveshaft Removalp. 266
+7.320 Tail Rotor Driveshaft Installationp. 267
7.321 Adjustment of Damper Frictionp. 269
7.330 Intermediate Flex Plate Installation and Shimmingp. 274
7.340 Checking Tail Rotor Drive Shaft Runoutp. 277
7.350 Two-Piece Tail Rotor Driveshaftp. 279
7.360 B224-1 Tail Rotor Driveshaft Corrosion Removalp. 282
+7.400 Tail Rotor Gearboxp. 283
7.410 Tail Rotor Gearbox Removalp. 283
7.420 Tail Rotor Gearbox Installationp. 283
7.430 Tail Rotor Gearbox Shimmingp. 284
7.440 Tail Rotor Gearbox Chip Indicatorp. 284
7.450 A021 Tail Rotor Gearbox Output Shaft Seal Replacementp. 285
7.460 B021 Tail Rotor Gearbox Output Shaft Seal Replacementp. 286
7.470 B021 Tail Rotor Gearbox Input Shaft Seal Replacementp. 288
+7.500 Actuator Assemblyp. 289
7.510 Actuator Removalp. 289
7.520 Actuator Installationp. 289
7.530 Actuator Gearmotor Replacementp. 289
7.540 Actuator Adjustmentp. 290
+7.550 Switch and Fuse Replacementp. 293
7.551 Switch Replacementp. 293
7.552 Fuse Replacementp. 293
+7.600 Rotor Brakep. 294
7.610 Rotor Brake Removalp. 294
7.620 Rotor Brake Installationp. 294
7.630 Rotor Brake Pad Replacementp. 295
+R22MM_8p. 299
+R22 Maintenance Manual – Section 8 Flight Controlsp. 299
Contentsp. 299
+8.000 Flight Controlsp. 303
8.001 Introductionp. 303
8.002 Descriptionp. 303
+8.100 Cyclic Controlsp. 303
+8.110 Cyclic Assemblyp. 303
8.111 Removal of Cyclic Assemblyp. 303
8.112 Installation of Cyclic Assemblyp. 306
+8.120 Cyclic Grip Assemblyp. 309
8.121 Removal of Cyclic Grip Assemblyp. 309
8.122 Installation of Cyclic Grip Assemblyp. 310
+8.130 Cyclic Lateral (Right) Trimp. 312
8.131 Right Trim Spring Assembly Removalp. 312
8.132 Right Trim Spring Assembly Installationp. 312
8.133 Right Trim Spring Replacement & Shimmingp. 313
+8.140 Selecting Longitudinal Elastic Trim Cordp. 317
8.141 Longitudinal Trim Cord Removalp. 321
8.142 Longitudinal Trim Cord Installationp. 321
+8.150 Cyclic Friction Assemblyp. 322
8.151 Cyclic Friction Adjustmentp. 322
+8.160 A121-7 Push Pull (P-P) Tubep. 323
8.161 A121-7 Push-Pull Tube Removalp. 323
8.162 A121-7 Push-Pull Tube Inspection/Repairp. 323
8.163 Sleeve Installation Onto A121-7 Push-Pull Tubep. 324
8.164 Push-Pull Tube Sleeve Inspectionp. 324
8.165 A121-7 Push-Pull Tube Installationp. 325
+8.200 Collective Controlp. 327
+8.210 Collective Stick Assemblyp. 327
8.211 Collective Stick Removalp. 327
8.212 Collective Stick Installationp. 328
+8.220 Collective Spring Assemblyp. 332
8.221 Collective Spring Removalp. 332
8.222 Collective Spring Installationp. 334
8.223 Collective Spring Adjustement for A038-1 thru -4 Assemblyp. 335
8.224 Collective Spring Adjustment for A038-5, -6, or -7 Assemblyp. 336
8.225 Collective Friction Adjustmentp. 336
+8.230 RPM Governor Systemp. 337
8.231 Governor Controller Removalp. 337
8.232 Governor Controller Installationp. 337
8.233 Governor Assembly Removalp. 337
8.234 Governor Assembly Installationp. 339
8.239 Governor Troubleshootingp. 339
+8.300 Jackshaft and Support Strutsp. 341
+8.310 Jackshaftp. 341
8.311 Jackshaft Removalp. 341
8.312 Jackshaft Installationp. 341
+8.320 Strut Assembly (Jackshaft Support)p. 341
8.321 Jackshaft Strut Removalp. 341
8.322 Jackshaft Strut Installationp. 344
+8.400 Swashplate and Main Rotor Pitch Linksp. 345
+8.410 Swashplatep. 345
8.411 Swashplate Removalp. 345
8.412 Swashplate Installationp. 346
8.413 Reservedp. 351
8.414 Reservedp. 351
8.415 Reservedp. 351
8.416 Shimming Upper (Unflanged) Spherical Sleeve with Aluminum Ballp. 354
+8.500 Tail Rotor Controlsp. 354
+8.510 Tail Rotor Pedalsp. 354
8.511 Tail Rotor Pedal Removalp. 354
8.512 Tail Rotor Pedal Installationp. 358
+8.520 A317-1 Lower Bellcrankp. 358
8.521 A317-1 Lower Bellcrank Removalp. 358
8.522 A317-1 Lower Bellcrank Installationp. 359
+8.530 A013-3 Upper Bellcrankp. 361
8.531 Bellcrank Removalp. 361
8.532 Bellcrank Installationp. 361
+8.540 A331-1 Intermediate Bellcrankp. 362
8.541 A331-1 Intermediate Bellcrank Removalp. 362
8.542 A331-1 Intermediate Bellcrank Installationp. 362
+8.550 A120-1 Aft Bellcrankp. 363
8.551 A120-1 Aft Bellcrank Removalp. 363
8.552 A120-1 Aft Bellcrank Installationp. 363
+8.560 A031 Pitch Controlp. 363
8.561 Pitch Control Removalp. 363
8.562 Pitch Control Installationp. 363
+8.570 Tail Rotor Pitch Linksp. 364
8.571 Tail Rotor Pitch Link Removalp. 364
8.572 Tail Rotor Pitch Link Installationp. 364
+8.600 A203 Yoke and A205 Fork Assemblyp. 366
+8.610 Bearing Removalp. 366
8.615 C648-2 Bearing Installationp. 366
8.620 A139-1 Bearing Installationp. 366
+8.630 B115-1 Bearing Installationp. 368
8.631 Interference-Fit Bearingsp. 368
8.632 Loctite-Secured Slip-Fit Bearingsp. 368
8.640 Yoke and Fork Assembly Installationp. 369
+R22MM_9p. 371
+R22 Maintenance Manual – Section 9 Rotor Systemsp. 371
Contentsp. 371
+9.000 Rotor Systemsp. 373
9.001 Introductionp. 373
9.002 Descriptionp. 373
+9.100 Main Rotorp. 373
+9.110 Main Rotor Bladesp. 373
9.111 Main Rotor Blade Removalp. 373
9.112 Main Rotor Blade Installationp. 376
9.113 Boot Removalp. 378
9.114 Boot Installationp. 378
9.115 Filling Root Fittingp. 379
9.116 Drilling Main Rotor Hub Boltsp. 381
+9.120 Main Rotor Hubp. 381
9.121 Main Rotor Hub Removalp. 381
9.122 Main Rotor Hub Installationp. 383
9.123 Assembly of the Main Rotor Hub Without RHC Static Balance Informationp. 384
9.124 Adjustment of Hinge Frictionp. 389
9.125 Shifting the Main Rotor Hubp. 390
9.126 Main Rotor Hub Bearing Replacementp. 392
9.130 Inspection and Repair of Main Rotor Bladesp. 394
+9.200 Tail Rotorp. 407
+9.210 Tail Rotor Removalp. 407
9.212 Tail Rotor Installation with Spherical Teeter Bearingsp. 409
9.213 Tail Rotor Installation with Elastomeric Teeter Bearingsp. 412
9.214 Tail Rotor Hub Spherical Bearing Replacementp. 415
9.215 Tail Rotor Hub Elastomeric Bearing Replacementp. 416
9.220 Inspection and Repair of Tail Rotor Bladesp. 419
+R22MM_10p. 423
+R22 Maintenance Manual – Section 10 – Rigging, Track and Balancep. 423
Contentsp. 423
+10.000 Rigging, Track and Balancep. 425
10.001 Introductionp. 425
10.002 Rod End Adjustment Procedures for Riggingp. 425
+10.100 Riggingp. 426
+10.110 Main Rotor Flight Controlsp. 426
10.111 Cyclic Controlsp. 426
10.112 Swashplatep. 427
10.113 Collective Controlp. 427
+10.120 Main Rotorp. 427
10.121 Cyclic Travel Riggingp. 432
10.122 Collective Travel Riggingp. 435
+10.130 Tail Rotor Flight Controlsp. 436
10.131 Pedalsp. 436
10.132 A316 Bellcrankp. 436
10.133 A331 Bellcrankp. 436
10.134 A120-1 Bellcrankp. 439
10.135 Tail Rotor Pitch Linksp. 439
10.140 Tail Rotor Riggingp. 439
10.150 Throttle Correlation Riggingp. 443
+10.200 Track and Balancep. 445
10.210 Equipment Requirementsp. 445
+10.220 Equipment Installationp. 446
10.221 Main Rotor Equipment Installationp. 446
10.222 Tail Rotor Equipment Installationp. 447
+10.230 Main Rotor Track and Balance Procedurep. 455
10.231 Main Rotor Balance Adjustmentsp. 456
10.232 Main Rotor Pitch Link Adjustmentp. 456
10.233 Main Rotor Blade Trim Tab Adjustmentp. 459
10.234 Main Rotor Track and Balance Troubleshootingp. 461
10.240 Tail Rotor Balance Procedurep. 463
10.250 Autorotational RPM Adjustmentp. 466
+R22MM_11p. 469
+R22 Maintenance Manual – Section 11 Heating and Ventilationp. 469
Contentsp. 469
+11.000 Heating and Ventilationp. 471
11.001 Introductionp. 471
11.002 Descriptionp. 471
+11.100 Cabin Heaterp. 471
11.110 Cabin Heater Removalp. 471
11.120 Cabin Heater Installationp. 472
+11.200 Ventilationp. 474
11.210 Cabin Air Vent Removalp. 474
11.220 Cabin Air Vent Cable Installationp. 476
11.230 Door Ventp. 476
+R22MM_12p. 477
+R22 Maintenance Manual – Section 12 Fuel Systemp. 477
Contentsp. 477
+12.00 Fuel Systemp. 479
12.001 Introductionp. 479
12.002 Descriptionp. 479
+12.100 Fuel Tankp. 479
12.110 Fuel Tank Removalp. 479
12.120 Main Fuel Tank Inspection and Repairp. 482
12.130 Main Fuel Tank Installationp. 482
12.140 Sump Drain Valve Removalp. 482
12.150 Sump Drain Valve O-Ring Replacementp. 482
12.160 Sump Drain Valve Replacementp. 482
+12.200 Fuel Quantity Systemp. 488
12.210 Removal of the Fuel Quantity Senderp. 488
12.220 Installation of the Fuel Quantity Senderp. 488
12.230 Fuel Quantity Sender Calibrationp. 488
12.240 Low Fuel Warning Sender Removalp. 490
12.250 Installation of the Low Fuel Warning Senderp. 490
12.260 Fuel Flow Checkp. 490
12.270 Low Fuel Sender Checkp. 491
+12.300 Gascolatorp. 491
12.310 Gascolator Removalp. 491
12.320 Cleaning the Gascolatorp. 494
12.330 Gascolator Installationp. 494
+R22MM_13p. 495
+R22 Maintenance Manual – Section 13 Instrumentsp. 495
Contentsp. 495
+13.000 Instrumentsp. 497
13.001 Introductionp. 497
13.002 Descriptionp. 497
13.100 Pitot-Static Systemp. 497
+13.200 Flight Instrumentsp. 497
13.210 Airspeed Indicatorp. 497
13.220 Altimeterp. 499
13.230 Vertical Speed Indicatorp. 499
13.240 Outside Air Temperaturep. 499
+13.300 Drive Train and Powerplant Instrumentsp. 499
13.310 Engine – Rotor Tachometerp. 499
13.320 Manifold Pressure Gagep. 500
13.330 Carburetor Air Temperaturep. 500
+13.340 Engine Instrument Clusterp. 500
13.341 Oil Pressure Gagep. 500
13.342 Oil Temperature Gagep. 500
13.343 Cylinder Heat Temperature Gagep. 500
13.344 Fuel Quantity Gagep. 500
13.400 Trouble Shooting Guidep. 501
+R22MM_14p. 503
+R22 Maintenance Manual – Section 14 Electrical and Avionics Systemsp. 503
Contentsp. 503
+14.000 Electrical and Avionics Systemsp. 505
14.001 Introductionp. 505
14.002 Descriptionp. 505
14.100 Dual Tachometer Adjustmentp. 506
14.200 Low Rotor RPM Warning Unit Adjustmentp. 507
14.300 Alternator Output Voltage Adjustment Without A942-Series ACUp. 507
+14.400 Trouble-Shootingp. 507
14.405 A569-5 Low Rotor RPM Warning Unitp. 507
14.410 Electrical Trouble-Shootingp. 510
14.420 Instrument Trouble-Shootingp. 512
14.430 Clutch Actuator Electrical Trouble-Shootingp. 513
14.440 Electrically Powered Instrument Calibration Valuesp. 514
14.500 Component Loadsp. 517
14.600 Electrical Schematicsp. 518
14.700 R22 Antennasp. 548
14.800 Avionics Schematicsp. 551
14.900 Upper Console Harness Plugsp. 585
+14.1000 IFR Trainerp. 587
14.1010 IFR Trainer Component Loadsp. 587
14.1020 IFR Trainer Console Accessp. 589
14.1030 IFR Trainer Component Locationp. 590
14.1040 IFR Trainer Avionics Schematicsp. 591
+14.1100 R22 Marinerp. 604
14.1110 R22 Mariner Avionics Schematicsp. 604
+R22MM_15p. 611
+R22 Maintenance Manual – Section 15 Furnishingsp. 611
Contentsp. 611
+15.000 Furnishingsp. 613
15.001 Introductionp. 613
15.002 Descriptionp. 613
+15.100 Seat Beltp. 613
15.110 Seat Belt Removalp. 613
15.120 Seat Belt Installationp. 613
+15.200 Seat Assemblyp. 615
15.210 Seat Bottom Assembly Removal and Installationp. 615
15.220 Seat Back Assembly Removal and Installationp. 615
+15.300 Carpetp. 616
15.310 Carpet Removalp. 616
15.320 Carpet Installationp. 617
+15.400 Foam Installationp. 617
15.410 Foam Removalp. 617
15.420 Foam Installationp. 617
+15.500 Map Holder Pocketp. 618
15.510 Map Holder Removalp. 618
15.520 Map Holder Installationp. 618
+15.600 Fire Extinguisherp. 618
15.610 Fire Extinguisher Holder Removalp. 618
15.620 Fire Extinguisher Holder Installationp. 619
+15.700 License Holderp. 619
15.710 License Holder Removalp. 619
15.720 License Holder Installationp. 619
+15.800 Operator's Manual Strapp. 620
15.810 Strap Removalp. 620
15.820 Strap Installationp. 620
+R22MM_16p. 621
+R22 Maintenance Manual – Section 16 Special Toolsp. 621
Contentsp. 621
16.000 Special Toolsp. 623
16.100 Tool Listp. 623
+R22MM_17p. 627
R22 Maintenance Manual – Section 17 Revision Logp. 627
Effective Pagesp. 629
Workshop Reference for R22 Maintenance
The manual contains numerous illustrations and tables that support hands-on work. Examples include helicopter external-dimension drawings, ground-handling-wheel installation diagrams, hoisting and leveling figures, center-of-gravity determination illustrations, torque tables, finish-code locations, inspection-access diagrams, structural inspection drawings, V-belt discrepancy illustrations, frame and tailcone figures, windshield installation details, and component-life tables. Because the procedures often refer from one section to another, the document is designed to support complete maintenance tasks rather than isolated specifications.
It also places strong emphasis on maintenance discipline. Warnings and cautions address personal injury, equipment damage, flight-control assembly, critical fastener torque, component condition, contamination, corrosion, and post-maintenance verification. The manual states that maintenance, repairs, and inspections described in it are to be performed by appropriately certificated mechanics who have completed the specified factory-sponsored maintenance course or are under direct supervision of such a mechanic, with additional authorization requirements for major-component overhaul work.
Maintain, Inspect and Repair the R22 with the Correct Reference
The Robinson R22 RTR 060 Maintenance Manual & Continued Airworthiness – April 2012 PDF supports a wide range of real maintenance work, from scheduled servicing, 100-hour and annual inspections, corrosion and damage checks, gearbox and drive-system service, airframe removal and installation tasks, rotor and flight-control inspection, rigging and balance work, through major calendar- and time-based overhaul planning. Using the specified procedures, limits, torque values, inspection criteria, and continued-airworthiness information helps technicians carry out work consistently and verify the aircraft correctly after maintenance. Delivery is instant as a PDF after purchase, with no shipping required; the file can be viewed on compatible computers, tablets, and phones and printed for workshop use.
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