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EXEC 162F MAINTENANCE 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 their helicopter. 5/98...
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RotorWay International Exec 162F Maintenance Manual WARNING The construction and operation of “Home-Built Aircraft” of this type is demanding and could inflict serious injury and possible death. No such operation, construction or undertaking should be initiated unless thorough and complete knowledge, preparation and instruction are available and utilized. The seller...
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RotorWay International Exec 162F Maintenance Manual INTRODUCTION In this Maintenance Manual, the components of the helicopter have been divided into 20 sections. Each of these sections begins with a brief description of the component, followed by an “Inspection Chart”. This chart shows the Inspection Interval, Recommended Change Out time (R.C.O.), and a Service Reference for each part.
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RotorWay International Exec 162F Maintenance Manual...
RotorWay International Exec 162F Maintenance Manual Rev. 1 10/01 Section 1: Airframe The airframe is constructed of various size tubes consisting of geometric shapes which will allow the airframe to flex at key areas during operation and still maintain a high structural integrity. The tubing is aircraft industry standard 4130 chrome- moly.
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RotorWay International Exec 162F Maintenance Manual Section 2: Tail Boom The main purpose of the tail boom in all conventional helicopters is to provide a mounting location for the anti-torque system or tail rotor. Its secondary purpose is to mount the vertical and horizontal trim fins which are used to stabilize the aircraft in forward flight, opposing aerodynamic forces from the windscreen and body.
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Section 3: Body The body of the EXEC 162F helicopter consists of several separate panels that when assembled make up a solid egg shape structure. This provides for a very efficient and aerodynamic airflow. Each panel is made using the hand lay-up squeeze method to give the piece the maximum strength to weight ratio.
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RotorWay International Exec 162F Maintenance Manual B. Care should be taken so that the windscreen screws are not over tightened (see “Working With Plexiglass” in the Standard Construction Procedures of the Construction Manual). This could cause stress cracks that may result in a major crack down or across the windscreen.
Section 4: Tail Rotor Drive The tail rotor drive of the EXEC 162F utilizes a V-belt design, rather than a drive shaft with gear boxes, to transmit power to the tail rotor. This design provides a simple and effective drive train with low maintenance.
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RotorWay International Exec 162F Maintenance Manual Rev. 1 6/04 Section 5: Tail Rotor The tail rotor’s function is to counter the torque of the power plant and keep the aircraft from rotating. It also provides the ability to turn the aircraft while hovering by adjusting the pitch of the tail rotor blades through use of the directional controls.
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RotorWay International Exec 162F Maintenance Manual Rev. 1 6/04 3. Remove bolt (part no. E00-2311) and two washers. Then slide the actuator arm to one side and place a small amount of grease on the bolt hole in the pivot casting. Reassemble the actuator arm, install bolt, and check the nut with cotter pins for security.
Exec 162F Maintenance Manual Section 6: Control Assemblies The Control Assemblies of the EXEC 162F helicopter transfer control inputs from the pilot and passenger to the associated location on the helicopter. The four areas that require control inputs are: A. Directional Controls B.
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RotorWay International Exec 162F Maintenance Manual 3. Remove bolt (part no. E00-2305) rod end (part no. E16-1200) and jam nut. Then count the number of turns to remove, and install the new rod end with the same number of turns. Tighten the locking nut, replace the bolt and verify the cable travel.
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RotorWay International Exec 162F Maintenance Manual 14. Removal of the throttle grip is easily done by placing an air hose nozzle into the hole on the front of the rubber grip and blowing air into the grip at a high velocity. The grip will expand and can be pulled off. Note: Do not cut off any length of the rubber grip.
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RotorWay International Exec 162F Maintenance Manual Rev. 2 10/01 Section 7: Oil System The oil sump/heat exchanger is a combined sump tank and oil cooler. Oil is drawn from the sump tank into the oil pump. From the oil pump it circulates through the oil filter, then through the engine. It then drains back into the sump tank and flows over the heat exchanger, where it is cooled by circulating engine coolant.
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RotorWay International Exec 162F Maintenance Manual Rev. 1 7/98 Section 8: Cooling System The RI 162F power plant is a liquid cooled engine. The water pump circulates coolant from the engine through the radiator. A fan is located over the closed radiator system to force cooler outside air across the radiator for effective cooling.
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Q. Install water pump/alternator belt. 3. Replace the thermostat, engine coolant, and hose clamps when changing the hoses. CAUTION: Use ONLY a RotorWay supplied thermostat for replacement. The correct type of thermostat was determined after many hours of testing at...
Exec 162F Maintenance Manual Rev. 2 6/04 Section 9: Engine and Exhaust System The RI 162F Engine has been designed specifically for the RotorWay Helicopter. RotorWay International manufactures the entire engine. Refer to the Engine Manual for further information. Reference prints: E25-2000, E27-2000...
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RotorWay International Exec 162F Maintenance Manual Rev. 1 12/99 4. The rubber oil drain hoses should normally be replaced at 500 hours, five years, or on condition, whichever comes first. Shelf life, or time before entering service, is not included if the hoses have not been exposed to the environment and have not been affected by aging.
RotorWay International Exec 162F Maintenance Manual Rev. 6 3/03 Section 10: Drive Train The drive train is a series of reduction pulleys and sprockets that transmit power from the engine to the main rotor system. No transmissions, gear boxes or drive shafts are used. The system is simple to monitor and maintain.
2. The secondary unit comes as a complete assembly and should not be tampered with or opened at any time. A visual inspection and a lock up inspection of the overrunning clutch should be done during the pre-flight inspection. Any other adjustments or work performed must be done by the factory service center at RotorWay, with the exception of the following: A.
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RotorWay International Exec 162F Maintenance Manual Rev. 2 3/03 5. Check the high temp fan for stress cracks on blades. Do not confuse stress cracks with excess resin cracks. Stress cracks will penetrate the fiberglass and resin cracks will be on the surface only.
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Section 11: Fuel System The RI 162F engine is equipped with RotorWay’s FADEC electronic fuel injection system. In this system, gasoline is delivered to the injectors at a very high pressure (up to 60 PSI). Braided stainless steel hoses and high quality fittings are used throughout the system.
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RotorWay International Exec 162F Maintenance Manual 3. Replace the fuel filter every 100 hours or OC. Check for fuel contamination by cutting the used filter in half and inspecting the inlet side of the filter element. If the element is contaminated, inspect and clean the pre-filter in the fuel shut-off valve/filter assembly (see note 4 below).
RotorWay International Exec 162F Maintenance Manual Rev. 1 7/98 Section 12: Fan Drive The fan drive system is a series of pulleys and belts providing the proper speed reduction for the fan design. Reference print: E31-2000 INSPECTION CHART INSPECTION SERVICE PART NO.
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RotorWay International Exec 162F Maintenance Manual Section 13: Main Rotor Blades The main rotor blades are one of the key components of the helicopter. Proper maintenance and care of the main rotor blades will increase their longevity. The main rotor blades are made from aluminum alloys, and are constructed from 3 pieces: the main spar (C section) and an upper and lower aluminum skin.
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RotorWay International Exec 162F Maintenance Manual 3. After the nut has been removed four or more times, it should be replaced with a new nut (part no. E00-3800). Torque to specs. 4. The elastomeric bearings (part no. E20-1400 and 1401) are comprised of thin layers of rubber and metal sandwiched together.
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Exec 162F Maintenance Manual Section 14: Electrical System The Electrical System of the EXEC 162F requires little maintenance if inspected properly. The three most common problems are corrosion, vibration of connectors, and chafing of wires. Reference prints: E31-2000, E35-2000, E35-2001...
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RotorWay International Exec 162F Maintenance Manual 7. Check spade connections on the starter relay for corrosion and poor connections. Check relay by unplugging the spade terminal that goes to the starter solenoid and activate the starter button. The relay should have a small clicking action (be sure the battery is connected and the key switch is on).
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Rev. 3 6/04 Section 15: Instrumentation Instrumentation on the EXEC 162F is normally maintenance free. It is, however, extremely important to keep it in perfect operating condition. The instrumentation provides the pilot continuous information on all the helicopter systems conditions.
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Section 16: Ground Handling Wheels The Ground Handling Wheels for the EXEC 162F were designed for the sole purpose of ground handling the helicopter when the rotors are not turning. This system allows you to handle the helicopter on asphalt, concrete and grass.
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RotorWay International Exec 162F Maintenance Manual Section 17: Ballast Weight The ballast weight and ballast weight transport system was designed to keep the helicopter within its operating limitations during solo and dual flight configurations. Reference print: E22-2000 INSPECTION CHART INSPECTION SERVICE PART NO.
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RotorWay International Exec 162F Maintenance Manual Section 18: Paint The choice of paint is left up to the owner/builder of the helicopter. Any maintenance required should follow the paint manufacturers recommendations. INSPECTION CHART INSPECTION SERVICE PART NO. DESCRIPTION R.C.O. INTERVAL...
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RotorWay International Exec 162F Maintenance Manual Rev. 1 6/04 Section 19: Rotor Hub The rotor hub system is comprised of three sub-assemblies: the rotor hub assembly, the swash plate and the main shaft. It comes from the factory as a completed assembly.
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RotorWay International Exec 162F Maintenance Manual Rev. 1 10/01 INSPECTION CHART INSPECTION SERVICE PART NO. DESCRIPTION INTERVAL R.C.O. REFERENCE E49-4610 Swash Plate Scissor 100 HR 2000 HR E49-4710 Scissor Clevis 100 HR 2000 HR E49-4720 Male Rod End 5/16 x 3/8...
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RotorWay International Exec 162F Maintenance Manual Rev. 2 6/04 4. Check hub alignment every 100 hours. If the alignment falls within the prescribed limits, it is not necessary to re-shim the hub. The stainless steel shims come in a variety of thicknesses, each with its own part number. When ordering replacement shims, order the shim kit, part no.
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RotorWay International Exec 162F Maintenance Manual Rev. 2 6/04 8. If this bolt requires replacement before the R.C.O. time of the aligner block assembly, follow these procedures: A. Remove the aligner block assembly from the blades. B. Clamp the aligner block in a vise using wood shims to prevent damage to the block.
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ROTOR HUB SHIMMING PROCEDURES The EXEC 162F Rotor System will require hub shimming at different intervals depending upon how smoothly you keep the rotor system adjusted. This section uses the “See-Do” concept like the Construction Manuals for clarification of the maintenance to be performed.
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RotorWay International Exec 162F Maintenance Manual 5. Next using the same marking on the hub, mark the shaft in relation to the hub and the teeter blocks. See photo #2. Photo #2: Mark the hub plate, shaft and teeter blocks.
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RotorWay International Exec 162F Maintenance Manual 7. Place the “C” clamp across the teeter blocks so that the jaws clamp at the base, close to the center of the block (photo #4). Using the 9/16" socket wrench and open end wrench, remove the locking nut from the bolt. After the nut has been removed and washers taken off, place the box wrench on the teeter block bolts.
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RotorWay International Exec 162F Maintenance Manual 8. Next remove the two snap rings and the large thin washer from the main drive pin. See photo #6. Photo #6: Remove snap rings. 9. Deburr the edge of the snap ring grooves and edge of the pin with 400-600 wet and dry sandpaper.
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RotorWay International Exec 162F Maintenance Manual Photo #7: Measure the shims. 13. Remove the four (4) allen set screws on top of the shaft knuckle. NOTE: There are two (2) screws in each hole. Failure to remove all four set screws will result in damage to the main drive pin. Lightly tap the pin out with a plastic hammer.
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RotorWay International Exec 162F Maintenance Manual 24. Rock the hub back and forth 15 to 20 times to set the shims and grease in their respective positions. 25. After reassembly, two objectives must be reached: A. The hub must be on center of the main shaft.
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RotorWay International Exec 162F Maintenance Manual Photo #9: Hub alignment fixture. Photo #10: Hub fixture located on hub. Photo #11: Proper placement of hub fixture.
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RotorWay International Exec 162F Maintenance Manual Photo #12: Dial indicator reading on center of main shaft. Photo #13: Reading poundage pull on hub. 28. Replace new large flat washers and snap rings on the main drive pin. CAUTION: Be sure you place the correct side of the snap ring towards the outside of the pin.
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RotorWay International Exec 162F Maintenance Manual Rev. 1 8/00 ROTOR HUB: SLIDER BALL ADJUSTMENT COLLAR The Slider Ball Adjustment Collar (part no. E49-3230) is adjusted and set on the swash plate assembly at the factory. However, it may need to be re-adjusted occasionally if the helicopter is exposed to severe or radical temperature changes.
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RotorWay International Exec 162F Maintenance Manual Rev. 2 6/04 Photo #16: Tighten set screws in collar. If incorrectly adjusted, the slider ball adjustment collar will produce a feedback through the cyclic controls that feels like the cyclic wants to travel in any one direction independent of any input from the pilot. The amount of feedback felt by the pilot indicates how much the collar is incorrectly adjusted.
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RotorWay International Exec 162F Maintenance Manual Section 20: Doors The EXEC 162F can be operated with the doors either on or off depending upon the weather and pilots discretion. Reference prints: E41-2000 INSPECTION CHART INSPECTION SERVICE PART NO. DESCRIPTION R.C.O.
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RotorWay International Exec 162F Maintenance Manual Rev. 1 6/04 Section 21: Torque Requirements The following torque requirements are standard for “AN hardware” and should be used throughout the helicopter. BOLT SIZE INCH LBS. FT. LBS. 6-32 7 - 10 8-32...
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Non-destructive inspections (NDI) may be available locally, however RotorWay will also perform these services for you on parts or components you return to the factory. Listed below are some of the major areas of concern in case of an accident.
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RotorWay International Exec 162F Maintenance Manual Section 23: Hourly Service Charts HOURLY SERVICE CHART EXEC 162F REFERENCE SECTION 1: AIRFRAME PART NO. DESCRIPTION 500 1000 1500 2000 E10-1001 EXEC 162F Airframe E00-2415 AN4-24A (1/4 x 2-1/2) Bolt E00-2601 AN6-10A (3/8 x 1) Bolt...
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RotorWay International Exec 162F Maintenance Manual HOURLY SERVICE CHART EXEC 162F REFERENCE SECTION 2: TAIL BOOM PART NO. DESCRIPTION 500 1000 1500 2000 E09-9000 Tail Boom E09-9010 Vertical Trim Fin E09-9021 Horizontal Trim Fins E09-3252 Vertical Trim Fin Bracket E00-2300...
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RotorWay International Exec 162F Maintenance Manual HOURLY SERVICE CHART EXEC 162F HOURLY SERVICE CHART EXEC 162F REFERENCE SECTION 3: BODY REFERENCE SECTION 3: BODY PART NO. DESCRIPTION 500 1000 1500 2000 Body E32-7210 Eyebrow Window, Pilot E32-7220 Eyebrow Window, Passenger...
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RotorWay International Exec 162F Maintenance Manual Rev. 1 6/04 HOURLY SERVICE CHART EXEC 162F REFERENCE SECTION 5: TAIL ROTOR PART NO. DESCRIPTION 500 1000 1500 2000 E17-1260 FS3 PP Bearing E17-1290 Snap Ring E00-2604 AN6-24A (3/8 x 2-1/2) Bolt E17-6126...
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RotorWay International Exec 162F Maintenance Manual HOURLY SERVICE CHART EXEC 162F REFERENCE SECTION 6: CONTROL ASSEMBLIES PART NO. DESCRIPTION 500 1000 1500 2000 E16-6131 Cross Shaft Bushing E16-6130 Scissor Mount Bushing E16-1200 3/16" Female Rod End E16-1130 1/4" Male Rod End E16-1140 1/4"...
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RotorWay International Exec 162F Maintenance Manual Rev. 1 10/01 HOURLY SERVICE CHART EXEC 162F REFERENCE SECTION 7: OIL SYSTEM PART NO. DESCRIPTION 500 1000 1500 2000 E28-7150 Oil Sump/Heat Exchanger E28-1192 Valve Cover Drain Hose E28-1230 Main Oil Drain Hose...
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RotorWay International Exec 162F Maintenance Manual HOURLY SERVICE CHART EXEC 162F REFERENCE SECTION 8: COOLING SYSTEM PART NO. DESCRIPTION 500 1000 1500 2000 E30-1161 Radiator E34-1180 Radiator Cap E34-1300 Hose E34-1310 Hose E34-1320 Hose E34-1330 Hose E34-1340 Hose E34-1350 Hose...
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RotorWay International Exec 162F Maintenance Manual Rev. 1 4/00 HOURLY SERVICE CHART EXEC 162F REFERENCE SECTION 9: ENGINE AND EXHAUST SYSTEM PART NO. DESCRIPTION 500 1000 1500 2000 E24-9710 Exhaust Gasket E24-9840 Heat Wrap E24-9011 Muffler/Tailpipe E24-9001 Header Weldment E24-1251...
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RotorWay International Exec 162F Maintenance Manual Rev. 5 3/03 HOURLY SERVICE CHART EXEC 162F REFERENCE SECTION 10: DRIVE TRAIN PART NO. DESCRIPTION 500 1000 1500 2000 E49-6172 Main Sprocket E49-7010 Sprocket Hub E00-2608 AN176H (3/8 x 3-1/8) Bolt E00-2450 AN4H12 (1/4 x 1-1/4) Bolt...
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RotorWay International Exec 162F Maintenance Manual Rev. 1 1/01 HOURLY SERVICE CHART EXEC 162F REFERENCE SECTION 11: FUEL SYSTEM PART NO. DESCRIPTION 500 1000 1500 2000 E25-2101 Fuel Cap E25-4011 Hose Assembly E25-4020 Hose Assembly E25-4030 Hose Assembly E25-4040 Hose Assembly...
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RotorWay International Exec 162F Maintenance Manual HOURLY SERVICE CHART EXEC 162F REFERENCE SECTION 12: FAN DRIVE PART NO. DESCRIPTION 500 1000 1500 2000 E31-1120 Bearings E31-1130 Belt (Upper) E31-1141 Belt (Lower) E31-5100 Pulley (Upper) E31-5120 Pulley (Lower) E31-6100 Shaft INSPECT...
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RotorWay International Exec 162F Maintenance Manual HOURLY SERVICE CHART EXEC 162F REFERENCE SECTION 13: MAIN ROTOR BLADES PART NO. DESCRIPTION 500 1000 1500 2000 E20-3000 Retention Strap Assembly E20-9010 Asymmetrical Rotor Blade E20-9011 Asymmetrical Rotor Blade E00-2800 NAS1309-54 (9/16 x 4-1/4) Bolt...
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RotorWay International Exec 162F Maintenance Manual HOURLY SERVICE CHART EXEC 162F REFERENCE SECTION 14: ELECTRICAL SYSTEM PART NO. DESCRIPTION 500 1000 1500 2000 E24-9760 12 Volt Battery E35-4000 Digital Display Monitor E35-4011 Engine Control Unit (ECU) E35-4030 Ignition Module E35-4060...
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RotorWay International Exec 162F Maintenance Manual Rev. 2 6/04 HOURLY SERVICE CHART EXEC 162F REFERENCE SECTION 15: INSTRUMENTATION PART NO. DESCRIPTION 500 1000 1500 2000 E36-1100 Hour Meter E36-1120 Water Temperature Gauge E36-1160 Oil Temperature Gauge E36-3110 Oil Pressure Gauge...
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RotorWay International Exec 162F Maintenance Manual HOURLY SERVICE CHART EXEC 162F REFERENCE SECTION 16: GROUND HANDLING WHEELS PART NO. DESCRIPTION 500 1000 1500 2000 E37-4090 Wheel and Tire Tire Track INSPECT REPLACE...
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RotorWay International Exec 162F Maintenance Manual HOURLY SERVICE CHART EXEC 162F REFERENCE SECTION 17: BALLAST WEIGHT PART NO. DESCRIPTION 500 1000 1500 2000 E22-9000 Support Tube Weldment E22-9010 Mount Tube Weldment E22-9020 Ballast Weight Tube E22-9030 Ballast Weight Pin E22-4120...
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RotorWay International Exec 162F Maintenance Manual HOURLY SERVICE CHART EXEC 162F REFERENCE SECTION 18: PAINT PART NO. DESCRIPTION 500 1000 1500 2000 Paint INSPECT REPLACE...
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RotorWay International Exec 162F Maintenance Manual Rev. 1 10/01 HOURLY SERVICE CHART EXEC 162F REFERENCE SECTION 19: ROTOR HUB CONTINUED PART NO. DESCRIPTION 500 1000 1500 2000 E49-4100 Cyclic Mount Bearing E49-4110 Snap Ring, Cyclic Mount E49-3531 Snap Ring, Rotating Swash Plate...
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RotorWay International Exec 162F Maintenance Manual HOURLY SERVICE CHART EXEC 162F REFERENCE SECTION 20: DOORS PART NO. DESCRIPTION 500 1000 1500 2000 E41-7120 Door (Pilot) E41-7130 Door (Passenger) E41-7140 Door Stiffener E41-7150 Door Stiffener E41-3110 Door Hinge E41-3120 Body Hinge...
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RotorWay International Exec 162F Maintenance Manual Section 24: Grease Requirements Using the correct type of grease is essential to proper performance. The recommended grease to be used on the Exec 162F helicopter is Mystik JT-6 Multi-Purpose Hi-Temp Grease. Mystik JT-6 is a product of Cato Oil and Grease Company.
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