100 Hour Service

This has come up just about the time were retrofitting our ship
with a new tail boom and secondary so were doing it about 3 hours early.

We ordered our parts from Robin at RotorWay Monday and we received them Friday.

Looking into this box it sure doesn't look like $536.00 bucks does it lol.

Thanx for the favor Robin!

100 Hour Service Costs

-

E-34-1310

RH Large Radiator Hose

-

$     19.03

-

E-34-1320

LH Large Radiator Hose

-

$     15.40

-

E-34-1300

Water pump to
engine manifold hose

-

$     22.98

-

E-34-1151

Clear Over Flow Hose

-

$       5.06

20 ft

E-34-1350

¾ ID
Fire Resistant Heater Hose

$ 2.50

$     49.97

1

E34-5000

Thermostat

-

$     14.31

3

CC2835

ES Compleat PG
Fleet Guard Antifreeze

$ 8.84

$     26.52

6

CC2602B

 3 Way Fleet Guard
Coolant Test Strips

$ 1.27

$       8.00

1

DCA60-L

DCA4 LIQ Additive

-

$     5.55  

1

E-29-1131

Alternator
Water Pump Belt

-

$     16.96

1

E-31-1130
Gates 3VX-335

Upper Fan Drive Belt

-

$     15.93

1

E-31-1141
Napa 25-08383

Lower Fan Drive Belt

-

$     15.86

2

E-18-1150

“118 inch”
Forward
and center tail rotor belt

$ 64.87

$   129.74

1

E-18-1160

“112 inch”
Rear Tail Rotor belt

-

$     48.11

1

N/A

Compression Checker Tool

-

$     40.00

5 qts

Aeroshell
W15W50

Motor Oil

$   3.69

$     18.45

1

E28-1110-P

Oil Filter

-

$       4.42

1

E25-4630-P

Secondary Fuel Filter

-

$     26.89

1

E25-4740

12mm fuel filter crush washer

-

$        1.31

1

E25-4750

14mm fuel filter crush washer

-

$       1.39

8

E24-9740

Spark Plugs

$   3.21

$     25.68

4

A24-4018-P

Valve Cover O-Rings

$    .22

$         .88

1

-

Ballast Weight safty Clip

-

$         .49

2

E00-2800-P

New main Rotor Blade Bolts

9/16 X 4 1/4 NAS1309-54

$ 23.96

$     47.92

4

E00-3800-P

New main Rotor Blade
9/16 - 18 fiberlock Nuts
AN365-918A

$   2.54

$       2.54

4

E00-4800-P

New main Rotor Blade
Washers

$    .31

$       1.25

-

-

Freight for bolts nuts and washers

-

$     10.95

1

-

White touch up paint
for touching up misc items

-

$       4.00

2

cheverolet orange

Orange spray paint
for painting misc. parts

$   4.00

$       8.00

-

-

Freight on 100 hour service
parts from RotorWay

-

$     11.48

-

-

100 Hour Service Total

-

$    580.62

This is the total Dollars
it took to get us past our 100 hour service and back in the air.


Extra Parts we Purchased but didn't end up needing.

Either way we wanted to have them on hand
in the event that we needed them for this service or in the future

1

E49-6330

Rotor Head Shim Kit 3/4 pin size

-

$     59.57

2

E49-5131

Rotorhead Pin Snap Rings

$1.30

$       2.60

-

-

Sub Total

-

$    62.17

Out of pocket Project Grand Total

$  4,686.33

Last Update February 16th 2005

This is a few shots of the main oil line that runs from the bottom of the engine to the oil tank.

At first we thought they were to short but the new one worked just great.  Whats going on here is the old hoses are swelled up and the new ones aren't.  Even if these hoses look good they need to be changed out when they are supposed to because when they reach there limits they can and will rupture.

We haven't checked around to see but were thinking parts like these maybe rare or perhaps special application items which means they may not be big sellers out in the world.  We can probably beat RotorWays Prices on some of these hoses and belts but we have no way of knowing just how old and how these items were treated prior to us buying them from an outside source which is why we think staying with RotorWay is a better way to go.

We would feel better if RotorWay wouldn't sand some of the logos and part numbers off the belts because we feel it may damage the belts.

Done 1/23/05

I have been told this lower oil hose sometimes has issues.

What happens sometimes is it delaminates on the inside which either restricts or compleatly shuts off the oil flow on its way back to the oil cooler.

We first inspected the old hose for indications of that problem and then we cut it in half lenght wise and found no problems.

This one inside hose clamp on the top right of the engine really kicked my arse

until a light bulb came on in my head that said DUH dummy! all you have to do is rotate the flywheel until the hole is over the clamp.  After the enlighting moment it was easy to do lol.

Done 1/22/05

We had to put a slight twist on the hose or it would rub

on top of the tork link bolt, something that would rub a hole into the hose in no taim at all.

Done 1/22/05

In these pictures you can see where were getting a bit of blow by at the bottom of the right hand side of our engine between the cyclinder head and sleeve.

We've had this going on since about 50 hours or so.  It gets better after we tork the heads each 25 hours.

Sunday
January 23rd 05

We didn't reinstall about 2/3 of the fire sleeve on the RH side of the ship
we originally had which should make the ship a couple of pounds lighter.

Tom Smith at RotorWay told us we didn't need all that way back when we were still building our ship but we choose to go the safe route and protect any hose that was within 3 to 5 inches of the exaust pipes.  In all of our travels looking at other peoples ships we were about the only ones who got that wild with the stuff so were going to try it like this and see how it goes.

It wasn't much fun and took us 3 full working days but we finally finished up the water and oil lines today.

Done 1/23/05

All we have left on the cooling system hoses are the two that connect the radiator to the rest of the system which we can't do until after we install our new Pro-Drive 40mm Secondary Unit which if work is slow tomorrow will be our next task.

January 27, 2005

Today we finally hit the end of our Pro-Drive Secondary installation, Yeahhhhh!

After getting our radiator reinstalled today we checked out all the clamps on the coolant and oil hoses we changed out.  We also rechecked to make sure that all the hoses had proper clearances from things like the airframe and moving engine parts.

Next we added the Fleetguard ES premix antifreeze solution.  Our ship took just a bit over 2.5 gallons to fill it up once it was all said and done with all the air was purged out of the system.

This is the 3 tests we did with the test strips.

The readings on the strips time out after 75 seconds
so the colors in the picture aren't the same as the ones we got in the time period window of 45 to 75 seconds.

The first one is from an old test strip from a pack of 50 that expired in 2000 that we paid about 45 dollars for if I remember right, so for what we paid for them before I threw them away, I wanted to make sure they weren't any good.

Sure enough the reading from the first one compared to the second new test strip was totally different
so out goes the old and in comes the new lol.

The second test strip is from a new single pack test strip package
we bought today that expires in November, 2005, at a cost $1.27 each.

Reading

Levels

Outcome

Outcome

A

Freeze Point =

60% Glycol

-60 degree Fahrenhight

B

Molybdate =

450 Parts Per Million

Sends us to Row 3

C

Nitrite =

1600 Parts Per Million

Sends us to Row F

Combining steps B and C gave us
a reading of 2.5 on the chart

2.5 = The amount of SCA Units per gallon in our cooling system

We added about 1/4 bottle ( 4 oz. ) of DCA4
and ran the engine up to operating water and oil temperatures to be sure it was mixed.

 

This is a chart that come with the coolant test strips

The Third test strip and our final reading for the day of the coolant.

Reading

Levels

Outcome

Outcome

A

Freeze Point =

60% Glycol

-60 degree Fahrenhight

B

Molybdate =

300 Parts Per Million

Sends us to Row 2

C

Nitrite =

1600 Parts Per Million

Sends us to Row F

Combining steps B and C gave us

a reading of 2.2 on the chart

2.2 = The amount of SCA Units per gallon in our cooling system

We started out with a 2.5 reading and now have 2.2
which is still in the green zone but
we still have no idea if that's a good thing or a bad one until we find someone that can explain the chart a little better to us.

We added about 1/2 bottle ( 8oz. ) of DCA4

We'll see what it does next time after we run the engine again.

Your! on your! own! lol.

January 31st 2005

We got to do another test on our Fleetguard engine coolant.

After we ran the ships engine and letting it come up to tempreture and cycle the theromostate a few time we shut it down and took a sample of the coolent from the water pump air bleed port.

At this point we put the test strip into the test sample bottle for one second and then took it out and shook it off,
then we waited the required 45 seconds and within the following 30 seconds we compaired our test strip colors to the chart below


Combining steps B and C gave us

a reading of 2.8 on the chart

Reading

Levels

Outcome

Outcome

A

Freeze Point =

60% Glycol

-60 degree Fahrenhight

B

Molybdate =

600 Parts Per Million

Sends us to Row 4

C

Nitrite =

1600 Parts Per Million

Sends us to Row F

 
We started out with a 2.2 reading and now have 2.8 after adding 1/2 bottle of DCA4

2.8 = The amount of SCA Units per gallon in our cooling system

Done 1/31/05

YEAh!!!!!!!!!

We got the lower front tub back on the ship today.

It sure makes it look and feel like were finally getting someplace
not to mention it gets a few body parts off the floor of the trailer.

Done 1/28/05

This  beginning part of this starts out with the 25 Hour Service

because it's part of the 100 hour service

Service Air Filter

clean as necessary & inspect for damage.

Done 1/28/05


Grease Main Drive Pulley

refer to the specification section for procedure & for correct type & quantity of grease.

Measure & Adjust Valve Lash & Inspect Valve Train – also, if any initial measurement is in excess of .008”, inspect the lash cap for wear & repeat valve adjustment at one hour intervals until the lash stabilizes.  If repeated excess lash is encountered, all related valve train components should be inspected.

Inspect Cooling System – check entire system, including engine, for any sign of leakage.  Check the security of all hoses, and make sure all hose clamps are installed past the bead or flare on the end of the adjoining tube or fitting.  Re-tighten all hose clamps.  Check the hoses, making sure there is no interference with vibrating or rotating parts or any sign of heat damage.

Done 2/1/05

Inspect Oil System   

check entire system for any sign of leakage.  Check the security of all oil line connections.  Also, check the lines for proper clearance from heat sources and other parts.

Done 1/25/05

Inspect Fuel System

check the security of all fuel hoses & check for any signs of leakage on the entire system.

Inspect Exhaust System – check entire exhaust system for cracks & leaks.  Proper fit of each exhaust manifold to its mating port is important.  Proper fit can be verified while idling the engine and positioning your finger approximately ½” away from the exhaust ports.  Test all the way around the circumference of each port for any escaping gases.  If no turbulence is felt within the proximity, the system will be sufficiently leak free at full RPM.  Also check the security & condition of all exhaust related shielding.

Done 1/28/05

Opps!,

We almost forgot to install these new fuel line vent crossover hoses

Rotorway sent us a different type of hose then what we originally had.

It's alot heaver and writtin on it, it states that it's not for use on fuel injected systems.
We called and talked to Mark at RotorWay and he said this is what they are using now.

Done 2/2/05

Inspect Ignition System

check all wiring, including spark plug wires, for proper mounting & condition.  Replace any wire that shows any sign of damage.

Done 1/28/05

Re-torque Bolts on exhaust manifold flanges

Done 2/1/05

Re-torque Bolts on  intake manifolds

Done 2/1/05

 

Re-torque Bolts on waterjacket elbows.

Done 1/31/05

Inspect Throttle Control

check return spring & linkage for proper adjustment & freedom of movement.  Check cable ends & cable for wear.

This is something we try to keep an eye on since a ship at the RotorWay Factory crashed

because of a problem they had with it.  If that stop on the bottom gets bent down to far and the pilots throttle is rolled of the passengers throttle control will become locked into position and the passengers side can't apply throttle.  What I understand an instructor and a student were practicing autorotations and the student rolled the throttle off so far off it locked up the CFI's throttle control and they hit the ground like a box of rocks.  It may be that the student just applyed so much pressure the bracket it bent, it wouldn't take much to do it, or the throttle may have just been improperly setup in the first place.

Done 1/28/05

Throttle Range on FADEC ----------------------------------checked 3/12/05

Collective Full Down in bottom of pocket = 0 to 75%
Collective Full Up = 18.7% to 100%

Change Oil & Filter

change oil & filter every six months even if 25 hours of operation has not yet occurred.

Done 1/25/05

-----------------------------------------------------------------

Engine oil Level -----------------------------------------------check on 3/12/05

1/8 over full mark on dipstick

Oil tank level

Lateral..............pass side high 0.4
For and Aft...................front hight 6.6

100 Hour Service


Engine

Replace spark plugs
Clean area around plugs first
Gaped plugs to .044
Coat threads with antiseize
Torque plugs to 10 ft. lbs.

 
We think our plugs are covered in soot like this because we were shuting it down by closing off the main fuel cutoff so we do our fuel system maintenance.

We couldn't torque the spark plugs to the 10 foot pounds
because there isn't room to for our torque wrench to access them

Done 2/1/05


Cylinder head service

Retorque cylinder leads (loosen then tighten bolts)

Done 1/28/05

Measure & Adjust Valve Lash & Inspect Valve Train

Also, if any initial measurement is in excess of .008", inspect the lash cap for wear & repeat valve adjustment at one hour intervals until the lash stabilizes.  If repeated excess lash is encountered, all related valve train components should be inspected.

Check spring retainer, check gap on spring keeper & check valve guide for play.

Date 2/1/05

97.0 Hours

Tight = T

Loose =L

Measure Exhaust Valve
Was

Valve Guide
Play

Measure Intake Valve
Was

Lash Cap

Adjusted Exhaust Valve
To

Lash Cap

Adjusted
Intake Valve
To

Cylinder 1

.005T

ok

.005

ok

.005T

ok

.005

Cylinder 2

.005T

ok

.007

ok

.005T

ok

 
.005T

Cylinder 3

.005

ok