A Mechanic reports a Raven R-44 helicopter MM was unclear and did not specifically require spacers to be installed after excess play discrepancy at the main rotor swash plate had been removed.

Date: 2010-11 · Aircraft: Robinson R44 · Phase: ground

Anomalies: aircraft-equipment-problem-critical|deviation-discrepancy-procedural-maintenance

Synopsis

A Mechanic reports a Raven R-44 helicopter MM was unclear and did not specifically require spacers to be installed after excess play discrepancy at the main rotor swash plate had been removed.

Narrative

Before performing a 100-hour Inspection; it was brought to my attention that some bolts and bushings were worn on a Mai rotor swash plate. This was causing excess play in the swash plate. The parts had previously been ordered by another individual and I replaced the two bolts and four bushings. When I removed the bolts and bushings; I found no spacers installed. I did not install spacers when I installed the new bolts and bushings. I performed the measurements and found that I had the gaps required by the Maintenance Manual (MM) and it reduced the amount of play in the swash plate to within acceptable limits of the MM.I was [later] informed [by] the Operator; that the play in the swash plate was back; and that the bolt had worn about 1/4' inch through. The Operator first said that it was over-torqued. I responded by informing them that I used the torque in the MM. Then the Operator informed me that it is required to have a spacer per the manufacturer; regardless of whether it measures within tolerance.

NASA callback

Reporter stated a fork link attaches at the lower end to a dogbone fitting that is bolted to the swashplate. Part of the dogbone fitting is positioned between the fork link. A single bolt through the fork link and dogbone with bushings in between and spacer as needed for removing play. However the MM does not state to specifically install a spacer; even if play has been removed without the spacer installed. Reporter stated he had also advised the Flight School Operator there was a fair amount of corrosion on the fork link. He was told the play in the swashplate was removed the second time by replacing the dogbone; fork link; bolts; bushings and spacer.

Source: NASA Aviation Safety Reporting System (public domain). Reports are voluntary submissions and are not verified by NASA.