HY SL! Helicopter A Textron Company Flight Controls and Hydraulics Training Academy COPYRIGHT 1998, 2003 Bel Helicopter Textron inc. A dhsion of Textron Inc. All Rohis Reserved For Training Purposes OnlyFLIGHT CONTROLS AND HYDRAULICS TABLE OF CONTENTS SUBJECT PAGE Main Rotor Controls 8-1 Cyclic 841 Collective 8.2 Tail Rotor 83 Control Column 83 ‘Swashpiate and Collective Lever 84 Dual Controls 84 Hydraulic System General 85 Hydraulic System Components 85 Hydraulic System Schematic 8-6 Cyclic and Collective Servo Actuators 87 Hydraulic System Check 88 Servicing 89 2090 Fgtt Cont nd Mystics 3 COPYRIGHT 1096, 203 Bol HelzoporToxton fe Fa etn Ine. ANRights Roverved For Training Purposes OnlFLIGHT CONTROLS and HYDRAULICS Main Rotor Controls The flight controls are mechanical linkages that are actuated by conventional controls and used to control flight attitude and direction. Both the cyclic (fore, aft, and lateral) and the collective controls incorporate hydraulic servo actuators. ‘The flight controls are routed beneath the pilot's and passenger seats aft to the center of the helicopter then up to the cabin roof through the control column that also serves as a primary cabin structure. Access panels on the aft side of the control column are provided for inspection of control components and maintenance accessibility. Dual controls are installed as an option to provide dual flight control capability either for ‘operations requiring a pilot and a copilot or for pilot training operations. Installation of dual contro's provides a collective stick, cyclic stick, and a tall rotor control pedal assembly for the copilot, Similar to the pilot controls in appearance and relative position, the copilot's controis provide all the major functions. Control feel for the copilot’s controls is the same as the pilot's controls. The copilot's controls are connected to the pilot's by means of the jackshaft, control tubes, and electrical wiring. Quick disconnects are provided for the collective stick and cyclic stick. Aluminum alloy control tubes are used throughout the collective, cyclic, and tail rotor controls. Some control tubes are fixed in length with bonded end fittings, while others may have adjustable fittings. Bellcranks, levers, and supports are used throughout the collective, cyclic, and tail rotor control systems. These parts transmit or control change movements in the particular system in which they are installed. Gyelic The cyclic controls consist of a control stick, torque tube, yoke, hydraulic servo actuators, control tubes, and bellcranks. Movement of the control stick is transmitted through linkage and hydraulic servo actuators to the swashplate, which actuates the rotating controls to the main rotor. Servo actuators are incorporated to minimize the effort required to move the controls and to reduce main rotor feedback forces. The cyclic stick extends upward and forward from the front of the pilot's seat. The torque tube conneets to the cyclic stick support, The cyclic system yoke extends aft from the cyclic stick support and torque tube. Movement of the cyclic stick is transmitted to the mixing lever by means of the yoke. at 20070 Fi Canto and Hotes 912008 ‘COPYRIGHT 1908 2000 et Heeler Teton ne Aisle of Tectron ne. All Rights Resecved For Tralning Purposes OnlyFLIGHT CONTROLS and HYDRAULICS This mixing lever transmits cyclic movement to the swashplate through mechanical linkage and servo actuators. A balance springis used in the system to minimize the cyclic stick mass imbalance forces. For helicopters with dual controls, the copilot's cyclic stick is installed in front of the copilot seat with all VFR control functions. A quick disconnect feature permits rapid removal of the stick. If the electrical connector is disconnected, an adapter must be installed to provide circuit continuity. A spring pin assembly is provided to ensure positive engagement of the stick. Collective The collective pitch controls consist of a collective stick, jackshaft, control tubes, bellcranks, and a hydraulic servo actuator. Movernent of the collective stick is transmitted by means of linkage and the servo actuator to the swashplate collective lever. Colective pitch control is transmitted to the main rotor controls by vertical movement of the swashplate. The servo actuator is mounted on a support, which is located on the cabin roof directly forward of the transmission, along with two servo actuators for the cyclic system. The collective stick is installed to the left of the pilot's seat, and it extends upward and forward through a flexible cover. The collective jackshaft provides 2 mounting point for the collective stick. An adjustable friction bearing mounted on the jackshatt allows the pilot to adjust the friction to his own requirements. A minimum friction adjustment clamp located at the left end |of the jackshaft ensures that the collective stick has a preset minimum friction. The collective trunnion and lever is installed between the collective jackshaft and control tube. It ties the collective controls to the mixing lever of the cyclic controls. When the collective stick is moved to change rotor pitch, the cyclic control servo actuators and linkage will move to maintain the swashplate in its relative plane. For helicopters with dual controls, the copilot collective stick is installed at the left of the copilot's seat with a fully functioning throttle control. A quick disconnect feature permits rapid removal of the copilot collective stick. A spring pin assembly Is provided for the collective stick to ensure positive engagement of the stick. B2 2068 FG Fgh Cots and Hicralics 3-4-2008 COPYRIGHT 1906, 2000 Bel HelopierTexoninc.” Adlision fToxtoninc. AI Rights Reser ror Training Purposes OnlyFLIGHT CONTROLS and HYDRAULICS Tall Rotor The tall rotor controls include the control pedal assembly, pedal adjuster, control tubes, belloranks, damper assembly, and a pitch control mechanism mounted through the tall rotor gearbox shaft. Moving the pedals causes pitch change in the tail rotor blades 10 offset the main rotor torque and to control the directional heading of the helicopter. The tail rotor control pedals mounted on the pilots compartment deck are connected under the center console to a belicrank pedal adjuster, which provides for manual agjustment of pedal position according to the pilot's needs. For helicopters with dual controls, the copilot's fully functional tail rotor control pedal assembly is installed ‘on the floor in front of the copilot's seat to provide a means for the copilot to control the tail rotor assembly. The control pedals are linked to the pilot's by means of contro! tubes and a bellcrank. For those helicopters ‘equipped with dual controls, the copilot’s pedals can be positioned as desired by means of the pedal adjuster. Connecting linkage consists of push-pull tubes, belicranks, levers, and supports that connect the pilot's tail rotor control pedals to the tail rotor pitch change mechanism. Tail rotor pitch control is accomplished by means of a bellcrank, rod, and lever assembly mounted on the tall rotor gearbox. This assembly actuates a contro! tube through the hollow tail rotor drive shaft to the crosshead and pitch links. Control Column The flight controls are routed beneath the pilot's and passenger seats aft to the vertical control column then up to the cabin roof. This control column also serves as a primary cabin support structure, Access panels on the aft side of the column, the bottom ofthe aircraft, and seat panels are provided forinspection of control components and maintenance accessibility. The cyclic controls are mixed with collective control through the mixing belicrank lever located at the base of the control column. 83 2000 POF Int Contoleondlyrmuice 31-2003 ‘COPYRIGHT 1008, 208 Bol Hep Taxon ne Atdvson of Textron Ine. All Rights Roservod For Training Purposes OnlyFLIGHT CONTROLS and HYDRAULICS ‘Swashplate and Collective Le ‘The main rotor controls consist of the swashplate and support assembly, sleeve drive link, and pitch links. The swashplate transfers cyclic control motions from the non-rotating to the rotating control system. The swashplate and support encircle the mast directly above the transmission. The swashplate mounts on a universal support (pivot sleeve or uniball) that permits it to move in any direction. Movement of the cyciic results in @ corresponding tit of the swashpiate and the main rotor. The collective lever and link assembly is mounted to the swashplate support assembly and transfers collective inputs to the lower swashplate. Movementof the collective pitch lever actuates the sleeve assembly that in tum raises or lowers the swashplate and transmits collective input to the main rotor. The swashplate drive assembly consists of a collar set, two idler links, and idler levers. The collar set is attached to the mast and the idler links are attached to the outer ring of the swashplate. This connects the upper swashplate to the mast, causing it to rotate with the mast. The pitch link assembly connects the pitch hom on the blade grips to the swashplate that transmits control input from both the collective and cyclic controls. Dual Controls Installation of dual controls provides a collective, cyclic, and a tail rotor control pedal assembly for the copilot. The copilot's controls are connected to the pilot's by means of the jackshaft, control tubes, and electrical wiring. Quick disconnects are provided for the collective and cyclic. The copilat's controls do not provide electrical cargo release, flight idle stop, throttle bezel, marking, starter switch, or landing Ps light controls. a4 2088 PG Fight Corot and Hyrasies 34-2008, ‘COPYRIGHT 1005, 09 HelcoterTexton we Aaon of Tann In. A Rigs Resteves er Training Purposes OnlyFLIGHT CONTROLS and HYDRAULICS Hydraulle System General The hydraulic system provides pressurized fluid to operate the cyclic and collective flight control servo actuators. Operation of the system is electrically controlled by means of the hydraulic system switch, When the hydraulic system solenoid valve is de-energized (switch ON), the pressurized hydraulic fluid flows to the three servo actuators. When it is energized (switch OFF), the pressurized hydraulic fluid flows to the reservoir and bypasses the three servo actuators, In case of a total electrical failure, the system is fail-safe ON. The cyclic and collective servo actuator support is installed on the cabin roof forward ofthe transmission. It serves as a mount for the three servo actuators and associated bell- cranks. The collective servo actuator is mounted in the center position and the two cyclic servo actuators are mounted on the outboard positions. 85 2008 FG Fight Conele anc yicauics 91-2000 COPYRIGHT 1908, 0 Bl Helcopor Txton ne Avion of Textron lo. Al Rights Reservas For Training Purposes OnlyFLIGHT CONTROLS and HYDRAULICS Hydraulic System Components The hydraulic pump and reservoir is mounted on and driven by the transmission. The hydraulic pump is driven by the transmission accessory drive. The pump is a gear type pump, pressure, is regulated by a bypass valve returning excess fluid to the Teservoir. The pump ‘is self-lubricating designed to operate continuously and provide arated discharge pressure of 600 + 25 PSI Hydraulic cooling is accomplished by ducting air from transmission oil cooler to the hydraulic reservoir. Fins on the sides of the reservoir dissipate heat from the fluid. Hydraulic Solenoid Valve - The hydraulic solenoid valve is mounted on the cabin roof forward of the hydraulic pump and reservoir. The valve is electrically closed and is controlled by the HYD CONT switch on the miscellaneous panel. The electrical circuit is protected by a circuit breaker on the overhead console. Because the valve must have electrical power to close, the system is roferred to as fail-safe ON. When the switch is turned off, hydraulic fluid bypasses the servos and returns to the hydraulic reservoir. A single hydraulic fiter is installed on a bracket on the forward right side of the cabin roof near the main transmission. This filter assembly contains a filter indicator that indicates _an impending clogged fier. The indicator consists of a red button mounted on the filler assembly housing. If the differential pressure across the filters 70£10 PSID the red button will rise. To prevent inaccurate indications of bypass, the indicator is locked out when the hydraulic fluid temperature is less than 35° F (2°C). Ifthe hydraulic fiuid temperature is more than 35° F (2°C) the indicator gives the correct indication of clogging. The filter is installed in the pressure line. The pressure filter assembly does not have bypass capability a6 ‘2086 Fight Conrote and Mydrasies 91-2008, ‘COPYRIGHT 1005, 209% Hoicopo Texto we. Aviso of Textron In, ARghts Reservas Fer Training Purposes OnlyFLIGHT CONTROLS and HYDRAULICS Cyclic and Collective Servo Actuators The cyclic and collective control servo actuator support is installed on the cabin roof. It serves as a mount for the servo actuators and associated bellcranks. The collective control servo actuator is mounted in the center position, and the two cyclic = servo actuators are mounted in the outboard positions. The cyclic and collective servo actuators reduce the operational loads of these flight control systems. An irreversible valve is incorporated in each servo valve. In case of loss of hydraulic pressure to a servo actuator, the plunger in the sequence valve is pushed up by the upper spring, which also holds the valve seat down. This action closes the hydraulicretum port and maintains irreversibility independent of hydraulic pressure. This provides safe control of the helicopter even though hydraulic power is lost. The sequence valve also serves to relieve thermal pressure build-up should this occur while the systemis inactive. ‘The sequence valve would normally be closed when system pressure is below 100 to 180 psi. If internal pressure builds up, the valve seat is pushed up compressing the upper spring. The poppet valve on the lower spring is prevented from following by the plunger. The differential relief valve serves to relieve pressure buildup that could occur from ‘excessive rotor loads. ACTUATOR EXTENDING ACTUATOR RETRACT &7 2068 PGF Contos andyjeraules 37-2003 ‘COPYRIGHT 106, 2008 Bat Helcaper Toni Ine Ardulnon of Tern Ine All Rights Rcvoe For Training Purposes OnlyFLIGHT CONTROLS and HYDRAULICS Preliminary Hydraulic Systems Check (Modified Excerpt from 206B-3 Flight Manuel) NOTE Uncommanded control movement or motoring with hydraulic system off may indicate hydraulic system malfunction. HYDRAULIC SYSTEM or CONTROL BOOST switch - OFF, then ON. Normal Hydraulic Systems Check NOTE ‘The Hydraulic Systems Check is to determine proper operation of the hydraulic actuators for each flight control system. |f abnormal forces, unequal forces, contro! binding or motoring are encountered, it may be an indication of a malfunction of a fight control actuator. Collective - Full down, friction removed. ROTOR RPM (Nr) - Set to 100%. HYDRAULIC SYSTEM or CONTROL BOOST switch - OFF. Cyclic — Centered, friction removed. Check normal operation of cyclic control by moving cyclic in an "X" pattern right forward to left aft, then left forward to right aft (approximately one inch). Center cyciic. Collective - Check for normal operations by increasing collective control slightly (1 to 2 inches). Repeat 2 to 3 times as required. Return to full down position. HYDRAULIC SYSTEM or CONTROL BOOST switch - ON. Cyclic and collective friction - Set as desired. a8 2068 PS Flot Conti and ysosies 31-2000 (COPYRIGHT 1968, 2703808 HeicoperTexton ie. Advi of Textan he. AlRights Reserves For Training Purposes.FLIGHT CONTROLS and HYDRAULICS Servicing Hydraulic fluids conforming to MIL-H-5606 (NATO H-515) and are approved for use in hydraulic flight control system and rotorbrake. Hydraulics Reservoir Capacity: 1.0 US. pint (0.5 liter). Hydraulic reservoir is located on top of fuselage, forward of transmission and under forward faring. A sight glass is provided to determine quantity of hydraulic fluid in reservoir. Service hydraulic system as follows: 4. Remove cap and fill reservoir until sight glass is full of hydraulic fluid. 2, Secure cap. 8-9 2000 POF Contolsandtyeauics 34-2000 COPYRIGHT 1008, 209 Bal Heel Toso tne Atavgon of Textron Ie, All Rights Reserved For Training Purposes Only