RotorWay Exec 162F User manual

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

RotorWay International
Exec 162F Maintenance Manual
2
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
(and its agents, servants, employees, contractors, successors, and assigns) makes no warranties express
or implied regarding the clarity or correctness of the plans, ease of construction or operation nor the
safety of this aircraft or any part thereof. Furthermore, buyer (and his heirs, administrators and assigns)
releases and holds said seller (and its agents, servants, employees, contractors, successors, and assigns)
harmless from any and all liability, damages, and causes of action which may be incurred by buyer or
any third party as a result of the purchase, use, construction and/or operation of said aircraft (or any part
thereof) or plans for same. Buyer assumes all risk and responsibility relative to the construction and/or
operation of said aircraft. Seller admits no liability by publication of this warning.

RotorWay International
Exec 162F Maintenance Manual
3
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. The Service Reference
directs the builder to the procedure to be followed for each inspection. In most cases, a Service Note (found on the
following page), a footnote, or a Construction Manual section will be referenced.
Many parts listed are given a specific lifetime to be replaced as specified in the Inspection Charts. In order to extend the
lifetime, these parts could require extensive inspection.Visual inspection of certain items may show the part to be serviceable,
but they may have a fatigue life that requires their replacement. This policy provides each part with a safety factor to
enable its replacement before failure.
The R.C.O. time represents the lifetime of a component as recommended by the manufacturer. A phrase called “on
condition” or O.C. is also utilized in this manual. This means the part should be monitored and replaced if suspect prior to
the R.C.O. time of the component. Common examples of parts that qualify for O.C. replacement are bearings and belts.
When these parts are not correctly installed or not cleaned properly, they may fail prematurely.
Even though close quality control procedures are adhered to, a part may fail prematurely due to a variety of reasons.
Incorrect manufacturing procedures, builder errors, environmental conditions and storage conditions may all contribute.
Because premature failures can happen, it is important to monitor all major components during pre- and post-flight
inspections.
Clearances and tolerances for proper inspection will be noted in the section, if applicable, for part replacement. Other data
such as crankshaft tolerances, rod clearance and cam dwell, etc., is proprietary information. If the need arises for the
builder to have this information, a technical representative from the factory should be contacted.

RotorWay International
Exec 162F Maintenance Manual
4

RotorWay International
Exec 162F Maintenance Manual
5
Rev. 1 10/01
CONTENTS
SECTION 1: Airframe Page 7
Airframe, landing gear, engine mount rubber ring, skids, bolts.
SECTION 2: Tail Boom Page 9
Tail boom, vertical trim fin, horizontal trim fin, vertical trim fin bracket, bolts.
SECTION 3: Body Page 11
Body panels, eyebrow windows, windscreen, upholstery, skid pants, cyclic boot, floor pan/instrument pod, seat bulkhead,
cabin comfort push/pull cable.
SECTION 4: Tail Rotor Drive Page 13
Idler pulley mounting scissors, idler pulley bearing assembly, idler pulley, tail rotor belts.
SECTION 5: Tail Rotor Page 15
FS3 PP bearing, snap ring, carriage slider assembly, carriage slider bearing, rod ends, tail rotor blade assembly, pitch
actuator arm pivot casting, pitch horns, slider to actuator arm clevis, tail rotor shaft, bearing mounting plate slider rail, tail
rotor pulley, thrust bearing assembly, alignment bearing assembly.
SECTION 6: Control Assemblies Page 17
Directional controls: cross shaft bushing, scissor mount bushing, rod ends, directional control cable. Cyclic controls:
Cross shaft bushing, nylon bushing, rod ends, cyclic control cables. Collective controls: cross shaft bushing, rod ends,
collective rod end plug, collective control rod. Throttle controls: pilot throttle shaft, transfer shaft, throttle shaft weldment,
rod ends, throttle cable assembly.
SECTION 7: Oil System Page 21
Oil sump/heat exchanger, oil hoses, oil filter.
SECTION 8: Cooling System Page 23
Radiator, radiator cap, hoses, water pump assembly, water pump pulley, water pump/alternator belt, thermostat.
SECTION 9: Engine and Exhaust System Page 25
Exhaust gasket, heat wrap, muffler/tailpipe, header weldment, exhaust knuckle spring, heat shield, rod end, torque link
rubber insert, torque link, RI 162F engine, spark plug wires, spark plug wire separator, spark plugs, air filter, engine pulley.
SECTION 10: Drive Train Page 27
Primary: main sprocket, sprocket hub, bolts, thin locknut, hose clamp, upper engine mount clevis, upper engine mount
cup. Secondary: secondary pulley assembly, upper bearing assembly, secondary shaft, lower bearing, main drive belts,
high temp fan, snap rings, fan pulley assembly, fan pulley bearing, retainer plate. Oil bath: top rear cover, lower oil bath
pan, top front cover, rear oil seal, tension spring, rain shield. Chain: drive chain with link. Clutch idler assembly: idler pulley
assembly, idler pulley bearing, rod ends, idler spring, clutch tube weldment, pulley arm weldment, clutch arm casting,
bolts.
SECTION 11: Fuel System Page 31
Fuel cap, hoses, fuel shut-off valve cable, fuel pump, fuel filter, fuel pressure regulator, fuel shut-off valve/filter, fuel tanks,
fuel gauge, fuel gauge sending unit.
SECTION 12: Fan Drive Page 33
Bearings, belts, pulleys, shaft.
SECTION 13: Main Rotor Blades Page 35
Retention strap assembly, rotor blades, 9/16 bolt and nut, elastomeric thrust bearings, tip weight, aligner block assembly,
pitch horn clevis, pitch horns, bolts, aligner block bearings.

RotorWay International
Exec 162F Maintenance Manual
6
Rev. 2 6/04
SECTION 14: Electrical System Page 37
Battery, digital display monitor, engine control unit (ECU), ignition module, man/baro pressure sensor, 9 pin cable, fuse
holder, toggle switch, fuses, battery terminal eyelet, starter relay, push button switch, LED indicator light, airframe wiring
harness, overhead wiring harness, instrument wiring harness, FADEC wiring harness, voltage regulator, alternator assembly.
SECTION 15: Instrumentation Page 39
Hour meter, water temperature gauge, oil temperature gauge, oil pressure gauge and sender, volt meter, dual engine/
rotor tach, altimeter, vertical speed indicator, air speed indicator, compass, manifold pressure gauge, full range tach, fuel
pressure gauge, fuel pressure sender.
SECTION 16: Ground Handling Wheels Page 41
Wheel and tire, tire track.
SECTION 17: Ballast Weight Page 43
Support tube weldment, mount tube weldment, ballast weight tube, ballast weight pin, safety clip.
SECTION 18: Paint Page 45
Paint.
SECTION 19: Rotor Hub Page 47
Rotor hub assembly: rotor hub plate, teeter block assembly, teeter block bearing, delrin shim, stainless steel shim, bolts,
main rotor drive pin, thin washer, snap rings, thrust blocks, thrust washer, thrust block alignment bearing, thrust block
liner, rod ends, pitch link, set screws, pitch pins, main rotor shaft, grease fitting, dust cap. Swash plate assembly: Non-
rotating swash plate, swash plate bearing, snap rings, rotating swash plate, slider ball adjustment collar, cyclic cable
mount, cyclic mount bearing, slider ball, spherical bushing, slider ball clamp, slider ball O-ring, swash plate scissor,
scissor clevis, rod ends, nylon scissor bushing, collective actuator fork, collective scissor, collective scissor mount, control
“T”, counter balance, rod end spacer, spring bracket, tension spring, delrin washer, scissor spacer, dust boot, rubber shaft
protector. Main shaft assembly: main thrust bearing, main bearing flange, main shaft safety spacer, lower main shaft
bearing weldment.
Rotor hub shimming procedures, Page 51
Slider ball adjustment collar, Page 60
SECTION 20: Doors Page 63
Doors, door stiffener, door hinge, body hinge, bolts, vents.
SECTION 21: Torque Requirements Page 65
Torque requirements for hardware used on the helicopter.
SECTION 22: Inspection Guide for Hard Landings, Tail Rotor Strike, or Roll Overs Page 67
SECTION 23: Hourly Service Charts Page 69
SECTION 24: Grease Requirements Page 91

RotorWay International
Exec 162F Maintenance Manual
7
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. Where tubing requires bending, a mandrel bender is used and tubes are scribed, cut, and coped to a tolerance of
.062 inch. The oxygen acetylene gas method of welding is used and all weldments are air cooled to retain the original
strength of the alloy.
Reference prints: E10-2000, E13-2000
SERVICE NOTES:
1. Remove all inspection panels including the two upper panels that are held on by nut plates. Using a flashlight or a
suitable source of illumination and a mirror, inspect for cracks on the round and square tubes, paying close attention
to the welded areas. If a small hairline crack appears, remove the paint from the airframe at that position to further
verify the crack. It may be necessary to apply a pressure or load in such a manner as to help open up the crack to
verify. If close inspection verifies the crack, contact the factory for further assistance. If verification is negative, repaint
the suspect area and reassemble.
2. Remove skid pants. Inspect the rear landing gear, gear gusset, the area 6 inches above and below the landing gear
step, and the rear landing gear attachment bracket.These are critical inspection areas. Approximately 80% of the total
aircraft weight is transferred on the rear gear. After inspection, reinstall the skid pants.
The rear landing gear may spread with age or after a hard landing. The gear should be replaced if the distance
between rear landing gear shoes, measured inside, is greater than 62 inches.
3. Removal of the two rear lower fiberglass body panels (part no. E32-7130 and E32-7140) will allow you access for a
visual inspection of the Engine Mount Rubber Ring, part no. E13-3121. This part must be kept clean from oil and
grease. Allowing the part to become contaminated will deteriorate the rubber over a short period of time, changing the
alignment of the secondary to engine height. If in question, check secondary and engine alignment.The tolerance is
plus or minus 1/8". Refer to the engine installation section of the Construction Manual for further assistance.
4. Because the helicopter can be operated in many different terrains and will experience a variety of landing conditions,
the landing gear skid will remain an on-condition inspection item. Lift the front skid off the ground approximately 10
inches and block it up with a 2x4 board. Look for a flat wear area across the bottom of the skid. If a flat area appears
and measures more than 1/2" in width, replace the skid tube. Keeping the helicopter in the upright condition, remove
the two (2) front skid shoe bolts (part no. E00-2414) on the right front skid shoe and drop the skid 3" below the shoe.
This will allow an inspection on top of the skid which is normally hidden by the shoe. Check the holes for an oblong
condition and for any cracks in the skid tube. Also, inspect the bolts for wear prior to reinstalling the skid on the landing
gear shoe.
INSPECTION CHART
PART NO.
E10-1001 EXEC 162F Airframe 100 HR 2000 HR/OC 1-1
E00-2415 AN4-24A (1/4 x 2-1/2) Bolt 100 HR 2000 HR/OC Torque
E00-2601 AN6-10A (3/8 x 1) Bolt 100 HR 2000 HR/OC Torque
E11-9010 Rear Landing Gear 100 HR 2000 HR/OC 1-2
E13-3121 Engine Mount Rubber Ring 50 HR 2000 HR/OC 1-3
E00-2507 AN5-10A (5/16 x 1) Bolt 100 HR 2000 HR/OC Torque
E11-3130 Landing Gear Skid (Pilot) 500 HR 2000 HR/OC 1-4
E11-3131 Landing Gear Skid (Passenger) 500 HR 2000 HR/OC 1-4
DESCRIPTION
SERVICE
REFERENCE
INSPECTION
INTERVAL R.C.O.

RotorWay International
Exec 162F Maintenance Manual
8

RotorWay International
Exec 162F Maintenance Manual
9
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.
The material used for the tail boom skin is aircraft industry standard, grade T-3 aluminum and is .025 thick. The sheet is
rolled in a cone shape to provide structural integrity.
Reference prints: E09-2000, E09-2001
SERVICE NOTES:
1. The tail boom is subject to most of its stress during take off and landing.The skin and its associated parts are subject
to high frequency vibrations that can cause stress cracks and generate loose rivets and bolts.
A. Stress cracks: Upon inspection of the tail boom skin, if you find that stress cracks have started, drill a small hole
at the very end of the crack. This hole will stop any further migration of the crack. The size of the drilled hole will
depend on the severity of the crack.
B. Loose rivets: Using the appropriate sized drill bit (depending upon the size and head diameter of the rivet), drill
out the head of the rivet by rotating the drill in an elliptical manner. This will remove the head without drilling
through the rivet hole. Then use a rivet shank or a small punch to knock out the remainder of the rivet. Clean the
area and deburr the hole if necessary. Replace the rivet using the original type and size.
2. Inspect the Vertical Fin bracket at bend areas for cracks. Also inspect the mounting holes outward to the edge of the
bracket.
INSPECTION CHART
PART NO.
E09-9000 Tail Boom 100 HR 2000 HR/OC 2-1
E09-9010 Vertical Trim Fin 100 HR 2000 HR/OC Rivet inspection
E09-9021 Horizontal Trim Fins 100 HR 2000 HR/OC Rivet inspection
E09-3252 Vertical Trim Fin Bracket 100 HR 2000 HR 2-2
E00-2300 AN3-4A (3/16 x 1/2) Bolt 50 HR 2000 HR Torque
E00-2301 AN3-5A (3/16 x 5/8) Bolt 100 HR 2000 HR Torque
E00-2303 AN3-6A (3/16 x 3/4) Bolt 50 HR 2000 HR Torque
E00-2305 AN3-11A (3/16 x 1-1/8) Bolt 100 HR 2000 HR Torque
E00-2306 AN3-12A (3/16 x 1-1/4) Bolt 50 HR 2000 HR Torque
E00-2307 AN3-13A (3/16 x 1-3/8) Bolt 50 HR 2000 HR Torque
E00-2308 AN3-15A (3/16 x 1-5/8) Bolt 50 HR 2000 HR Torque
E00-2309 AN3-17A (3/16 x 1-7/8) Bolt 100 HR 2000 HR Torque
E00-2414 AN4-23A (1/4 x 2-3/8) Bolt 100 HR 2000 HR Torque
E00-2432 AN4-12A (1/4 x 1-1/4) Bolt 50 HR 2000 HR Torque
SERVICE
REFERENCE
INSPECTION
INTERVAL R.C.O.

RotorWay International
Exec 162F Maintenance Manual
10

RotorWay International
Exec 162F Maintenance Manual
11
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. A gel coat is applied to the mold prior to the
fiberglass lay-up so that the parts are ready for light sanding and paint.
Reference print: E32-2000
SERVICE NOTES:
1. Care of the body panels is very minimum. However, two factors which may damage them are heat and prolonged
exposure to gas and oil from lack of cleaning. When doing pre- and post-flight inspections, avoid exposing any
removed panels to excess heat or direct sunlight. Stand the panels upright and avoid placing them in an abnormal
position. Prolonged exposure to excessive heat or sunlight in an abnormal position could result in a deformed panel.
Fiberglass is resistant to most chemicals; however, panels that are exposed to gas and oil over long periods of time
will eventually be weakened. Wipe off oil and gas with a dry cloth. Then clean off any remaining residue using a cloth
moistened with acetone. Use CAUTION when working with acetone because of its high flammability.
Check to make sure that all metal parts protruding through the fiberglass have a minimum of 1/4" clearance. If the
clearance requires enlarging, this process can be done by using a round or flat file or an air or electric grinder.
2. Care and cleaning of Plexiglass parts:
A. Cleaning: A mild soap and water solution on a cloth can be used to remove dirt and fingerprints. A plastic cleaner
such as Meguiar’s #2 can be used to remove overspray and oxidation and #9 should be used to preserve and
protect the windscreen and to bring up a high gloss.
INSPECTION CHART
PART NO.
Body 100 HR OC 3-1
E32-7210 Eyebrow Window, Pilot 100 HR OC 3-2
E32-7220 Eyebrow Window, Passenger 100 HR OC 3-2
E32-7231 Windscreen 100 HR OC 3-2
E32-1301 Seat Upholstery 100 HR OC 3-3
Skid Pants 100 HR OC 3-4
E32-1111 Cyclic Boot 100 HR OC
E32-3131 Floor Pan/Instrument Pod 100 HR OC
E32-6111 Seat Bulkhead 100 HR OC
E32-7102 Bottom Tub 100 HR OC
E32-7111 Fuselage (Right Front) 100 HR OC
E32-7113 Fuselage (Right Rear) 100 HR OC
E32-7122 Fuselage (Left Rear) 100 HR OC
E32-7123 Fuselage (Left Front) 100 HR OC
E32-7130 Fuselage (Lower Right) 100 HR OC
E32-7140 Fuselage (Lower Left) 100 HR OC
E32-7152 Doghouse (Front) 100 HR OC
E32-7160 Bracing Panel 100 HR OC
E32-7170 Bracing Panel 100 HR OC
E32-7180 Roof Panel 100 HR OC
E32-7272 Doghouse (Rear) 100 HR OC
E54-4010 Push/Pull Cable 100 HR OC Oil (20 W)
DESCRIPTION
SERVICE
REFERENCE
INSPECTION
INTERVAL R.C.O.

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. If a stress crack appears, stop drill the crack with the appropriate
size drill bit.
C. If a cover is used while trailering, make sure the cover has a soft inside lining and fits tight enough to the body to
avoid flapping.
3. Use any commercially available upholstery cleaner on the seats or cabin interior if they become soiled. Carefully read
the instructions on the cleaner to obtain desirable results. This will help prevent any shrinkage from occurring.
4. Check to make sure that the skid pants do not chafe against the body tub or the landing gear. If contact is present, file
the fiberglass to make clearance between the two parts.
12

RotorWay International
Exec 162F Maintenance Manual
13
Rev. 1 7/98
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.
Reference print: E09-2000
SERVICE NOTES:
1. Remove the two bolts (part no. E00-2405) that attach the idler pulley assembly to the tail boom and slide the idler
pulley mount scissors down and out of the tail boom. (See note 2 below for inspection of idler pulley assembly.) Place
a small amount of grease on each of the mating surfaces and reinstall the pulley in its original position. Tighten the
nuts on the bolts only enough to hold the part firmly. The part should not swing loosely but require slight pressure to
move it. (Refer to Construction Manual.)
2. Tail Rotor Idler Pulley Assembly (part no. E18-2012)
A. Remove the pulley by removing bolt part no. E00-2604.
B. Remove two (2) snap rings.
C. Heat the pulley in an oven or other appropriate means to 225-275 degrees F. CAUTION: Do not exceed 300
degrees F or the heat treatment of the pulley will be affected.
D. Using appropriate tools, fixtures, and presses, press out the old bearing.
E. Let the pulley air cool, then clean the inner mating service with acetone.
F. Clean the outer surface of the bearing with acetone and position the bearing ready for reinstallation.
G. Apply a thin even film of Loctite #609 to the outer surface of the bearing only. (Do not use your fingers.)
H. Install one snap ring.
I. Heat the pulley to 225-275 degrees and drop the bearing in place. If a press is necessary, use light pressure to
insure contact of the bearing to the snap ring. (When using a press, press only on the outer race of the bearing
and not the inner race.) Wipe off remaining Loctite.
J. Install the second snap ring and let the assembly cool.
K. Check to see that both snap rings have seated completely and that there is no play between the bearing and the
pulley.
L. Install the pulley, make sure the spacers are in their proper place and torque the bolt.
M. Rotate the pulley on its new bearing and check the feel with your fingers for smoothness and ease of rotation.
3. Inspect for wear and anodizing on the pulley. Also inspect for cables and wires that may have shifted or come loose in
the tail boom, allowing them to rub on the pulley.
4. Visually inspect and check tension of the tail rotor drive belts at every pre-flight and post-flight inspection. Detailed
procedures regarding proper installation, tension and maintenance of these belts are given in the Flight Manual and
in Section 25 of the Construction Manual (Rigging Procedures). Thoroughly inspect the condition of the belts every
100 hours.
Replace the tail rotor drive belts at 250 hours of operation, or at 2 years, or on condition, whichever comes first. Shelf
life, or time before entering service, is not included if the belts have not been exposed to the environment and have not
been affected by aging. Conditional replacement includes damage resulting from excessive slipping, oil absorption,
cracking, glazing, abnormal wear, or any other damage.
INSPECTION CHART
PART NO.
E18-6130 Idler Pulley Mounting Scissors 250 HR 2000 HR 4-1
E18-1131 Idler Pulley Bearing Assembly 250 HR 250 HR/OC 4-2
E18-2012 Tail Rotor Idler Pulley 100 HR 2000 HR/OC 4-3
E18-1150 Tail Rotor Belt Pre/post flight 250 HR/OC or 2 yrs 4-4
E18-1160 Tail Rotor Belt Pre/post flight 250 HR/OC or 2 yrs 4-4
DESCRIPTION
SERVICE
REFERENCE
INSPECTION
INTERVAL R.C.O.

RotorWay International
Exec 162F Maintenance Manual
14

RotorWay International
Exec 162F Maintenance Manual
15
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.
Note: Refer to the Construction Manual for replacement details of these components.
Reference prints: E17-2000, E17-2001
SERVICE NOTES:
1. Remove bolt (part no. E00-2604) from the tail rotor barrel. Using a knife or a tool with a sharp edge, pry under the lip
of the bearing (part no. E17-1260) removing the bearing from the barrel. Replace with new bearings and insert the
bolt, tightening it just enough so that the head of the bolt can be rotated slightly with your fingers. Check end play by
using your hand and fingers, pushing the barrel from side to side to confirm proper end play.
2. Use the following procedure to remove tail rotor blades (part no. E17-6000) and pitch pins (part no. E17-6173):
A. First, mark each blade and pitch horn assembly as A and B. Indicate identity on the tail rotor barrel so reassembly
will be the same. This will maintain tail rotor balance.
B. Remove the two bolts that hold the blade to the pitch pin (part no. E00-2305 and E00-2308).
C. Carefully grasp the tail rotor blade and barrel with your hand and rotate while pulling outward.
D. Remove the snap rings and deburr the snap ring hole if needed. CAUTION: Be careful while doing this procedure
not to mark or scratch the inner surface of the tail rotor barrel.
E. Grasp the pitch pin and pull it out of the barrel. It may be necessary to insert a bolt in the tail rotor pin to lightly tap
on for removal. NOTE: A slide hammer may be fabricated to facilitate the removal of the pitch pin. See drawing on
the next page.
F. After removal of the pitch pin, remove the alignment bearing assembly (part no. E17-1270) and the thrust bearing
assembly (part no. E17-1280). Immerse the parts in a solvent to clean and remove the grease. After inspection of
parts, reassemble according to original procedures as outlined in the Construction Manual and on prints E17-
2000 and E17-2001.
NOTE: When changing out the tail rotor blades, refer to the tail rotor balancing procedures in the Construction Manual.
INSPECTION CHART
PART NO.
E17-1260 FS3 PP Bearing 100 HR 500 HR/OC 5-1
E17-1290 Snap Ring 100 HR 500 HR
E00-2604 AN6-24A (3/8 x 2-1/2) Bolt 100 HR 500 HR/OC
E17-6126 Carriage Slider Assembly 25 HR 1000 HR/OC 5-5
E17-1300 Carriage Slider Bearing 100 HR 500 HR/OC
E17-1210 Rod End 5/16 Teflon 100 HR 1000 HR/OC
E17-6000 Tail Rotor Blade Assembly 100 HR 500 HR/OC 5-2
E17-5120 Pitch Actuator Arm Pivot Casting 100 HR 2000 HR 5-3
E17-1340 Bearing Assembly 100 HR 250 HR/OC
E17-5110 Pitch Horn 100 HR 500 HR
E17-9010 Slider/Actuator Arm Clevis 100 HR 2000 HR
E17-6150 Tail Rotor Shaft 100 HR 2000 HR/OC
E17-1360 Bearing Plate Slider Rail 100 HR 2000 HR
E17-5101 Tail Rotor Pulley 100 HR 2000 HR/OC
E16-1200 Female Rod End 100 HR 1000 HR/OC
E17-1270 Alignment Bearing Assembly 50 HR 500 HR/OC 5-4
E17-1280 Thrust Bearing Assembly 50 HR 500 HR/OC 5-4
E17-6100 Tail Rotor Barrel 50 HR 2000 HR/OC 5-4
DESCRIPTION
SERVICE
REFERENCE
INSPECTION
INTERVAL R.C.O.

RotorWay International
Exec 162F Maintenance Manual
16
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.
4. Every 50 hours, add grease to the fitting on the tail rotor barrel until the grease comes out near the pitch horns, and
wipe off excess. Drill a 3/16 inch hole in each blade tip cap so that grease thrown out by centrifugal force will not build
up inside the blade.
5. Slowly inject one shot of Mystik JT-6 grease while moving the slider back and forth to spread the grease evenly. Add
grease again every 25 hours of operation or as needed.

RotorWay International
Exec 162F Maintenance Manual
17
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. Cyclic Controls
C. Collective Controls
D. Throttle Controls
Coordinated inputs of these controls allow the pilot to maintain control of the helicopter throughout all maneuvers.
Reference prints: E14-2000, E15-2000, E16-2000, E17-2000, E17-2001, E49-2002
SERVICE NOTES:
1. Remove the cross shaft bushing (part no. E16-6131) by clipping the safety wire from the bolt (part no. E00-2501) and
then removing the bolt. Drill out the rivets that attach the bushing to the bracket on the airframe. Lift up on the end of
the foot pedal cross shaft (part no. E16-3101) just enough to remove the cross shaft bushing. Clean the bushing,
apply a small amount of grease and reassemble. Re-torque and safety wire the bolt, and pop rivet the bushing to the
bracket. Perform this procedure for both pilot and passenger sides.
2. Remove the scissor mount bushing (part no. E16-6130) by removing bolt (part no. E16-2406). Lower the bushing
away from the scissor beam (part no. E16-3120). Clean, grease lightly, and reassemble. Check clearance between
head of bolt (part no. E16-2406) and front airframe tube. There should be a minimum of 1/16" clearance. If proper
clearance cannot be obtained, shim under nylon scissor beam pivot bushing (part no. E16-6120) to achieve clearance.
INSPECTION CHART
PART NO.
Directional Control
E16-6131 Cross Shaft Bushing 1000 HR 2000 HR 6-1
E16-6130 Scissor Mount Bushing 1000 HR 2000 HR 6-2
E16-1200 3/16" Female Rod End 100 HR 1000 HR/OC 6-3
E16-1130 1/4" Male Rod End 100 HR 1000 HR/OC 6-4
E16-1140 1/4" Female Rod End 100 HR 1000 HR/OC 6-4
E16-1212 Directional Control Cable 100 HR 2000 HR/OC 6-5
Cyclic Control
E14-6131 Cross Shaft Bushing 1000 HR 2000 HR 6-6
E14-1241 Nylon Bushing 1000 HR 2000 HR 6-7
E14-1150 5/16" Male Rod End 100 HR 2000 HR/OC 6-8
E14-1211 Cyclic Control Cable 100 HR 2000 HR/OC 6-9
E14-1221 Cyclic Control Cable 100 HR 2000 HR/OC 6-9
Collective Control
E15-6131 Cross Shaft Mount Bushing 1000 HR 2000 HR 6-10
E15-1230 5/16" Male Rod End 100 HR 2000 HR/OC 6-11
E15-6130 Collective Rod End Plug 100 HR 2000 HR/OC
E49-1400 Collective Control Rod 100 HR 2000 HR/OC
Throttle Control
E15-3150 Pilot Throttle Shaft 1000 HR 2000 HR 6-12
E15-3170 Transfer Shaft 1000 HR 2000 HR 6-13
E15-9021 Throttle Shaft Weldment 1000 HR 2000 HR 6-14
E15-1150 1/4" Male Rod End 100 HR 2000 HR/OC 6-15
E24-7531 Throttle Cable Assembly 100 HR 500 HR/OC
DESCRIPTION
SERVICE
REFERENCE
INSPECTION
INTERVAL R.C.O.

RotorWay International
Exec 162F Maintenance Manual
18
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. Refer to the Construction Manual for detailed procedures.
4. Remove bolts (part no. E00-2406) and remove both rod ends. Using calipers, measure and note the distance from
center to center. Reinstall the new rod end with the same measurement. Refer to the Construction Manual for detailed
procedures.
5. CAUTION: Under no conditions should any type of lubrication or oil be used on the sliding inner cable.
6. Grease the cross shaft pivot bushing. Refer to the Construction Manual for detailed procedures.
7. Remove bolt (part no. E00-2414) and the two large fender washers. Place a small amount of grease (Mystik JT-6) on
the bolt, bushing and mating surfaces. Reinstall the bolt and two fender washers.Tighten the bolt enough to hold firmly
while still allowing the cyclic clevis to move easily without any end play.
8. Remove bolt (part no. E00-2510) and pull the rod end away from clevis. Loosen the locking nut and on the rod end and
unscrew it, counting the number of turns. Install the new rod end with the same number of turns. Tighten locking nut
and install bolt. Refer to the cyclic control section and rigging procedures for the elastomeric rotor hub in the Construction
Manual to verify adjustments.
9. CAUTION: Under no conditions should any grease or lubricant be used on the sliding inner cable.
10. Cut safety wire and remove bolt (part no. E00-2501). Drill out the rivets that attach the bushing to the bracket. Lift the
collective control shaft (part no. E15-3120) enough to remove the cross shaft mounting bushing (part no. E15-6131).
Clean and lightly grease with Mystik JT-6 grease. Reassemble the bushing, position the collective control shaft in the
bracket and insert the bolt. Torque and safety wire the bolt, then pop rivet the bushing to the bracket.
11. Refer to prints E49-2002 and E15-2001.
A. Remove the bolt (part no. E00-2516) that holds the rod end to the collective actuator fork.
B. Remove the rod end spacer (part no. E49-1410) and spring bracket (part no. E49-1470). Relax spring tension.
C. Remove bolt (part no. E00-2514) from the “G” control arm. Remove the collective control rod (part no. E49-1400)
from the helicopter.
D. Measure and remove the old rod ends from the collective control rod, counting the number of turns it takes to
remove them.
E. Reinstall the new rod ends using the same number of turns as in step D, then confirm this position by measurement.
F. Reconnect the lower rod end first and torque the bolt.
G. Inspect the upper bolt (part no. E00-2516) then reassemble the spring bracket and rod end spacer and align the
hole in the rod end to the hole in the actuator fork.
H. Pull the spring assembly and insert the bolt. Reinstall the remaining rod end spacer and torque the bolt.
I. Reconfirm collective pitch setting by reviewing collective rigging procedures in the Construction Manual.
J. Make sure rod end lock nuts are firmly in place.
12. Remove bolt (part no. E00-2306). Remove “B” control arm (part no. E15-5110). Remove washer (part no. E00-4600)
and slide pilot throttle shaft (part no. E15-3150) out toward the front of the helicopter. Lightly grease the throttle shaft
where the nylon bushing makes contact on the shaft. Reassemble by inserting the throttle shaft through the bushing.
Replace the washer and “B” control arm in their respective positions. Reinstall the bolt in the control arm casting and
torque.
13. Remove bolt (part no. E00-2306). Remove both “B” control arm castings (part no. E15-5110), marking their position.
Remove washer (part no. E00-4600) and slide the transfer shaft (part no. E15-3170) out toward the front of the
helicopter. Lightly grease the transfer shaft where the nylon makes contact on the shaft. Reassemble by inserting the
transfer shaft back through the bushing the washer and both “B” control arm castings in their respective positions.
Insert bolts back through the castings and torque.

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.The part of the grip that extends past the throttle and onto the non-rotating part of the collective stick
will help act as a friction lock for the throttle. Removal of the throttle shaft is done by removing the bolt (part no. E00-
2306) and the “B” control arm castings (part no. E15-5110). Slide the throttle shaft completely out of the pilot collective
stick. Place a small amount of grease on the throttle shaft (part no. E15-3150) and also on the plastic bushings. Re-
install the throttle shaft back in the collective stick and rotate several times until the throttle moves freely. Finish
assembly.
15. Remove bolts (part no. E00-2407). Measure center of rod ends on Throttle Connector (part no. E15-3160). Loosen
lock nuts and count the number of turns to remove the rod ends(part no E15-1150). Install new rod ends using the
same number of turns and check center line measurement. Confirm throttle settings by referring back to the Construction
Manual.
19

RotorWay International
Exec 162F Maintenance Manual
20