Robinson R-22 Returns After Governor Failure Maintenance

Feb 18, 2025

New from Helicopter Online Ground School (H.O.G.S.), creator Kenny Keller and owner Chris Nelson dive into the recent maintenance undertaken on the Robinson R-22 helicopter. They're excited about the return of this aircraft and its significance for their flight training endeavors. We’re going to break down everything discussed, from the maintenance details to some insightful tips about operating helicopters.

 

 

Understanding the Issue
Chris Nelson gets right into the heart of the problem: irregular RPM and throttle behavior encountered during a flight. Keller recounts how Chris Hauser and Joe experienced the issue while prepping for a CFI add-on check-ride. Spotting the erratic behavior in RPM and throttle was an unsettling experience, pushing them to practice flying with the governor off—a key skill every pilot needs but hopes never to use under duress.

Diagnosing the Problem
Maintenance technician Chris—one of the many "Chris’s" involved in the operation—identified that oil leaks around the magneto were causing the irregularities. This confirms the importance of instructing pilots to be proficient at flying without the governor. When the governor malfunctioned, knowing how to override it proved crucial to landing safely.

Maintenance Actions Taken
Chris shared that every 500 hours, Robinson helicopters require magneto inspections. Their R-22 had clocked 503 hours, just in time for a mandatory check. The magnetos were then serviced, rebuilt with new seals, points, and internal components. This overhaul ensures the aircraft’s operational efficiency for another 500 hours.

Additional Repairs
Apart from the magneto service, the R-22 received a minor fix on the co-pilot door, which had shown signs of wear. A doubler plate was installed to strengthen the door hinge, eliminating minor inconveniences like the door not fully sealing.

Importance of Regular Maintenance
Regular and proactive maintenance checks, such as the every-500-hour magneto service specified by Robinson, are crucial for the safety and longevity of any aircraft. Chris emphasized that while their R-22 hadn’t flown much over recent years, these checks remain imperative regardless of flight frequency.

Recognizing Warning Signs
Keller highlighted an often-overlooked aspect: recognizing and interpreting minor deviations like slightly low magneto checks. These small signs can precede significant issues, allowing pilots and maintenance crews to address problems before they escalate.

Governor-Off Training
Switching off the governor and flying manually isn't commonly required, but this incident underscored its importance. Both Keller and Nelson stressed this necessity for real-world preparedness. Regular training under 'governor-off' scenarios should be an integral part of pilot education to ensure confidence and competence.

 

 

Impact on Operations
Keller and Nelson expressed excitement about the R-22’s return and the soon-to-return R-44. These helicopters offer essential variety for training, and having both available enlarges their scope of operations. By early March, both aircraft should be back together, facilitating smoother and broader training schedules.

Fleet Management
The experience highlighted the importance—and logistical challenge—of maintaining a small fleet. Keller shared insights on planning maintenance to minimize operational disruptions, like scheduling the R-44’s annual check in a manner that coincides with the R-22’s return to service.

Lessons Learned
Keller asserts that the episode was a lesson in preparedness. Aircraft maintenance isn’t just a mechanical task but a cornerstone of flight safety and training integrity. Additionally, knowing how to manage in-flight mechanical failures should be part of every pilot's skillset.

Future Plans
With both helicopters returning and maintenance completed, Keller and his team are eager to resume advanced training maneuvers. This includes specialized exercises like advanced auto rotations, utilizing the full span of their fleet’s capabilities.

The conversation between Kenny Keller and Chris Nelson, laden with personal anecdotes and technical insights, serves as an indispensable resource for anyone involved in helicopter operations, from pilots to maintenance crews. It reinforces that vigilance, preparedness, and compliance with maintenance schedules are pivotal for flight safety and operational success.