TM-1-1520-265-23 H-60 Helicopter Series Manual

SECTION I INTRODUCTION
GENERAL INFORMATION - TM-1-1520-265-23_29
Table 1-1. Supporting Technical Documentation
Special Terms, Abbreviations, and Acronyms
1.1.3. Inspection Item Code
METHOD OF INSPECTION USED IN ILLUSTRATIONS TO IDENTIFY THE TYPE OF INSPECTION METHODS BEING ILLUSTRATED
Figure 1-2. General Configuration of UH-60A Helicopter
Figure 1-3. Stations, Waterlines, and Buttlines (Sheet 1 of 2)
Figure 1-3. Stations, Waterlines, and Buttlines (Sheet 2 of 2)
TYPE OF CONSTRUCTION
Flight Control System.
Figure 1-4. Access and Inspection Provisions (Sheet 1 of 2)
Figure 1-4. Access and Inspection Provisions (Sheet 2 of 2)
Table 1-2. Access Panels and Fairing
Table 1-2. Access Panels and Fairing - Continued
MARKING AND/OR RECORDING OF INSPECTION RESULTS
Selecting the NDI Method.
NDI General Safety Precautions
Figure 1-5. Bond Testing Reference Block Displays
Fluorescent Penetrant (PT) Method
Table 1-3. Penetrant Procedure (Type I, Method A)
Table 1-4. Penetrant Procedure (Type I, Method B)
Table 1-5. Penetrant Procedure-Portable or Field Application (Type I, Method C)
Table 1-6. Penetrant Procedure (Type I, Method D)
Safety Precautions During Fluorescent Penetrant Inspection
Magnetic Particle (MT) Method
Magnetic Particle Inspection Equipment
Figure 1-6. Portable Magnetic Particle Inspection Equipment
Demagnetization of Inspection Parts
Radiation Hazard
Safety   Precautions   During   Eddy   Current   Inspection
Bolthole Inspection
Figure 1-7. Signatures of EDM Notches in Test Block
Figure 1-8.   Typical Metal Sorting Display
Ultrasonic Instrument Standardization.
Acceptance/Rejection Criteria
Table 1-7. Equipment Used for NDI
Table 1-8.   M aterials Used for NDI
Table 1-8.   M aterials Used for NDI - Continued - TM-1-1520-265-23_67
Table 1-8.   M aterials Used for NDI - Continued - TM-1-1520-265-23_68
SECTION II ROTOR   SYSTEM
Table 2-1. Rotor System Inspection Index - Continued
Figure 2-1. Rotor System (Sheet 1 of 2)
Figure 2-1. Rotor System (Sheet 2 of 2)
SPLIT CONES (PT)
FERROUS ROTOR SYSTEM BOLTS AND PINS (MT)
NONFERROUS ROTOR SYSTEM BOLTS AND PINS
MAIN ROTOR SHAFT NUT (MT)
MAIN ROTOR HUB (ET)
2.6.3.2 Preparation of Helicopter
Figure 2-6.   M ain Rotor Hub
2.7.3.2 Preparation of Helicopter
Figure 2-7.   Spindle
ANTIFLAP BRACKET (ET)
2.8.3.5 NDI Equipment Settings
Figure 2-8. Antiflap Bracket
Primary Method. Eddy Current.
2.9.3.6 Inspection Procedure
BALANCE WEIGHT BRACKET (MT)
Figure 2-10. Balance Weight Bracket
Marking and Recording of Inspection Results
2.11.3.2 Preparation of Helicopter
Figure 2-11. Spindle Horn
Aircraft Marking Pencil, refer to Table 1-8
Figure 2-12.   Droop Stop Cam
NDI Equipment and Materials. (Refer to Appendix B.)
PITCH CONTROL RODS (ET)
Figure 2-13.   Damper Assembly
Preparation of Part
Figure 2-14 Pitch Control Rods
2.15.3.5 NDI Equipment Settings
Figure 2-15. Rotating Swashplate
LOWER LINK (ET)
NDI Equipment Settings - TM-1-1520-265-23_103
BIFILAR VIBRATION ABSORBER (ET).
NDI Equipment Settings - TM-1-1520-265-23_105
Figure 2-17. Bifilar Vibration Absorber
BIFILAR WEIGHT (UT)
(SETUP - DEFAULT SETTINGS)
Ultrasonic Method
Figure 2-18. Bifilar Weight (Sheet 1 of 3)
Bifilar Weight Bushings (PT)
BIFILAR WEIGHT TAPERED WASHERS (PT)
MAIN ROTOR BLADE TIP CAP FAIRING (ET).
Backup Method
Figure 2-19. Main Rotor Blade Tip Cap Fairing
Figure 2-20. Main Rotor Blade (Voids)
Maintenance Platforms/Workstands - TM-1-1520-265-23_118
MAIN ROTOR BLADE CUFF ASSEMBLY (ET).
NDI Equipment and Materials
Inspection Procedure - TM-1-1520-265-23_121
Defects.
Attach cable and probe to Bondmaster
Figure 2-22. Tail Rotor Blade (Voids)
TAIL ROTOR BLADE (FLUID) (RT)
Inspection Procedure - TM-1-1520-265-23_126
Figure 2-23. Tail Rotor Blade (Fluid) (Sheet 1 of 2)
Figure 2-23. Tail Rotor Blade (Fluid) (Sheet 2 of 2)
Maintenance Platforms/Workstands - TM-1-1520-265-23_129
Figure 2-24. Tail Rotor Blade Tip Cap
Access. Not applicable
TAIL ROTOR PITCH CONTROL ROD ENDS (MT)
Figure 2-25. Tail Rotor Pitch Horn
Preparation of Part.
Figure 2-26. Tail Rotor Pitch Control Rod Ends
PITCH BEAM WASHER (MT).
Figure 2-27. Pitch Beam Washer
PITCH BEAM RETAINING NUT (MT) - TM-1-1520-265-23_138
Preparation of Part The part shall be thoroughly cleaned
Figure 2-28. Pitch Beam Retaining Nut
Primary Method
TAIL ROTOR INBOARD/OUTBOARD RETENTION PLATES (ET)
Figure 2-29.   Pitch Beam
NORTEC-19e
Figure 2-30   Tail Rotor Inboard/Outboard Retention Plates
System Securing
SECTION III DRIVE SYSTEM
Figure 3-1. Transmission/Drive System
MAIN TRANSMISSION (ET)
INTERMEDIATE GEARBOX (ET)
Figure 3-2. Main Transmission
Access
Figure 3-3. Intermediate Gearbox
TAIL ROTOR DRIVE SHAFT (ET)
System Securing
Figure 3-4. Tail Rotor Drive Shaft
TAIL ROTOR DRIVE SHAFT SUPPORTS (ET)
Inspect the part
TAIL ROTOR DRIVE SHAFT COUPLING (PT) - TM-1-1520-265-23_159
Figure 3-6.   Tail Rotor Drive Shaft Coupling
Eddy Current Method
Figure 3-7.   O il Cooler Drive Shaft
Hand-held magnetic coil may be used - TM-1-1520-265-23_163
OIL COOLER FAN BLADES (ET)
Make the following initial settings on the Eddy Current Inspection Unit, NORTEC-1 9e
TAIL GEARBOX (ET)
Preparation of Helicopter - TM-1-1520-265-23_167
Figure 3-10. Tail Gearbox
TAIL GEARBOX MOUNT FITTING (ET)
Refer to Eddy Current Method, paragraph
Figure 3-11.   Tail Gearbox Mount Fitting
Figure 3-12. Tail Rotor Gearbox Inner/Outer Split Cones
SECTION IV AIRFRAME AND LANDING GEAR SYSTEM
Table 4-1. Airframe and Landing Gear System Inspection Index - Continued
Figure 4-1.   Airframe and Landing Gear System
AIRFRAME SKIN, PANELS, DOORS, COVERS, AND FAIRINGS - METAL (ET)
System Securing.
Figure 4-2.   Airframe Skin, Panels, Doors, Covers, and Fairings - Metal
HONEYCOMB AND COMPOSITE STRUCTURES (BT)
Press SET and select DISPLAY - PHASE.
Figure 4-3. Honeycomb and Composite Structures
FLUID IN HONEYCOMB CORE PANELS AND STRUCTURES (RT)
Figure 4-4. Fluid in Honeycomb Core Panels and Structures (Sheet 1 of 2)
Figure 4-4. Fluid in Honeycomb Core Panels and Structures (Sheet 2 of 2)
VIBRATION ABSORBER SPRINGS (MT)
Demagnetization
Figure 4-5. Vibration Absorber Springs
VIBRATION ABSORBER STRUCTURAL FITTINGS (ET) - TM-1-1520-265-23_188
Null probe on test block - TM-1-1520-265-23_189
Figure 4-6. Vibration Absorber Structural Fittings
ALUMINUM STRUCTURAL BEAMS AND FRAMES (ET) - TM-1-1520-265-23_191
Figure 4-7. Roll Vibration Absorber
Eddy Current Inspection
Figure 4-8. Aluminum Structural Beams and Frames
PILOT/COPILOT SEAT MIDFRAME SUPPORT (MT)
Figure 4-9. Pilot/Copilot Seat Midframe Support
Aircraft Marking Pencil
Figure 4-10. Troop/Cargo Door Upper Track
GUNNER'S WINDOW LOWER TRACK (ET)
GUNNER'S WINDOW UPPER TRACK (ET)
Figure 4-11. Gunner's Window Lower Track
Null probe on test block - TM-1-1520-265-23_202
Figure 4-12. Gunner's Window Upper Track
TROOP/CARGO DOOR LOWER TRACK (ET)
OIL COOLER COMPARTMENT ACCESS DOOR (PT)
Figure 4-13. Troop/Cargo Door Lower Track
Figure 4-14.   Oil Cooler Compartment Access Door
TAIL PYLON ATTACH FITTING (ET)
TAIL ROTOR PYLON SKIN, STATION 200 (ET) - TM-1-1520-265-23_209
Figure 4-15. Tail Pylon Attach Fitting
Preparation of Part
Figure 4-16. Tail Rotor Pylon Skin, Station 200
TAIL ROTOR PYLON ATTACHING HARDWARE (PT)
Figure 4-17. Tail Rotor Pylon Attaching Hardware
TAIL PYLON LOWER STEP (ET)
STABILATOR ATTACH FITTING (ET).
Figure 4-18. Tail Pylon Lower Step
4.19.3.2. Preparation of Helicopter
Figure 4-19. Stabilator Attach Fitting
Hand-held magnetic coil may be used - TM-1-1520-265-23_220
Figure 4-20. Stabilator Actuator Attach Fittings
STABILATOR ACTUATOR HOUSING (PT)
Figure 4-21. Stabilator Actuator Housing
Preparation of Helicopter - TM-1-1520-265-23_224
Figure 4-22. Drag Beam Support Fitting
MAIN LANDING GEAR DRAG BEAM (MT)
4.23.3.2. Preparation of Helicopter
Figure 4-23. Main Landing Gear Drag Beam
4.24.3. Primary Method
4.24.3.6. Inspection Procedure
Figure 4-24. Main Landing Gear Shock Strut Upper Cylinder
4.25.3.2. Preparation of Helicopter
Figure 4-25. Main Landing Gear Shock Strut Lower Stage Piston
4.26.3. Primary Method. Eddy Current
4.26.3.6. Inspection Procedure
MAIN LANDING GEAR BRAKE (MT).
Figure 4-27. Main Landing Gear Brake
4.28. MAIN LANDING GEAR BRAKE HOUSING (ET)
4.28.3.5. NDI Equipment Settings
Figure 4-28. Main Landing Gear Brake Housing
4.29 PARKING BRAKE VALVE COMPONENTS (PT)
4.30 SLAVE MIXER VALVE PARTS (PT)
Figure 4-30.   Slave M ixer Valve Parts
4.31.3.2. Preparation of Helicopter
Figure 4-31. Tail Landing Gear Yoke
TAIL LANDING GEAR FORK (ET)
4.32.3.6 Inspection Procedure
TAIL LANDING GEAR LOCK ACTUATOR ASSEMBLY (MT)
TAIL LANDING GEAR WHEEL ASSEMBLY (ET)
Figure 4-33. Tail Landing Gear Lock Actuator Assembly
4.34.3.2. Preparation of Helicopter
Figure 4-34. Tail Landing Gear Wheel Assembly
4.35.3.2 Preparation of Helicopter
Figure 4-35. Cargo Hook
Table 5-1. Power Plant System Inspection Index
Figure 5-1. Power Plant System
5.2 DESWIRL DUCT VANES AND LOOP CLAMP (PT)
Figure 5-2.   Deswirl Duct Vanes and Loop Clamp
5.4 AIR INLET ASSEMBLY AND BLEED-AIR EXHAUST SLOTS (ET).
Figure 5-3. Engine Tubing, Couplings, Air Ducts, Fittings, Supports, Brackets, and Clips
Figure 5-4. Air Inlet Assembly and Bleed-Air Exhaust Slots
AFT ENGINE MOUNT STRUTS (IT).
5.5.3.3 Access
Figure 5-5. Aft Engine Mount Struts
Backup Method. Fluorescent Penetran
Figure 5-6. Aft Engine Mount Fittings
AFT ENGINE MOUNT LINKS (PT)
Figure 5-7.   Aft Engine Mount Links
5.8.3.2 Preparation of Helicopter
Figure 5-8.   Aft Engine Mount Support
CROTCH ASSEMBLY AND SEGMENT RING (PT)
FORWARD SUPPORT TUBE (PT)
Figure 5-10.   Forward Support Tube
EXHAUST EJECTOR AND ATTACHING ANGLES (PT)
EXHAUST FAIRINGS (PT)
HIRSS AND NACELLE FAIRING SUPPORT MOUNTS (PT)
SUPPRESSOR CORE AND BAFFLE (PT) - TM-1-1520-265-23_277
Figure 5-13.   HIRSS and Nacelle Fairing Support M ounts
HIRSS EXHAUST EXTENDER (PT)
Figure 5-14.   Suppressor Core and Baff le
Figure 5-15.   HIRSS Exhaust Extender
ROTARY INPUT ASSEMBLY (PT)
ENGINE LOAD DEMAND CONTROL CABLE SUPPORT (PT)
ENGINE AIR INLET V BAND CLAMP (PT)
Figure 5-18.   Engine Air I nlet V Band Clamp
5.19.3.2 Preparation of Helicopter
Figure 5-19.   Starter Flange
ENGINE LOAD DEMAND SPINDLE BELLCRANK SUPPORT (ET)
5.21.3.1 NDI Equipment and Materials
ENGINE COMPONENTS (PT) - TM-1-1520-265-23_290
5.22.2   Defects
5.22.2 Defects
SECTION VI FLIGHT CONTROL SYSTEM
Table 6-1. Flight Control System Inspection Index - Continued
Figure 6-1. Flight Control System
6.2 TOE PEDAL ACTUATOR (PT)
6.3 TOE PEDAL ASSEMBLY (ET)
6.3.4 Backup Method
6.4 YAW PEDAL SUPPORT SHAFT (MT)
YAW PEDAL BRAKE CYLINDER SUPPORTS (ET)
6.5.3.3 Access
PEDAL ADJUSTER ARMS AND LINK (ET).
6.6.3.5 NDI Equipment Settings
PILOT/COPILOT CYCLIC AND COLLECTIVE STICK SOCKET (ET)
6.7.3.4 Preparation of Part
Figure 6-7. Pilot/Copilot Cyclic and Collective Stick Socket
Figure 6-8. Collective Boost and Yaw Boost Servo Input/Output Piston Shafts and Cylinders
YAW/PITCH COUPLING LINK (ET)
6.9.3.4 Preparation of Part
Figure 6-9. Yaw/Pitch Coupling Link
6.10.3.2 Preparation of Helicopter
NONFERROUS FLIGHT CONTROL SYSTEM PUSH-PULL RODS (ET)
6.11.3.5 NDI Equipment Settings
PILOT COLLECTIVE STICK BELLCRANK SUPPORT (ET)
6.12.3.4 Preparation of Part
PILOT/COPILOT COLLECTIVE STICK SUPPORT (ET)
6.13.3.5 NDI Equipment Settings
Figure 6-13. Pilot/Copilot Collective Stick Support
6.14 PILOT COLLECTIVE STICK BELLCRANK (ET)
Marking and Recording of Inspection Results
FERROUS CONNECTING LINKS, ROD ENDS, CLEVISES, LEVERS, AND ATTACHING PARTS (MT)
Figure 6-15. Ferrous Connecting Links, Rod Ends, Clevises, Levers, and Attaching Parts
NONFERROUS CONNECTING LINKS, ROD ENDS, CLEVISES, LEVERS, AND ATTACHING PARTS (ET)
6.16.3.5 NDI Equipment Settings
Figure 6-16. Nonferrous Connecting Links, Rod Ends, Clevises, Levers, and Attaching Parts
SWASHPLATE LINKS (MT)
Figure 6-17. Swashplate Links
6.18.3.2 Preparation of Helicopter
Figure 6-18. Walking Beam
6.19.3.2 Preparation of Helicopter
LATERAL BELLCRANK (MT)
6.20.3.4 Preparation of Part
AFT BELLCRANK (MT)
Figure 6-21. Aft Bellcrank
HYDRAULIC/PNEUMATIC SYSTEM COMPONENTS (PT) - TM-1-1520-265-23_335
Figure 6-22. Hydraulic/Pneumatic System Components
APPENDIX A MAINTENANCE ALLOCATION CHART NONDESTRUCTIVE INSPECTION
APPENDIX A MAINTENANCE ALLOCATION CHART NONDESTRUCTIVE INSPECTION CONT. - TM-1-1520-265-23_338
APPENDIX A MAINTENANCE ALLOCATION CHART NONDESTRUCTIVE INSPECTION CONT. - TM-1-1520-265-23_339
APPENDIX A MAINTENANCE ALLOCATION CHART NONDESTRUCTIVE INSPECTION CONT. - TM-1-1520-265-23_340
APPENDIX A MAINTENANCE ALLOCATION CHART NONDESTRUCTIVE INSPECTION CONT. - TM-1-1520-265-23_341
APPENDIX A MAINTENANCE ALLOCATION CHART NONDESTRUCTIVE INSPECTION CONT. - TM-1-1520-265-23_342
APPENDIX A MAINTENANCE ALLOCATION CHART NONDESTRUCTIVE INSPECTION CONT. - TM-1-1520-265-23_343
APPENDIX B EQUIPMENT LISTING
APPENDIX B EQUIPMENT LISTING CONT. - TM-1-1520-265-23_346
APPENDIX B EQUIPMENT LISTING CONT. - TM-1-1520-265-23_347
APPENDIX B EQUIPMENT LISTING CONT. - TM-1-1520-265-23_348
APPENDIX C ILLUSTRATED FIELD MANUFACTURE ITEMS LIST
Figure C-1. Composite Test Blocks
Aluminum Structural Beams and Frames (ET) - TM-1-1520-265-23_352
Crotch Assembly and Segment Ring (ET)
Engine Components (PT) - TM-1-1520-265-23_354
Ferrous Bolts and Pins Contained within the Airframe and Landing Gear System (MT)
General Information - TM-1-1520-265-23_356
Hydraulic/Pneumatic System Components (PT) - TM-1-1520-265-23_357
Main Landing Gear Shock Strut Lower Stage Piston (MT)
Main Rotor Shaft Nut (MT)
Nonferrous Flight Control System Push-Pull Rods (ET)
Pedal Adjuster Arms and Link (ET)
Pitch Beam Retaining Nut (MT) - TM-1-1520-265-23_362
Spindle (ET)
Suppressor Core and Baffle (PT) - TM-1-1520-265-23_364
Tail Landing Gear Yoke (ET)
Tail Rotor Drive Shaft Coupling (PT) - TM-1-1520-265-23_366
Tail Rotor Pylon Skin, Station 200 (ET) - TM-1-1520-265-23_367
Vibration Absorber Structural Fittings (ET) - TM-1-1520-265-23_368

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