TM 1-1520-237-23 (SUP)

CHAPTER 16

SECTION 1

FAST ROPE INSERTION/EXTRACTION SYSTEM

SECTION OVERVIEW

SUB-SECTION TITLE PAGE

A EQUIPMENT DESCRIPTION AND DATA 16-1-2

16-1A-1 General 16-1-2
16-1A-2 Principles of Operation 16-1-2
16-1A-3 System Components 16-1-2
16-1A-4 Component Locations 16-1-2

B INSPECTION PROCEDURES 16-1-4

16-1B-1 General Inspection 16-1-4
16-1B-2 Special Inspections 16-1-4

C MAINTENANCE PROCEDURES 16-1-6

16-1C-1 Replace FRIES Bar Assembly 16-1-6
16-1C-2 Replace FRIES Bar Support Assembly 16-1-8
16-1C-3 Replace FRIES Bar Cap Assembly 16-1-11
16-1C-4 Replace Cable Assembly 16-1-13
16-1C-5 Replace Crew Chief’s Release Handle Assembly 16-1-14

D FAULT ISOLATION PROCEDURES/WIRING DIAGRAMS 16-1-15

Not Applicable

E PARTS LISTING 16-1-16

16-1E-1 Parts Listing 16-1-16

16-1-1
TM 1-1520-237-23 (SUP)
Sub-Section A EQUIPMENT DESCRIPTION AND DATA
16-1A-1. General.
The Fast Rope Insertion and Extraction System
(FRIES) is included in all MH-60L Assault and IDAP
aircraft. It is mounted in the aircraft overhead, so
troops can deploy from sides of the aircraft via the cargo
doors. Fast ropes are attached to the slide-out portion of
the FRIES bar.
16-1A-2. Principles of Operation.
a. The FRIES is a mechanical system that uses two
fast ropes to provide rapid insertion of multiple troops
and extraction in areas not suitable for helicopter
landings due to terrain obstructions or threat conditions.
With loads on the FRIES, maximum airspeed is limited
to 80 KIAS, pitch and bank angles are limited to 30
degrees. FRIES operations are prohibited during icing
conditions and when turbulence exceeds the low
condition level.
CAUTION
Extend bars prior to using the FRIES
for infiltration. The FRIES must be
used in the partially extended (17”)
position for extraction operations.
Check rope attach/release mechanism to
assure that the rope retention bar is
secure with the safety pin installed prior
to using FRIES for extraction.
b. The maximum load limits on either side of the
FRIES bar shall not exceed 1500 pounds symmetrical.
Figure 16-1A-4. Fast Rope Insertion/Extraction System (FRIES) Location (1 of 2).
16-1-2
The asymmetrical maximum is 1300 pounds and
everything above 1300 pounds will be symmetrical.
NOTE
K-DUCK (CRRC) harness may also be
connected to the FRIES bar.
16-1A-3. System Components.
a. FRIES Bar Assembly. Includes a square
weldment assembly to which the FRIES bar is attached.
b. Handle Rope Release. A handle is installed on
both sides of the cargo compartment to release rope
from FRIES bar. A dual action is required to pull down
on the handle to release the safety and pull up to release
the rope.
c. Release Assembly. Mounted on the end of each
FRIES bar, it contains safety mechanism and rope
support assembly.
16-1A-4. Component Locations (Figure 16-1A-
4).
a. The FRIES bar is attached to hard points
beneath the main transmission. The FRIES bar is
positioned near the center of either cargo door opening.
b. The release handles are located on the cargo
compartment walls.
 TM 1-1520-237-23 (SUP)

TO RELEASE ROPE TO SAFETY RELEASE

50 - 70 IN. LBS

Figure 16-1A-4. Fast Rope Insertion/Extraction System (FRIES) Location (2 of 2)

16-1-3
TM 1-1520-237-23 (SUP)

Sub-Section B INSPECTION PROCEDURES

16-1B-1. General Inspection. Table 16-1B-1. Routine servicing consists of cleaning

equipment and keeping all surfaces free of dirt, grease,
Inspection procedures for the FRIES are Preventive and moisture. Routine maintenance consists of replacing
Maintenance Checks and Services (PMCS) specified in missing screws, spot painting, and corrosion control.

Table 16-1B-1. PMCS for FRIES.

SEQ. NO. ITEM AND PROCEDURE

1 Verify security and location of all components.

2 Ensure all visible exterior surfaces of unit are clean. If necessary, clean exterior surfaces as follows:
1. Remove dust and loose dirt with a clean, soft cloth.
2. Remove dust or dirt from plugs and jacks with a soft brush.
3. Remove grease, fungus, and ground-in dirt using a cloth dampened (not wet) with general purpose
detergent.
3 Ensure that all cables and wiring are not frayed, damaged, loose, corroded, split or cracked.

4 Inspect all securing hardware, screws, self-locking retainers, for stripped threads, bent or broken
threaded shafts.

16-1B-2. Special Inspections. (d) Severe corrosion on the interior surfaces

of the two .625 diameter holes shall require that the bar
a. Corrosion control and inspection will be be returned to Raytheon Systems Co. for refurbishing.
conducted IAW unit corrosion control SOP. Treatment of
corrosion will be as follows: (e) Interior same as above.

(1) Main Support Bar. (2) Round Support Tubes.

(a) Severe corrosion on the exterior
surfaces of the main support bar shall require that the bar
be returned to a depot facility for refurbishing.
(b) Light and moderate corrosion on the
exterior surfaces of the main support bar shall be treated
as follows:
• Removal per TM 1-1500-344-23, Section 8-12
• Washprime per MIL-C-8514
• Prime per MIL-P-53022
• Paint per MIL-C-46168, CC 36231 (Gray)
(c) Light and moderate corrosion on the
interior surfaces of the two .625 diameter holes shall be
treated as follows:
• Removal per TM 1-1500-344-23, Section 8-12
• CPC per MIL-C-81309, Type II and MIL-C-
16173, Grade 4 apply per TM 1-1500-344-23 and
appropriate MIL-SPEC
(a) Severe corrosion on the interior or
exterior surfaces of the round support tubes shall require
that the tubes be returned to Raytheon Systems Co. for
refurbishing.
(b) Light and moderate corrosion on the
exterior surfaces of the round support tubes shall be
treated as follows:
• Removal per TM 1-1500-344-23, Section 8-12
• Solid film lubricant per MIL-L-23398
(c) Light and moderate corrosion on the
interior surfaces of the round support tubes shall be
treated as follows:
• Removal per TM-1500-344-23, Section 8-12
• Washprime per MIL-C-8514
• Prime per MIL-P-53022

16-1-4

(3) Release Mechanism and Other Ferrous
Material.
(a) Severe corrosion on the surfaces of the
release mechanism and other ferrous material shall
require that those parts be returned to Raytheon Systems
Co. for refurbishing.
(b) Light and moderate corrosion on the
release mechanism and other ferrous material shall be
treated as follows:
• Removal per TM-1500-344-23, Section 8-12
• Washprime per MIL-C-8514
• Prime per MIL-P-53022
• Paint per MIL-C-46168, CC 36231 (Gray)
(4) General Definitions (TM 1-1500-344-23).
(a) Light Corrosion: At this degree, the
protective coating is scarred or etched and the condition
TM 1-1520-237-23 (SUP)
of the metal is characterized by discoloration and pitting
to a depth of approximately one MIL (.001 inch)
maximum. This type of damage is normally removed by
light hand sanding.
(b) Moderate Corrosion: This looks like
corrosion except that there may be some blisters or
evidence of scaling and flaking of the coating or paint
system, and the pitting depths may be as deep as 10 MILS
(0.10 inch). This type of damage is normally removed by
extensive hand sanding or light mechanical sanding.
(c) Severe Corrosion: Its general
appearance may be similar to moderate corrosion with
severe inter-granular corrosion, blistering exfoliation,
scaling or flaking. The pitting depths are deeper than 10
MILS (0.010 inch). This damage must be removed by
extensive mechanical sanding or grinding.
16-1-5
TM 1-1520-237-23 (SUP)

Sub-Section C MAINTENANCE PROCEDURES

_________________________________________________________________________________________

INITIAL SETUP Personnel Required

Tools • One: MOS 67T Tactical Transport Helicopter

Repairer
• Aircraft Mechanic’s Toolkit, SC 5180-99-CL-A01 • Three: Assistants
• Torque Wrench 0 - 30 in. lb, A-A-2411
• Torque Wrench 30 - 150 in. lb, GGG-W-686 References

• Torque Wrench 150 - 750 in. lb, GGG-W-686 • TM 1-1500-204-23

• Torque Wrench 700 - 1600 in. lb, GGG-W-686
_________________________________________________________________________________________

16-1C-1. Replace FRIES Bar Assembly (Figure
16-1C-1).
16-1C-1.1. Remove.
WARNING
Injury to personnel or damage to
equipment will result if FRIES bar is not
supported during removal. Use at least
three assistants to support FRIES bar
during removal/installation. Do not
remove bolts without three assistants
supporting FRIES bar.
a. Remove cable assemblies (Paragraph 16-1C-4).
c. Remove FRIES bar and spacers.
16-1C-1.2. Install.
a. Install spacers and FRIES bar with at least three
assistants supporting FRIES bar.
NOTE
Bolts and barrel nuts must be replaced after
15 installations or removals.
b. Install bolts, thin washers, and thick washers with
three assistants supporting FRIES bar.
c. ALTERNATELY TORQUE BOLTS TO 1100
- 1300 INCH-POUNDS.

b. Remove bolts, thin washers, and thick washers d. Install cable assemblies (Paragraph 16-1C-4).
with three assistants supporting FRIES bar.

16-1-6
 TM 1-1520-237-23 (SUP)

Figure 16-1C-1. Replace FRIES Bar Assembly.

16-1-7
TM 1-1520-237-23 (SUP)
16-1C-2. Replace FRIES Bar Support Assembly
(Figure 16-1C-2).
16-1C-2.1. Remove.
NOTE
Right and left FRIES bar support assembly
removal procedures are the same.
a. Remove cable assemblies (Paragraph 16-1C-4).
b. Remove mount assembly as follows:
(1) Remove bolt, washers, and nut securing
release bar assembly (Figure 16-1C-2, Sheet 2, Detail C).
(2) Remove quick release pin from mount
assembly.
(3) Remove release bar assembly from mount
assembly.
(4) Remove bolt, wedge, spacer, washer, and nut
from mount assembly (Figure 16-1C-2, Sheet 1, Detail
B).
c. Slide support assembly out of FRIES bar.
d. Remove FRIES bar cap assembly (Paragraph 16-
1C-3).
16-1C-2.2. Disassemble.
a. Disassemble release bar assembly as follows:
(1) Remove screws, washers, and self locking
nut securing cable anchor (Figure 16-1C-2, Sheet 2,
Detail D).
(2) Remove cable anchor from release arm.
b. Remove spring pin and remove release arm from
body (Figure 16-1C-2, Sheet 2, Detail D).
16-1-8
c. Remove retainer screw, compression spring, and
shoulder pin from body (Figure 16-1C-2, Sheet 2, Detail
D).
16-1C-2.3. Assemble.
a. Install shoulder pin, compression spring, and
retainer screw in body. TIGHTEN RETAINER
SCREW UNTIL FLUSH WITH BODY (Figure 16-2C-
2, Sheet 2, Detail D).
b. Install release arm in body using spring pin.
PRESS SPRING PIN INTO BODY UNTIL FLUSH
WITH SURFACE.
c. Install cable anchor on release arm with screw,
washers, and self locking nut.
16-1C-2.4. Install.
NOTE
Right and left FRIES bar support assembly
installation procedures are the same.
a. Install FRIES bar cap assembly (Paragraph 16-
1C-3).
b. Slide support assembly through FRIES bar.
c. Install mount assembly as follows:
(1) Position mount assembly on support
assembly
and and install
install bolt, wedge,bolt, wedge,
spacer, spacer,
washer, and washer,
nut with and nutpin.
cotter
(Figure 16-1C-2, Sheet 1, Detail B). TORQUE NUT
TO 100
99 - -121
140INCH-POUNDS.
INCH POUNDS. Any combination of washers item
#11, with at least 1 under the nut, and a maximum of 3 to align cotter pin.
(2) Install release bar assembly in mount
assembly, install quick release pin (Figure 16-1C-2, Sheet
2, Detail C).
(3) Install bolt, washers, lanyard, and nut
securing release bar assembly (Figure 16-1C-2, Sheet 2,
Detail C). TORQUE NUT TO 247 - 302 INCH-
POUNDS.
 TM 1-1520-237-23 (SUP)

Figure 16-1C-2. Replace FRIES Bar Support Assembly (1 of 2).

16-1-9
TM 1-1520-237-23 (SUP)

Figure 16-1C-2. Replace FRIES Bar Release Assembly (2 of 2).

16-1-10
 TM 1-1520-237-23 (SUP)

16-1C-3. Replace FRIES Bar Cap Assembly 16-1C-3.2. Install.

(Figure 16-1C-3).
NOTE
16-1C-3.1. Remove.
Right and left cap assembly installation
NOTE procedures are the same.

Right and left cap assembly removal
procedures are the same.
a. Remove cable assemblies (Paragraph 16-1C-4).
b. Remove quick release pins if installed (Figure 16-
1C-3).
c. Remove support assembly from FRIES bar
(Paragraph 16-1C-2).
d. Remove rivet securing cap assembly to support
assembly tube (TM 1-1500-204-23).
e. Remove cap assembly from support assembly
tube.
a. Install cap assembly onto support assembly tube
until rivet hole in cap assembly and support assembly tube
line up.
b. Install rivet (TM 1-1500-204-23).
c. Install support assembly through FRIES bar
(Figure 16-1C-3).
d. Install support assembly on FRIES bar (Paragraph
16-1C-2).
e. Install quick release pins if required (Figure 16-
1C-3).
f. Install cable assemblies (Paragraph 16-1C-4).

16-1-11
TM 1-1520-237-23 (SUP)

Figure 16-1C-3. Replace FRIES Bar Cap Assembly.

16-1-12

16-1C-4. Replace Cable Assembly.
16-1C-4.1. Remove.
NOTE
Right and left cable removal procedures are
the same.
a. Remove all clamps and hardware securing cable
(Figure 16-1C-4).
b. Remove bolt release cable.
(1) Remove nut, three washers and bolt securing
cable latch to arm.
(2) Cut safety wire and remove nut securing
cable to end plate.
(3) Remove cable assembly by sliding cable up
through top of end plate.
(4) Remove nut from bolt on release handle
pulley.
(5) Remove bolt and unwind cable to back of
handle.
(6) Cut safety wire, loosen nut securing cable to
bracket assembly and remove nut.
(7) Slide cable up through hole in bracket and
remove cable.
c. Remove Safety Release Cable.
(1) Remove nut, washer and bolt securing cable
to safety release mechanism.
(2) Cut safety wire and remove nut securing
cable to release adaptor.
(3) Remove cable assembly by sliding cable up
through top of release adaptor.
(4) Cut safety wire and remove nut from cable
assembly on bracket attached to release handle.
(5) Remove screw and nut securing ball to safety
release handle attaching point
(6) Pull cable up through hole in bracket.
(7) Remove safety release cable from aircraft.
TM 1-1520-237-23 (SUP)
16-1C-4.2 Install
NOTE
Right and left cable assembly installation
procedures are the same.
a. Install bolt release cable.
(1) Route cable and loosely install cable into
existing clamps.
(2) Slide cable through end plate.
(3) Loosely install nut on inside of end plate.
(4) Place ball end of cable into latch and secure
latch to arm with bolt, threw washers and nut. Place
three washers under head of bolt with head on side of
release adaptor.
(5) Run cable through top of bracket assembly.
(6) Place nut on end of cable to loosely secure to
bracket.
(7) Run cable around pulley and secure to pulley
with bolt and nut.
(8) Check quick release mechanism for proper
operation.
(9) Adjust cable by changing position of nuts to
alter cable length.
(10) Tighten all nuts to standard torque.
(11) Safety wire two cable end nuts to end plate
and to bracket.
b. Install Safety Release Cable.
(1) Route cable and loosely install cable into
existing clamps.
(2) Slide cable through end of release adaptor.
(3) Loosely install nut on inside of release
adaptor.
(4) Place ball end of cable into safety release
mechanism.
(5) Secure ball end with screw and nut.
16-1-13
TM 1-1520-237-23 (SUP)
(6) Run cable down through top of safety release
bracket on the side of the release handle.
(7) Place nut on end of cable to loosely secure to
bracket.
(8) Place end of cable into attachment point on
handle and secure with screw and nut.
(9) Check safety release mechanism for proper
operation.
(10) Adjust cable by changing position of nuts to
alter cable length.
(11) Tighten all nuts to standard torque.
(12) Safety wire two cable end nuts to release
adaptor and to bracket on release handle.
16-1-14
16-1C-5. Replace Crew Chief’s Release Handle
Assembly.
NOTE
Right and left crew chief’s release handle
assembly removal/installation procedures
are the same.
16-1C-5.1. Remove.
a. Remove cable assemblies securing cables to crew
chief’s release handle assembly.
b. Remove nut and bolt collars securing crew chief’s
release handle assembly to bracket.
16-1C-5.2. Install.
a. Position crew chief’s release handle assembly in
bracket and secure with bolt and nut. Use standard
torque.
b. Install cables assemblies (Paragraph 16-1C-4).
 TM 1-1520-237-23 (SUP)

Sub-Section D FAULT ISOLATION PROCEDURES/WIRING DIAGRAMS

NOT APPLICABLE

16-1-15
TM 1-1520-237-23 (SUP)

Sub-Section E PARTS LISTING

16-1E-1. Parts Listing. reflected in Figures and Tables 16-1E-1-1 through 16-1E-
1-3.
The parts listing for the Fast Rope installation, crew
chief release assembly and FRIES bar assembly are

Figure 16-1E-1-1. FRIES Parts Breakdown.

16-1-16
 TM 1-1520-237-23 (SUP)

Table 16-1E-1-1. Parts Listing for FRIES.

ITEM PART NUMBER NSN DESCRIPTION QTY

NO.

1 NAS1310-72 5306-01-313-9064 Bolt 2

2 MS20002C10 5310-00-275-9211 Washer, Recessed 2
3 140-007-41-34F7 5310-00-529-1645 Washer 2
4 LEX-2168 None Assigned Spacer, LH 1

5 LEX-2169 None Assigned Spacer, RH 1

6 RMLH2577-108 5310-01-061-3323 Nut, Barrel 1

16-1-17
TM 1-1520-237-23 (SUP)

Figure 16-1E-1-2. Crew Chief’s Release Assembly.

16-1-18
 TM 1-1520-237-23 (SUP)

Table 16-1E-1-2. Parts Listing for Crew Chief’s Release Assembly.

ITEM PART NUMBER NSN DESCRIPTION QTY

NO.
1 A612 None Assigned Safety Release Handle 1
2 A613 None Assigned Fitting 1
3 A614 None Assigned Release Handle 1
4 A615 None Assigned Release Handle Cap 1
5 A629 None Assigned Bracket 1
6 A632 None Assigned Release Adaptor 1
7 A633 None Assigned Latch 1
8 A634 None Assigned Fitting 1
9 A635 None Assigned Pulley 1
10 A1078-001 None Assigned Release Cable Assembly 1
11 A1078-003 None Assigned Release Cable Assembly 1
12 A1301 None Assigned Release Handle Mount 1
13 34085A80 None Assigned Ball Plunger 1
14 92311A245 None Assigned Set Screw 1
15 9652K56 None Assigned Spring 1
16 AN3C10A 5306-00-156-2329 Bolt 1
17 AN4C15A 5306-00-156-2345 Bolt 1
18 AN5C21A 5306-00-180-1928 Bolt 1
19 MS14237C03P102 None Assigned Bushing 1
20 MS14237C03P125 None Assigned Bushing 1
21 MS21042L08 5310-00-807-1473 Nut 1
22 MS21042L3 5310-00-807-1474 Nut 1
23 MS21042L4 5310-00-807-1476 Nut 1
24 MS21042L5 5310-00-807-1476 Nut 1
25 MS224694-S12 None Assigned Screw 2
26 MS27039-1-27 5305-00-936-0044 Screw 2
27 NAS1149D0316K 5301-01-342-9568 Washer 2
28 NAS1149D0363K 5310-01-385-4624 Washer 2
29 NAS1149D0432K 5310-01-352-9565 Washer 2
30 NAS1149D0532K 5310-01-434-3790 Washer 2
31 NAS1149DN816K 5310-01-352-9567 Washer 2
32 NAS1149DN832 None Assigned Washer 2
33 NAS43DD3-16 5365-00-684-2093 Spacer 1
34 NAS620A10L 5310-00-660-2215 Washer 4
35 8831 None Assigned Seal, Locktite AR
36 A1305 None Assigned Fitting 1
37 MS51957-33 None Assigned Screw 1
38 MS21942L06 None Assigned Nut 1
39 NAS1149DN632K 5310-01-352-9561 Washer 2

16-1-19
TM 1-1520-237-23 (SUP)

Figure 16-1E-1-3. FRIES Bar Assembly (1 of 3).

16-1-20
 TM 1-1520-237-23 (SUP)

Figure 16-1E-1-3. FRIES Bar Assembly (2 of 3).

16-1-21
TM 1-1520-237-23 (SUP)

Figure 16-1E-1-3. FRIES Bar Assembly (3 of 3).

16-1-22
 TM 1-1520-237-23 (SUP)

Table 16-1E-1-3. Parts Listing for FRIES Bar Assembly.

ITEM PART NUMBER NSN DESCRIPTION QTY

NO.
LEX-1965 None Assigned FRIES Bar Assy See Figure 16-1E-1 For NHA 1
1 MS20615-6 5320-00-118-1775 • Rivet 2
2 LEX-2106 None Assigned • Cap Assembly 2
3 LEX-2109 None Assigned • • Cap 1
4 LEX-2107 None Assigned • • Cable 1
5 LEX-2108 None Assigned • • Cable 1
6 MS17984C435 5315-01-235-6193 • • Pin, Quick Release 1
7 MS17984C306 5315-00-901-3888 • • Pin, Quick Release 1
8 MS51844-62 4030-01-088-2952 • • Swaging Sleeve, Wire 4
9 LEX-2090 None Assigned • Support Assembly 2
10 AN5-20
AN 175-2 5310-00-180-0473
5306-01-382-3781 • • Bolt 2
11 AN960-516 OR 516L 5310-00-167-0820
AN960C416L 5310-00-167-0820OR 0836 • • Washer, Flat 2
12 LEX-2093 None Assigned • • Spacer 1
13 LEX-2092 None Assigned • • Wedge 1
14 AN310-5 5310-00-167-1285
5310-00-167-1286 • • Nut, Castellated 2
15 MS24665-136
MS24665-156 5315-00-017-9252
None Assigned • • Pin, Cotter 2
16 LEX-2094 None Assigned • • Rope Support Assy 1
17 Deleted
18 MS21250-06036 5306-00-883-9244 • • • Bolt, Tension 1
19 NAS1149F0616P 5310-01-432-3633 • • • Washer, Flat 1
20 MS21044N6 5310-00-950-0039 • • • Nut, Self-Locking 1
21 Deleted
22 LEX-2100 None Assigned • • • Bar Assy, Release 1
23 MS16562-44 5315-00-844-3962 • • • • Pin, Spring 1
24 MS35206-247 5305-00-984-6195 • • • • Screw 1
25 AN960PD8L 5310-00-184-9002 • • • • Washer, Flat 2
26 MS21044N08 5310-00-811-3494 • • • • Nut, Self-Locking 1
27 LEX-2103 None Assigned • • • • Arm, Release 1
28 LEX-2101 None Assigned • • • • Cable Anchor 1
29 LEX-2105 None Assigned • • • • Screw, Retainer 1
30 MS24585-114 None Assigned • • • • Spring, Compression 1
31 LEX-2104 None Assigned • • • • Pin, Shoulder 1
32 LEX-2102 None Assigned • • • • Body 1
33 See Figure 16-1E-1-2 For both safety and release cable
34 LEX-2094 None Assigned • • • Mount Weldment Assy 1
35 LEX-2091 None Assigned • • Tube Support 1
36 LEX-2084 None Assigned • Weldment Assembly 1
37 A632 None Assigned • Release Adapter 1
38 MS17984C20 5315-00-904-1671 • Pin, Quick Release 1

16-1-23