— Ss STRUCTURAL REPAIR plore esis | maCH-47D STRUCTURAL REPAIR DOCUMENT REVISION A Prepared by Boeing Defense & Space Group Helicopters Division P.O. Box 16858 Philadelphia, PA 19142-0858 USA for Department of the Army CH-47 Modernization Program Project Manager SFAE-AV-CH-L 4300 Goodfellow Blvd. st. Louis, MO 63120-1798INTRODUCTION ‘THE CH-47D STRUCTURAL REPAIR DOCUMENT HAS BEEN PREPARED TO PROVIDE FIELD PERSONNEL WITH A METHOD TO QUICKLY AND ACCURATELY IDENTIFY STRUCTURAL DAMAGE WHICH WILL REQUIRE PARTS AND PROCEDURES NOT PROVISIONED IN RPSTL ‘TM 55-1520-240-23P OR DESCRIBED IN AVUM/AVIM MAINTENANCE MANUAL TM 55-1520-240-23. ‘THIS DOCUMENT MUST NOT BE USED TO REPLACE THE REPAIR PROCEDURES IN TM §5-1520-240-23. IT SHOULD BE USED ONLY TO PICTORIALLY DESCRIBE STRUCTURAL ASSEMBLIES/SUBASSEMBLIES THAT REQUIRE FACTORY MANUFACTURE AND ASSEMBLY. THE PARTS, FASTENERS, AND INSTRUCTIONS WILL BE PROVIDED TO CH-47D UNITS AS A COMPLETE KIT.CH-47D STRUCTURAL REPAIR DOCUMENT PROCEDURE: 1. This document is provided to Boeing Field Service Representatives and to Army CH-47D Unit Maintenance Officers by the CH-47 Mod PMO (SFAE-AV-CH-L). 2. When an aircraft has sustained structural damage that requires structur assemblies/subassemblies not normally provisioned as spares, prepare two of these documents. Supplement the documents with photographs and word descriptions of the damage, including complete pictures of the damaged and undamaged surrounding areas. Select an illustration in this document that best presents the damaged area and “color” or “mark” the structural areas that require repair or replacement. Different colors for repair and replacement will aid in the interpretation of the diagrams. 4. Include the aircraft tail number, location, and the organization designation of the unit performing the repair on each marked illustration in this document. 5, When the damage has been assessed and a determination has been made that the repair is within the capability of intermediate maintenance (AVIM), a kit part number will be furnished by the Boeing Field Service Representative or CH-47 Mod PMO (SFAE-AV-CH-L). AVIM will then place the kit part number on n through the Army system. All further correspondence should reference part number.6. Airmail one copy of the completed repair document and data (photographs, word descriptions) to: Department of the Army CH-47 Modernization Program Project Manager Attn: SFAE-AV-CH-L 4300 Goodfellow Blvd. St. Louis, MO 63120-1798 Airmail the second copy with all photographs and data to: Boeing Defense & Space Group icopters Division ae P.O. Box 16858 Philadelphia, PA 19142-0858 USA 7. Identify every illustration, photograph, and word description with the aircraft tail number and kit part number when assigned. 8. Boeing will prepare and ship a complete kit of parts, materials, and fasteners for each kit part number. ivLIST OF ILLUSTRATIONS Figure 1 Stations & Waterlines Figure 17 Centerline, R.H.* Figure 2 Aircraft Breakdown Figure 18 Former Stations 51.75, 70.62 & 95.0 Figure 3 Fairing Structure, LH. Figure 19 Former Station 120 Figure 4 Fairing Structure, R.H.* Figure 20 Former Station 160 & 440 Figure 5 Production Breakdown, R.H.* Figure 21 Former Station 200 Section 41 Figure 22 Crown Former Stations 180, 220, 260, 300, 340, 380, 420 Forward Pylon Figure 23 Forward Station 240 Section 43, LH. Figure 24 Former Station 280, 320 Figure 9 Section 43, R.H.* Figure 25 Former Station 360 - 400 Figure 10 Section 46, LH. Figure 26 Former Station 482 Figure 11. Section 46, R.H.* Figure 27 Former Station 502.43, Figure 12 Aft Pylon, LH. Figure 28 Former Station 520 Figure 13 Aft Pylon, R.H.* Figure 29 Former Station 534 Figure 14 Basic Structure, LH. Figure 30 Former Station 555 ure 15 Basic Structure, R.H.* Figure 31 Former Station 575, Figure 16 Centerline, LH. Figure 32 Former Station 594 * ALL RIGHT HAND views have been developed from mirror views of LEFT HAND drawings. Structure that is not symmetrical may appear in the wrong position from centerline of aircraft.B33 Fauge 556 575 62050 a a ee ee, a a) wea seuice FUSELAGE STATION & WATER LINES MFG SPLICE FIGURE 1, STATION & WATERLINESRING CROWN AFT FAIRING CROWN M10 . FAIRING CROWN FWO assea7 FAIRING LEADING EDGE 14554806 ENGINE com. 23450057 XMSN FAIRING "asPs004 FIGURE 4. FAIRING STRUCTURE, Ri. 26505(CROWN PANEL Se x SIDE PANEL -a5s1681 SKIN 14551561 ‘skin 14551504 FIGURE 6. SECTION 41 26807SIDE PANEL ‘assz001 ‘SKIN 14552571 ‘SKIN 14552577 BOTTOM PANEL ‘ss2006 SKIN 14552574 FIGURE ®, SECTION 43, LH.L rescue poor tower s14sza02 PANEL 14582577 SIDE PANEL ‘SKIN 14582571 14552001, FIGURE 9. SECTION 43, RM. 26510FRAME 1es4128 canteD ocx: wassen Bye assent FRAME AFT CROWN, sssa7e [ENGINE SUPPORT. waste FRAME AFT CROWN ‘usssan0 LONGERON 11453356 14583379 staazo Sta too STA 300) \ name “11452339 FRAME 11452010 STA 340) | FRAME 1452229: Stal"az0 FRAME AFT CROWN sstie5, BeaN 41453156 ean 414s3ts2 ean FRAME 11483107 STA 5200 ae FRAME 14583175 STA 502.434 Sta. 190 FRAME 14553184 STA 4820 FRAME 11453101 STA 440.0 FRAME 61452119 STA 4900 FRAME 11452127 STA 2600 FRAME winoOW 11452722 FRAME 11452101 & 41451108 STA 1600 FRAME COCKPITALASHY03 STA 1400 \ oe SERRE COCKOIT 14551192 STA 1200, suLKnead se851171 Sta 950 oc NONABLES FIGURE 14. BASIC STRUCTURE, LH 265157 Staas20 snare AFT CHOWN 1855981 a / rene st FRAME AFT CROWN 16852074 RAME AFT CROWN 14552300, eee ee LONGERON 11453386 frame AFT CROWN SSP mame AFT CROWN 41453502 STA 4600 mame ArT CROWN 14553170 nue vusuiasva 00 FANE AT CRO Sa ERAME 11452919 STA 4000 P S Y, FRAME 11452912 STA 3900 AME 11452091 STA 3600 " RAMe 11452310 STA 3400 RAME 11452329 STA 2200 AME 14559179 STA 955 x 5 RAM 11452008 STA 300.0 eam ves5at74 FRAME 11452327 STA 2800 FaaMe 14559178 STA 5340: R a AME 11482006 STA 2600 ‘ean 91450182 y . ‘ g FRAME 14562075 STA 2400 FRAME 11452004 STA 220.0 name 11453107 STA $200. RAN 14559175 STA 802.494 FRAME 14562188 STA 482. RaMe 41452309 STA 200.0 name 41452302 STA 180.0 ‘eave KMSW SUPT 14551175 mame 41452113 STA 4000 Loren sit 1688673 FRAME 11452120 STA 3200 rRAME 11452127 STA 2800 wes 5 mame 11452101 & 41451108 STA 1600 ‘inant cocnPrr «1451103 STA 1400~) / ‘caain p00n RAME COCKPIT 14551172 STA 1200 oe L sernisonaate D008 PiLor & coPLOT 26516FHGURE 16, CENTER LINE, RM 26517N- FIGURE 17. CENTER LINE, LH. 2esieSTA 180 avasza02 STA az0 11452514 FIGURE 22. CROWN FORMER STATIONS 180, 220, 60, 300, 808 420, La a0 2652326528FIGURE 29. FORMER STATION 594