DMWR 55-1520-210 AIRCRAFT DEPOT MAINTENANCE WORK REQUIREMENT ADM UH-1H/UH-1V HELICOPTERS NSN 1520-00-087-7637 (UH-1H) NSN 1520-01-043-4949 (UH-1V) This publication is not available through U.S. Army Publication Distribution Centers. It must be obtained from U.S. Army Aviation and Troop Command, ATTN: AMSAT-I-MTS, 4300 Goodfellow Blvd., St. Louis, MO 63120-1798. DISTRIBUTIONSTATEMENTA: Approved for public release; distribution is unlimited. Tl PUBLICATION IS A REPRINT OF DMWR S6-120-210, DATED 31 ULY 180,18 (CHANGES 1 THROUGH 11. HINCLUDING US ARMY AVIATION AND TROOP COMMAND 31 JULY 1984DMR 55-1520-210 WARNING PAGE acIDs DANGEROUS CHEMICALS ARE USED IN NICKLE-CADNIUM BATTERIES The electrolyte used in nickle-cadmium batteries contains potassium hydroxide (KOH), which is a caustic chemical agent. Serious and deep burrs of body tissue will result if the electrolyte comes in contact with eyes or any part of the body. Use rubber gloves, rubber apron, and protective eye covering when handling the battery. If accidental contact with the electrolyte is made, use ONLY clean water and imme diately (seconds count) flush contaminated area. Continue flushing with large quan- tities of clean water. Seek medical attention innediately. Before renoving or in- stalling the battery ensure that the battery switch 1s off and the battery nas cooled down if overhéated. Removal or installation of the battery connector while the battery is under load may result in explosion, electrical arcing, and possible severe burns to personnel. Acids and Alkalines. Do not add water to acids. A violent action will result. ACIDS should be added to WATER in SMALL quantites. Ruststripper is an alkaline solution. Avoid contact with the skin. Wear protective clothing. Wash thoroughly after using. COMPRESSED AIR Do no use more than 30 psi compressed air for cleaning purposes. Wear protective goggles. Debris trajected under pressure can cause injury to eyes. Compressed air shall not be used for cleaning purposes except where reduced to less than 30 psi and only then with an effective chip guarding and personnel protection equipment. TOXIC CHEMICALS Solvent and Cleaning Solutions. These materials are generally toxic and many (toluene, benzene, xylene, methl-ethyl-ketone, perchlorethylene, naptha, tri- choloroethylene) are highly flammable. Work in a well-ventilated area avay from open flames. Do not inhale fumes. Avoid prolonged contact with skin. Wear pro- tective clothing and goggles. Wash thoroughly after using. Solvent flash point must not be less than 100°F. Paints, Varnishes, Dopes, Thinners, Lubricants and Fuels. These materials are generally highly flammable and may be irritants. Work in a well-ventilated area way from open flames. Do not inhale fumes. Avoid prolonged contact with the skin, Wash thoroughly after using. Epoxy, Resins, Cenents, and Adhesives. These materials may contain toxic or irr- itating ance. They may also be flammable. Work in a well-ventilated area avay from open flames. Do not inhale fumes. Avoid prolonged contact with the skin. Wash thoroughly after using. Change 7 a/(b blank)DMWR 55-1520-210 LIST OF EFFECTIVE PAGES NOTE: On a changed page, the portion of the text affected by the latest change is indicated by a vertical line, co other change symbol, in the outer margin of the page. Changes to illustrations are indicated by miniature pointing hands. Changes to wiring diagrams are indicated by shaded areas. Dates of issue for original and changed pages are: 31 duly 1984 30 September 1988 31 August 1989 +++ 30 March 1990 15 March 1991 31 December 1991 31 August 1994 1-22 blank .. 1-3- 1-4deleted .. 13-146. 4-7-1-01 1-12 1-13. 1-14-1-18 1-19 2-8 2-10-2-11 . 2-12-2-14 | 2-15. 2-16. 2417. 2-18. *Zero in this colurnn indicates an original page. 0 3-10.27 - 3-10.28. 7] 3-10.29 - 3-10.35. 9 3-10.36 blank 7 311-312 9 "1DMWR 55-1520-210 LIST OF EFFECTIVE PAGES (CONTINUED) Page *Change Page No. ‘No. No. 0 3-179- 3-183 6 3-184. 6 3-185 deleted .0 3-186 . 4 . 3-187. . 3-188 .... 0 ‘3-189 blank . 7 3-190 - 3-192 . .0 .0 31921. oe n 3-192.2 blank oe 0 3-193 9 n 3194 .0 nN 3195 n .0 3-196 - -0 1 3-205 n .0 3-206 1 5 3-207 n 0 3-208, ° 3-110. nv 3-209 7 3-111-3-114 . ed 3-210 0 3-115 n sen 1 3-116 - 3-125 . 0 3-212 -3-218 . oO 3-126 10 3-218.1-3-218.8 1 3126.1 .9 3-219 1 3-127 -3-1% . ~0 ‘3-220 °o 3-196.1 - 33-1363 6 3-220.1 7 3-136.4 7 3-2202 blank 7 3-136.5 6 3-221- oO 3-136.6 . 6 41.. wn 3-137 - 3-138 .. oO 0 3-139 -3-141 .. n 2 3-142 -3-149 . oO oO 3-150 n 7 3-151 7 9 3-152 1 1 3-153 - 3-164 - 0 1 (3-165 - 3-166 - eau 0 3-167 0 un 3-168 | 0 ‘3-169 - 3-170 . ° . 10 3171 .. 1 oO 3-172 - 3-174 deleted . 11 3 3-175 1 6 3-176 . 10 oO 3+178.1 -3-178.4 - 10 0 Zero in this column indicates an original page. B Change 11Me DMWR 55-1520-210 LIST OF EFFECTIVE PAGES (CONTINUED) Page "Change Page "Change No. No. No. No. 4-83 - 4-88 deleted... 5 4-1783-4-1785..... 11 4881... 4 4178.6 blank ” 4 4179 4-185 ° 1 4-186 6 10 4187-4215 = 1 7 4216 on 1 4-217 0 ° 4-218 - 4-219 3 1 4-220 - 4-221 ° nO) 3 " 0 0 0 rr 0 40-401 62222. 0 3 a2 ES 8 4-113 -4-120 20 0 4120.1 .... 14 6 4-120.2 blank 4 7 4-121 10 0 4122-4127 0 4-128 ut 4-129 10 4-130 3 4131 20 4-132 : 8 4-133 - 4-135 20 4-136 7 4137 0 4-139 eons ata aaa To 4145. 10 4146-4147 | ° 4148. 1 4149 4151 ° 182. 1" 12 10 4-152.2 blank.....+10 4-153 = 4-171 o ALT2ecseeeee 9 Bel 73.cceeeee 7 FelTbseeeseee 9 4-278. 0 4-175 ~ 4-176 0 4-278.1 ~ 4-278.2.. 7 SLT eceee = 4-279. ceceeeeeeeeeel 4-178... ean 4-280. .eeeeceeeseee 2 GHLTB.Leeeeeeeeeee edd 4-281 ~ 4-282....4. 0 4-178.20000eeeeee 10 4-283....ceeeeeeeeel 4-1782A- 447828 -. 11 4-284 ~ 4-287...... 0 “Zero in this column indicates an original page. Changet1 CDMWR §5-1520-210 LIST OF EFFECTIVE PAGES (CONTINUED) Page ‘Change No. No. - 4-384 - 4-413 ......... 0 6-3 - 6-4. 4-333 4-335 4-337 4-38 - 4-340 - 434. 4-345 4-347 Soleseeeeeee +348 5-2 blank... 4-349 G1 - 6-202. 4-350 4-351 RERREREEOGAA *Zero in this column indicates an original page. D Change 11DMWR 55-1520-210 ‘Depot Maintenance U.S. ARMY AVIATION ‘Work Requirement AND TROOP COMMAND No. $5-1520-210 31 July 1984 AIRCRAFT DEPOT MAINTENANCE, ‘WORK REQUIREMENT ADM ‘UH-1H/UH-1V HELICOPTERS [NSN 1520-00-087-7637 (UH-1B) [NSN 1520-01-943-4949 (UB-1V) REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS ‘You can help improve this DMWR. If you find any errors or if you know of a way to improve this DMWR, let us mow, Mail your letter, DA Form 2028 (Recommended Changes to Publications and Blank Forms), or DA Form 2028-2 located in the back of this DMWR, direct to: Commander, US Army Aviation and Troop Command, ATTN: [AMSAT-I-MP, 4300 Goodfellow Blvd, St. Louis, MO 63120-1798. A reply will be furnished to you. DISTRIBUTION STATEMENT A: Approved for pablic release; distribution is unlimited. ‘TABLE OF CONTENTS: Paragraph Page CHAPTER1. INTRODUCTION 1 Section I. . 7 a a ‘Section U. Description, Data Plates and Tabulated Data . 1s 121 Difference Between Models - 2 119 24 24 2A 26 22 21222 34 31 34 on U. Airframe PSA. 38 34. Section I. Task Group 02 Landing 312 310 ‘Section IV. Task Group 03 Power Plant . BS 37 Section V. Task Group 04 Rotor and Transmission 32300337 Section VI. Task Group 06 Hydraulic System ..... 3290-3458DMWR 55-1520-210 ‘Section VIL. ‘Section VIII. ‘Section IX. Section X. Section X1. Section XII. CHAPTER 4. CHAPTER 5 a 12 13 14 Ls 16 M7 18 19 110 Lu, 00-01 01-00 01-01 1-02 01-03 01-04 01-05 01-06 01-08 01-09 01-10 ont 1-12 113 O14 o1-is 01-16 1-17 01-18 ‘TABLE OF CONTENTS - (Continued) ‘Task Group 08 Aircraft Instruments ‘Task Group 09 Electrical System ....« ‘Task Group 10 Fuel System . ‘Task Groop 11 Flight Control Systems ‘Task Group 12 Utility Systems ‘Task Group 19 Avionics PSA... — MAINTENANCE AND REPAIR PROCEDURES . PREPARATION FOR ACCEPTANCE FLIGHT TEST . QUALITY ASSURANGE/QUALITY CONTROL REQUIREMENTS General Inspection Requirements . PACKAGING .... REFERENCES .. ‘Overhaul Data Plate (P/N 100-068-1) . Modification Data Plate (P/N MS27253-2) - ‘Aircraft Depot Maintenance Flow Chart-Typical ‘Quality Standard for Rivet Spacing and Minimum Edge Distance . Center Service Deck Alignment Tool. Insallation of Fuselage ato Major Assembly Fie Spacing and Size ....01-19 01-20 01-21 01-22 01-23 01-24 01-25 01-26 01-27 01-28 01-29 01-30 1-31 01-32 01-33, 01-34 01-35, 01-36 01-37 01-38 01-39 01-398, 01-40 01-41 01-42 01-43 01-44 01-45, 01-46 01-47 01-48 01-50 01-51 01-52 01-53 01-54 01-55 01-56 01-57 01-58 01-59 01-60 01-61, 01-62 01-63 LIST OF ILLUSTRATIONS - Continued Tile ‘Comer Cracks in Double-Formed Flange . Sige eum in Skin ana'Veb «= ‘Skin Oil Can Repair . . Replacement of Potted Type Inserts .. ‘Fractures or Punctues in One Facing Not Exceeding Fractures or Punctures Through Fiberglass Skins ....... epi of kin and Core Damage Fractaes or Puncturs in Oe of Repair of Stingers, Siiffeners,Channeis, Intercowals and Webs «...... Doubler Repair at Lower Door Tracks .. : Doubler Repair to Closure Strip at Upper Door Track Minor Edge Damage to Main Beam Caps - ‘and Vertical Cracks in Main Beam Caps. ‘Cracks at 129.00 Main Beam Caps ‘Sup Splice Installation Fwd Landing Gear Mounting Strap Splice Installation Aft Landing Gear Mounting Points Lift Beam Web Cracks or Punetures, ‘Main Beam Repair FS 243.00 . (Channel Repair L/H and RH «2... Pylon Stiffener Repair LH and R/HL ‘Web Repair Bulkhead Repair FS 243.89 . DMWR 55-1520-210 SR88 SSERSREERLE an 4102 4108 4-105 Change titDMWR 55-1520-210 Saas EREEeaa ses BEBB SBES EERE ‘Skin Peeling Tool in Use (Figure 3 and 4) . ‘Typical Reference Structure for NDI (Figure5) .......+.++ FWD Compartment Drain . Repair of V-Band Corrosion. pee ee Rowse Blade Dazage (153-L-13) Before and Afr ‘Repair (All Stages) Flange and Baffle Repair ...... “Typical Repair of Paticle Separator Sheet Metal Parts .. ‘Test Schematic and Procedure for Testing Oil Cooling System. “Thermostat Valve Assembly . . 4.128 4129 4130 4131 4132 4133 4136 4137 4139 4140 4141 4143 4144 4145 4146 4147 4148 4149 4151 41521 4153 4-156 4-160 4176 41781 41782 417824 417828 41784 41785 4180 4181 4182 4183 4184 4.185 4209 4210 4211 4212 4214 4215 4216 4218 4230 4231 4232 4236 4237 4239 4242 420210437 0438 0439 erry LIST OF ILLUSTRATIONS - Continned Title ‘npot Drive Quill P/N 204-040-363 Root End View of Tail Rotor Blade Patch Repair Limitations ‘Tail Rotor Hub Assembly .. ‘Upper Swashplate Damage Limits WEEE Allo Romane olin of Sasi aia Ronny Damper Fis and Gers Rotary Damper, Prt No, 2000-7, 21089, ‘2008-101 and 20208-103 Collective Lever ‘MWR 55-1520-210 4248 4249 4.252 4.253 4-260 4261 4-267 4274 4215 4-276 4228 42781 42782 4279 4279 4-284 4285 4.286 4287 4.288 4.289 4290 4293 4.294 4.296 4297 4298 4298.1 42983 42986 4298.8 4300 4301 4-302 4313 4315 4316 4317 4318‘DMWR 55-1520.210 Figure 04-42 04-43, 044d 044s 04-46 04.47 04-48, 0449 LIST OF ILLUSTRATIONS - Continued ‘Temperature Bulb and Thermoswitch Oil Cooler Turbine Blower Assembly (P/N 132101-1) Oil Cooler Turbine Blower Assembly (P/N 20152-3) . MILS-Peak to Peak Max Displacement MILS-Peak to Peak Max Displacement . . ‘Hentficaton Tags for Field Fabricated Hose Assemblies ‘Typical Electrical Systems Troubles ‘Test Set-Up for Fuel Shutoff Valve ‘Valve and Actuator Test System . Test Set-Up ‘Air Mixing Valve (Pueumatic) Inspection Replacement Data . Fire Detector System . Deleted Deleted EEERREREEREERE 5Tab] ee f2o Tzer 310 #1 00-01 01-01 03-01 03-02 03-03 03-04 04-01 04-02 04-03 08-01 10-01 10-02 Principal Dinensiens.... 0.0.0.0... Typical Utility and Space Recuirenente, Special Tools List......,.../- Inspection and Test Equipments... Expendable Consumable Maintenance Supplies and Materials... Modification Work Orders (Mi0s). Preshop Analysis (PSA) Checklist Mandatory Modifications. ......+..., Inspect For/Linits Fuselage Skin... Tailboom Alignnent Check Criteria..... Skid Tube Repairable Limits.....-0.000.., Engine Mandatory Replacement Conditions... Netal Particles Contamination of Pover Plant... Inspection Linits-All Tubing and Hose Assenbiies Inspection Linits For Control Rods, Tube Assemblies and Connecting Links... Inspect For/Limits For Tail Rotor Blades... Transmission Mandatory Replacement Conditions. Inspect /Linits-Interior and Exterior Lighting. . Standard Requirenents for Rivet Edge Distance.. Approved Honeycorb Adhesives... Engine Performance Ratings for Standard Day Sea Level Conditions... Compensating Factors... Troubleshooting Data. ‘i Calibration Data for Torquemeter and Engine O11 Pressure Transnitters......... Main Transmission Test Requirement: Tail Rotor Blade Repair Resistance Bulbs... Troubleshooting........ Contents of Fuel Cell Repair Kit Group 1.. Contents of Fuel Cell Repair Kit Group 2.. Change 4 vii/ (viii blank)DMWR55-1520-210 CHAPTER 1 INTRODUCTION Section L 1-1. Scope. These instructions are for use by depot! ‘contractor personnel. They apply tothe UH-1H and UH-1V helicopters (figures 1-1 and 1-5), and, in case of conflict, take precedence over all other documents pertinent to its ‘overhaul and inspection. 1-2. Deviations and Exceptions. When any work segment as set forth in this depot maintenance work requirement cannot be accomplished, or can be accom- plished only in a manner other than specified, the contrac- {or shall submit a Request for Action Form AMSATI-M through the Contracting Officer to AMSAT--MP with a copy to AMSAT-I-SM. If the problem is publications related or requires a change to a publication, 2 DA Form 2028 shall also accompany the Request for Action. The ‘Request for Action shall sta the problems, the reason for urgency and give the following specific. GENERAL 4. Serial number (if applicable), part number, and NSN of affected equipment. 3, Work elements which will not be completed or ‘which will not be accomplished exactly as specified berein. ¢ Reason for nonaccomplishment or deviation. d. Action taken to correct condition causing nomac- complishment or need for deviation. ¢ _ Data relative to availability of parts required, if applicable. A Estimated man-hours. Instructions and inspection required to maintain the integrity of the end item becanse of such omission or Change Il 1-1DMWR 55-1520-210 Figure 1-1, UH-1HV Helicopter 121.3. _ Maintenance Forms and Records. Depart- ‘ment ofthe Army forms and procedures used for equipment ‘maintenance shall be those prescribed by DA PAM 738-751. 1-4. Reporting Equipment Improvement Recom- mendations (EIR). EIRs shall be submitted by anyone ‘who is aware of an unsatisfactory condition with the equip- ‘ment design or use It is not necessary to show a new design DMWR 55-1520-210 Ot list a better way to do a procedure. Simply tell why the design is unfavorable or why a procedure is difficult. EIR will be prepared using STD Forms 369, Maintenance Request. Instructions for preparing EIRs are provided DA. PAM 738-751. The Army Maintenance Management Systems (TAMMS). EIRs should be mailed directly to Commander, U.S. Army Aviation and Troop Command, ATTN: AMSAT-L-MDO, 4300 Goodfellow Blvd, St. Louis, MO 63120-1798. Section IL DESCRIPTION, DATA PLATES, AND TABULATED DATA. 1-5. Description. The UH-1H and UH-1V helicop- ters (Ggures 1-1 and 1-5) are essentially all metal helicop- ters with one main rotor and one tail rotor, and powered by a murbine engine. Features include the two-bladed main rotor, low silhouette, wide cabin and skid-type landing gear. A more detailed description ofeach system and types of structures in specific areas is contained in the applicable ‘section of chapters 3 and 4, Principle dimensions appear in table 1-1. Pages 1-3 thru 1-5, including figures 1-2, 1-3 and 1-4, have been deleted, Change 11 1-2.1/(1-22 blank)DMWR 55-1520-210 (1-5 blank) /1-6 Heating Burner and Blower Unit Engine Oil Tank Filer Fuel Tank Filler ‘Transmission Hydraulic Reservoir (Pressure Type) Forward Navigation Lights (4) Pilot's Station Forward Cabin Ventilator (2) ‘Cargo Suspension Mirror Pilot Tube (Nose Mourt) Tail Rotor (90°) Gear Box Aft Navigation Light ‘Tail Rotor intermediate (42°) Gear Box ronized Elevator Tail Rotor Drive Shatt ‘Anti-Colision Light 8 SSBB VRRSBR Battery Altemate Battery Location (Armor Protection Kit) Pitot Tube (Roof Mount) ‘Aft Cabin Ventilators (2) Stabilizer Bar Hydraulic Reservoir (Gravity-feed type) Engine Cowiing Figure 1-5. General Arrangement Diagram — Typical ‘All data on pages 1-7 through 1-11 have been deleted. Change 11DMWE 55-1520-210 ‘Table 11, Principal Dimensions LENGTH Overall (main rotor fore and aft and tail rotor horizontal) 57 ft. 0.67 in. Overall (main rotor fore and aft and tail rotor vertical to aft end of tail skid 4 ft. 1.67 in. Nose of cabin to aft end of vertical fin (tail rotor vertical) 41 ft 50 in, ‘Nose of cabin to aft end of tail rotor (tail rotor horizontal) 44 ft. 100 in. ‘Nose of cabin to center line of main rotor 11 ft, 8.65 in. ‘Skid Gear . 12 ft. 2.0 in. WIDTH Synchronized elevator 9 ft 43 in ‘Skid Gear 8 ft. 66 in. Stabilizer Bar 9 ft. 0.5 in. HEIGHT (to static ground line) ‘Tip of main rotor forward blade ‘Secured aft 17 1.49 in, Pressed down forward 7 ft. 9.19 in. ‘Top tip of tail rotor vertical 14 ft, 8.20 in. ‘Top of stabilizer bar 18 ft. 7.40 in. ‘Top of cabin 6 ft 8.13 in Bottom of cabin 1 ft, 8.48 in, ‘Tail rotor clearance (ground to tip, rotor turning) 6 ft. 3.0 in Tail skid to ground 4h. 90in DIAMETER (swept circle) Main rotor 48 ft 3.2 in. Main rotor Chordwise 1f.90in Tail Rotor 8 ft. 6.0 in. ‘Tail rotor chordwise 841 in. Stabilizer bar 9 ft. 05 in. ‘Turning radius 34 ft 04 in. (1-11 blank) /1-121-6, Reference Lines. The reference lines of the UH-1H and UH-1V helicopters appear in igure 1-6. Refer- cence lines are defined as follows: 2, Station Lines. Station lines (STA) are vertical reference lines against the helicopter which are used to locate major assemblies and pars ofthe structure by a mum ber indicating the distance in inches from a line ot origin, ‘which is designated as Station O. b. Water Lines. Water lines (WL) are horizontal reference lines used to locate major assemblies and parts of the structure by a number indicating the distance in inches ‘oneach side ofa line or origin, which is designated as Water Line 0. ¢. Buttock Lines. Buttock lines (BL) are vertical reference lines used to locate major assemblies and parts of, structure by a number indicating the distance in inches on ‘cach side ofa line or origin at helicopter center-line, which is designated as Buttock Line 0. 1-7. Data Plates. a. Plate Location. See figure 1-7 for locations of the ‘identification, overhaul, and/or modification data plates. The plates shall conform to the standards presribed in MIL-STD-130 and MILP-514, CAUTION Do not stamp directly on surface of installed ata plate. b. Identification Plate (Figure 1-8). This plate P/N 100-030-1, contains the manufacturer's identity code (FSCM), name, address, and system. In addition, the speci- fication, NSN, manufacturer’s part and serial numbers, ‘contract or order mumber, and ownership are stamped on the plate. (2) Reasonable facsimile nameplates may be ‘manufactured from 0.032 inch thick sensitized aluminum alloy sheet if Quality personnel determines the original nameplate is missing or mutilated beyond further use. Mutilated nameplates which have been replaced shall be and then cat up by or in the presence of DMWR 55-1520-210 aircraft serial numbers, and all other records pertaining to replacements of Manufacturer's Aircraft Association (MAA) nameplates shall be retained by Quality personne! ‘as evidence of proper disposition. 2) Lecally manufactured nameplates shall ‘contain all available data that has appeared on the lost or ‘mutilated original and will include full date of acceptance and MAA Number if available. Rubber stamp part number on “reverse side of replacement nameplate: P/N UH-1-00032-1. “Trademarks contained on the original nameplate shall not be reproduced without consent of the trademark owner.” (3) The following log book entry shall be entered on Form 2408-15 of the aircraft which is receiving the replacement nameplate: “This aircraft was inducted (Date) with original MAA Nameplate (Missing) (obliterated beyond further use) (ENTER APPROPRIATE TERM). Replacement nameplate manufactured and installed in ¢. Overhaul Data Plate (Figure 1-9). This plate, P/N 100-068-1, is installed at first overhaul and replaced at ‘subsequent overhanl. The overhaul data plate is stamped with the overhaul agency symbol, contract number, date of ‘overhaul, and part number. Any pertinent data should be transferred from old data plate. 4. Modification Data Plate (Figure 1-10). The data chal be stamped on the data plate using letters and fig- tures 1/8 inch high, placed in the area adjacent to the ‘manufacturer’s data. In the event modification numbers have exceeded stamping spaces on the data plate, the plate shall be replaced and all pertinent data will be transferred to the new plate, 18. Work Definition. 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NOLLARIOSHG Wall daa 2010 (Panujue) sjepayoyy PUB soyddng soucUayUYY aquMINsUCD aIqupHadxA “y-Z 714RI, “224 Change ILDMWR 55=1520-210 quaTeaTnbe toy 61909. 7h, coseoryD a ‘unetpoom a o9g¢ "4409 edez >T384H Toree w2SyL *ON (@FTsI9y) Trog wnutunty ‘edey, 181 . ois MK ‘Thea ‘ag txoqu99 We ° T21399Tg Tex0UsD ‘eatsouPY £61 suofaeuTueT €00" ZI aFAydmog 8 X ¥Z x ZE0" 6018-B19-SES6 66%22~S-TIH 3901S Uys wnUTUNTY zor 916-X-LL aust Ax 161 Ovs-S-ad 20 98%-W1IK wnupunty ‘TooK 06t : yLessHY SupPTen ‘23TH 68T €L1-A-11K Tro ‘ysyuse, eet pereTog cet TeoFUyoaL, T ady *079-I-0 “peatqryal ‘eueyze0r0TYOFAL 1‘ TT 981 8yS-I-LL [woruyDeY, ‘euenToy ser 9ez-4-0 ‘suet kyaezotyszeq ver AZGI-101SS NH ‘THea ‘as yequep 3g0zz HE/AFO dey TeyAasnpuL 1860-¥1S-00-0608 | 18€92 ELD ON %OFUL WOUT €00°O ‘TAUEA ‘edey, eet 60680 CN ‘yOFASUNIG AON 119 xog *o°a ‘1 AemusTH "sn ‘+09 Kraay 30 apa ‘edeq Teveuxed 2466 alld (@FTAa9y) Tod wnuTunTY ‘odes, zer NSN ‘BoVD “ON diva 30 Ogas NOIsaTuosad > WALL aad 0 11h (ponuyauop) Seyasa"q pub GeT[ddng sousUeIUTEH eTqeuNeoD eTqupusdy “h-Z OT4EL iPUBLICATION NUMBER, MWO 55-1500-219-30-4 and Changes MWO 55-1500-219-30-8 and Changes MWO 55-1500-219-30-9 and Changes MWO 55-1520-210-3034 and Changes MWO 55-1520-210-30/36 and Changes MWO 55-1520-210-30/37 and Changes MWO 55-1520-210-30-39 ‘and Changes ‘MWO 55-1520-210-30-42 and Changes MWO 55-1520-210-30-43 ‘and Changes ‘MWO 55-1520-210-30-45 ‘MWO 55-1520-210-30-48 and Changes MWO 55-1520-210-30-54 and Changes MWO 55-1520-210-30-55 and Changes MWO 55-1520-210-50/2 MWO 55-1520-210-50-6 and Changes ‘MWO 55-1520-210-50-7 MWO 55-1560-284-50-1 MWO 55-1520-210-50-25 Table 2-5. Modification Work Order (MWOs) TITLE Installation of Provisions for AIMS Altimeter Installation of Five (5)-Volt Instrument Lighting System (MEDEVAC) Installation of Main Rotor Mast Insert (Plug) Update of Provisions for the AN/APX-44 & 72 ‘Transponder, Kit LA/TSEC Computer and MT- 3949A/U Computer Mount Modifications to Install Provisions for AN/ARC-114 (VHF Radio Set) Modification to Install Provisions for ‘AN/ARC-115 (VHF/AM Radio Set) Installation of Crashworthy Breakaway Valves for Fuel and Oil Lines Installation of Crashworthy Auxiliary Fuel ‘System Provisions for 300 Gallon Internal ‘Auxiliary Fuel Cells Installation of Roll Over Vent Valves for Fuel Tank Installation of Glidescope/Marker Beacon Radio Receiver R-1963/ARN Installation of Altimeter Set Electronic AN/APN-209 (MEDEVAC) Provisions for Installation of KAFLEX Main Drive Shaft Installation of an Improved Closed Circuit Refueling Receptacle Installation of Additional Roof Access Step Installation Provisions for Radar Warning Receiver (RWR) AN/APR-39 ‘To Provide Modification Instructions for Night Vision Goggles (NVG) Compatability Modification for Infrared (IR) Suppressor Duct Assembly Installation Provisions for Improved Particle Separator P/N CE-00553-1 DMWR 55-1520-210 PSA TASK NO. a4 35 37 38 39 3:10 3a 312 313 344 BAS 3.46 347 318 319 319.1DMWR 55-1520-210 Table2-6. Flight Safety Parts PART NUMBER NOMENCLATURE CRITICAL CHARACTERISTIC 204-011-401-11 Scissors/Sleeve Assembly 1, Proper Lubrication of Bearings 2. Proof Load of Bearing 204-040-611-1 Seal 1. Must be free of installation damage (nicks, cuts etc.) 2. Fully seated in coupling 204-040-353-23 Case, ‘Fluorescent penetrant inspection 204-040-354-9 ‘Support ‘Fluorescent penetrant inspection 205-001-914-5, -25, Elevator Hom 1. W.ofbom 2. Minimum radius (2 PLS) 204-040-600-11 Hanger Assembly Presence of grease in couplings 204-040-6101 Plate ‘Seal must be free of installation ‘damage (cuts, nicks, etc) 204-040-603-7 ‘Cocominm plate bake cycle 204-040-620-7 ‘TR Drive Shaft Surface finish (32 RMS) 204-011-801-121 ‘TR Hub Assy 1, Installation of shims 2, Installation of split cones 3. Safety feanures (Lockwire) 4, Proper torque of retain nut 5. Installation of lockplate 204-011-406-15 Scissors Assembly ‘Minimum thickness of lag 204-011-402-13 Jimner Ring Gimbal mount boss ear minimum thickness (0.240 inch) 204-011-404-5 Swashplate Support (Gimbal mount ears minimum thickness (0.200 inch) 204-011-307-1 ‘Stab Bar Cir Frame Fluorescent penetrant inspection. 204-011-326-7 Stab Bar Assy 1, Installation of safety feature (cotter —228 Change IL in) 2. Minimum tbe engagement in weight‘Table 2-6. Flight Safety Parts (Cont) DMWR 55-1520-210 PARTNUMBER NOMENCLATURE CRITICAL CHARACTERISTIC 204-012-101-137, -141 204-011-127-1 204-001-793-5 204-001-795-5 204-001-800-1 205-001-728-1 MIR Hub Assy (MIR Pitch Links ‘Support L Existance/installation of safety features (lockwire) 2 Existance/installation of clamp and Tocknut Installation of Safety features (cotter pin) L w rope ye Re Bearing staking Bdge break Bearing staking Edge break Bearing stake Penetrant inspection Eaige break Bearing stake Penetrant inspection Edge break Change 11 2-29/(2-30 blank)CHAPTER 3 DMWR 55~1520-210 PRE-SHOP ANALYSIS Section I. 3-1. Purpose. The purpose of pre-shop analysis is to determine; prior to the beginning of depot maintenance and at the highest assembly level possible, the extent of repair, modification, and replacement needed in order to make the aircraft a completely ser- viceable unit, as specified herein and to prepare estimates of work and Parts required for performing the depot maintenance. If inspection at the highest level of assembly is pre- cluded by missing, damaged, or diagnosed defective assemblies, consideration will be given to techniques that would allow continued inspection at that level. If this is not possible, in- spection will proceed at the next lower level. A preshop analysis check- list will be used to record the results of the analysis and any required main- tenance. All safety of flight and mandatory inspections and/or modifica~ tions will be accomplished. 3-2. General. a. Pre-shop analysis (PSA) con~ sists of a thorough physical examina— tion and evaluation of aircraft, related components, and aircraft engine, utiliz- ing visual and diagnostic test tech- niques. PSA shall determine the speci- fic depth and extent of work to be per- formed and shall certify all aircraft, engine and component records in accordance with DA PAM 738-751. After com- pletion of PSA, a cost and manhour estimate shall be computed and aircraft disposition made in accordance with TB 750-99-15. The following PSA instruc tions are provided to ensure a com- plete examination of the incoming aircraft. The information from this GENERAL AIRCRAFT RCN PSA examination should be used by the depot maintenance facility in preparing estimates which will determine the ex- tent of repair, modification, and replacement needed in order to make the aircraft 2 completely serviceable unit. The results of pre-shop analysis will be recorded on a copy of the pre- shop analysis checklist, table 3-1. Quality standards contained in the Depot Maintenance Work Requirement (DMWR) shall be adhered to. Detail cleaning and corrosion treatment methods have been included where ap- plicable. Items pending performance of maintenance shall be preserved to Prevent damage or deterioration due to corrosion or decay. c. This PSA chapter employs the concepts of reliability centered main- tenance (RCM). RCM identifies and directs only those maintenance actions that (1) are required to preserve in- herent design reliability of the equip- ment, or (2) are cost-effective for non- critical itens, or (3) insure mission capability. 3-3. Inspection of Forns. NOTE Assure that all tags and forms are checked to determine the reason for re- moval from service. Record reason and any other helpful data on the preshop analysis checklist, table 3-1. Also determine what open items of work or delayed discrepancies, including any TMs, TBs or HWOs are not accomplished. Change 4 341DMWR 55-1520-210 @. Review all DA Form 2408 Aircraft Historical Records {for completeness: if records are incomplete or missing, every ‘effort shall be made to obtain required information from the shipping activity. In the event this information cannot be obtained, the contractor shall request instructions from USAAVSCOM, ATTN: AMSAV-MMD, 4300 Goodfeliow ‘BI4., St Louis, MO 63120-1798, telephone: (314) 263-1879 (AV 693-1879). 'b. Areview will bemade initially ofall incoming aircraft records to determine the following minimums: (1) Modification Requirements. A physical inspec- ‘ion of the aircraft, in conjunction with a check of DA Forms 2408-5 and 2408-15, and review of the mandatory modifica- tions as listed table 3-2 shall be accomplished to determine ‘outstanding mandatory modifications. The term mandatory ‘modifications includes Modification Work Orders (MWOs) and other modifications that were approved and implemented without use of MWOs. Physical check of the aircraft for ‘mandatory modifications compliance can be accomplished utilizing figures referenced in table 3-2 as a guide. All out- standing mandatory modifications will be accomplished as, specified in the contract or PWDs. Contracting officer shall be contacted if kits are not obtainable through requisitioning. DA Form 2407 shall be initiated for each mandatory modification. 2) Sams of Time Change Items. A physical in- spection of the aircraft will be made in conjanction with a check of DA Form 2408-16 of all Time Change and Condition Components as listed in TM 55-1520-210-23, Chapter 1, Section V. Criteria for reuse of aircraft components shall be those listed in TM 55-1500-326-25 and AR 750-1, and specific performance criteria identified andjor referenced in this DMWR, ensuring that aircraft meets requirements for transfer within CONUS theater of operations or unless other- ‘wise directed by the contracting officer. DA Form 2410 shall be initiated for each time change item due replacement in accordance withDA Pam 738-751. (3) Inventoriable Items. Inventoriable items will be checked against the Aircraft Inventory Record, DA Form 2408-17. Listed items are contained in TM 55-1520-210-23, ‘Appendix C. "Missing or deteriorated mission essential equip- ‘ment will be replaced. Repairs will be made in ‘accordance with chapter 4 of the DMWR." (@ Mission Essential Equipment. Mission essential ‘equipment, i, avionics, winterization kits, etc., will be determined by equipment for the ultimate destination of the sircraft upon completion of depot maintenance. This infor- mation is obtainable from the contracting officer. All required. mission essential equipment will be installed and functional tested prior to release of the aircraft for issue or assigament. 3-4, Aircraft will be received either in a flyable status or for short term or intermediate term storage (See ‘Appendix E, TM 55-1520-210-23). Aircraft will be main- ‘tained in an appropriate storage category in accordance with ‘Appendix E, TM 55-1520-210-23. Aircraft received ‘preserved for intermediate storage may be represerved for imermediate storage and processed directly into the PSA ‘process without the benefit of a maintenance test flight onr).3-5, Maintenance Test Flight. A maintenance test flight ‘will be performed on all aircraft to be inducted to PSA from flyable or short term storage status in accordance with TM '58-1520-242-MTF, unless otherwise specified by the con- tracting officer. Findings shall become a part of the PSA. ‘evaluation and information used in evaluating the aircraft in accordance with the contents of this chapter. NOTE Preliminary PSA. Immediately upon comple- tion ofthe maintenance test flight, inspect for ol ‘and fuel leaks, and general condition of rotating parts for loose or missing pars. 3-6, Pre-PSA Cleaning Requirements. 2. The following procedure shall be adhered to, insuring ‘that only necessary and economical paint stripping is per- {formed on inducted aircraft. NOTE ‘All Time Change finite life and condition items ‘which require removal shall be removed prior to leaning and stripping. () Prior to cleaning and stripping aircraft, PSA personne! shall conduct an examination of exterior paint and identify those areas which require selective stripping. ‘Selective stripping shall be employed ifless than 35 perceat cf main fuselage or 25 percent of tilboom painted areas require removal. If painstripping is required in excess of these percentages, the entire fuselage or tailboom as ap- plicable shall be stripped. Refer to Chapter, Section I. (2) Epoxy primer shall be stripped only in areas of deterioration and as specifically specified for visual inspec- tion. DMWR 55-1520-210 'b. On category 1 aircraft only, the following listed areas, ‘shal be stripped by PSA for dye penetrant inspection unless ‘other non-destructive testing methods approved by the con- tracting officer are employed (.., ultrasonic, eddy current, ‘tc) in which case paint stripping may not be required. (2) On category [aircraft only. (@) Transmission mounts will, visually be in- spected. Ifacrackis then suspected, the fluorescent penetrant, co other approved NDT method will be used to confirm suspected crack. Mounts need not be removed for inspection tunless a suspected crack cannot be confirmed except by removal. ~ (®) Teilboom attach fittings (fuselage and tail- boom). (2) On category I, I and Il aircraft strip the upper ‘beam cap, FS 129.00 RH and LH, WL. 22. ‘Above areas will be and stripped in accordance with ‘Procedures specified in Chapter 2, Section II. ‘e. Prior to cleaning with liquid detergents, vacuum the imerior of the aircraft structure and cabin area, removing as ‘much loose debris as practicable. Scrape areas of accumu- ‘ated dirt-oll deposits beneath floor boards and vacuum. 4. Visually inspect honeycomb panels for punctures that ‘would expose the core to moisture. If punctures are detected, seal the hole. After preparation and identification of stripping requirements aircraft will be cleaned and stripped in accord- ‘ance with procedures specified in Chapter 2.DMWR 55-1520-210 ‘Section III, and returned to PSA for further evalua- tion. NOTE PSA may identify additional areas to be stripped for further visual inter- pretation. This is in addition to man- datory paint stripping requirements. 8-7. PSA Procedures. NOTE There are a number of separately funded programs for conducting depot maintenance on aircraft: some for accomplishing minor repair, some for overhaul. The determination of whether the aircraft is to be inducted and processed under @ minor repair program or an overhaul program is ‘made prior topre-shop analysis and is specified in the contract or PWDs. However, pre-shop analysis may deter- mine that an aircraft inducted for minor repair actually requires over- haul. Aircraft inducted for minor repair are processed in accordance with TM 55-1520-210-23. Aircraft in- ducted for overhaul are processed in accordance with the PSA and repair chapters of the DMWR. The pre-shop analysis depth of inspection, as defined by the pre-shop analysis (PSA) checklist (table 3-1), will determine component parts and assemblies that table 3-1 should be observed. Over- Processing will be restricted by ‘segregation of component parts and assemblies that are within table 3-1 limits. @. TM 65-1520-210-28 shall be used for removal and reinstallation of component parts and subas- semblies. Unless required as a maintenance ex- pedient, parts removal and disassembly are limited to that contained in the PSA and repair chapters of this DMWR. 3-4 Change 10 &, ‘The access and inspection doors and panels (in- spection Taak 3-01) will be used for performing the PSA. Table 3-1 is a mandatory listing of items requir ing PSA and a cross reference to the appropriate PSA figure, table, and/or paragraph numbers. ¢. The PSA is broken down for the entire aircraft into various inspection task groups for clarity of presentation and in no way should indicate the se- ‘quence of operation. Local farmats may be adopted to fit physical plant layouts, etc. However, all indicated position made will be available for each aircraft processed by the depot/contractor for a period of two years or as directed by the contracting officer, to provide objective evidence of PSA evaluation and find- ings obtained. This information will be immediately available to the contracting officer upon request. d. The PSA inspection tasks in this chapter show typical and specific areas to be inspected. Each item on a photo or illustration is keyed to the “INSPECT FOR/LIMITS" column by means of an index number. ‘This column lists the items being inspected along with the type of damage or wear to inspect for. The limits listed are the repairable or acceptable limits. Unless otherwise stated the item is to be replaced when the limits are exceeded. When inspections and limits apply to general or multiple use items, i., hoses, ‘tubes, skins, etc.,the information will be presented as using the criteria in Inspection Task 3-02 and Table 38.Section II. AIRFRAME PSA 3-8. General. This section contains the detailed PSA requirements for the fuselage structure. The PSA instruc tions for the tail boom are contained in DMWR 55-1560-222. 3-9. Removed Equipment. The follow ing items must be removed to allow for performing the PSA. These items shall be removed, evaluated, repaired in accordance with chapter 4, and re~ tained for later installation in the aircraft. Pilot and co-pilot seats < Crew seats Litter Installation (UE-1V) Mission Operators Seat(s) (EH~1H/X) Mission Equipment Racks (EH-1H/X) Shoulder harness Seat belts Insulation blankets Access plates and covers (Inspection Task 3-01) Tailboom Fuel boost pump Fuel cells 3-10. Structural Description. Prior to performing the PSA on the airfrane system, evaluation personnel shall be- cone familiar with chapter 4, struc~ tural description of the UH-1H/V and EH-1H/X aircraft. : 3-11. Structural Modifications. Cer- tain sheet metal modifications to air- craft structures are required on all aircraft. This information shall become a part of the PSA information as described in para. 3-7. Descrip- tion of specific sheet metal modifi- cations is contained in chapter 4. 3-11.1. Attaching Hardware and Seals. Inspect all rivets and hardware for proper installation, security, and correctness. All loose rivets and hardware and improper fasteners shall DMWR 55-1520-210 be identified and replaced. Missing or deteriorated seals and chafing strips will be replaced. Loose seals will be re-bonded. 311.2. Structural Alignment. a. Refer to Inspection Task 3-02 for alignment verification criteria. If a determination is made to place the main fuselage structure into the major assenbly fixture (item 27, table 2-2) the following parts must be re~ moved from the aircraft in order to provide tooling accessibility. (2) Main Rotor Blades. (2) Transmission and Engine Cowling. (3) No. 1 Hanger Bearing Bracket. (4) Releated Drive Shafting. (5) Engine Quick Change Assem- bly (QCA) including engine support mounts and firewalls. (6) Main Transmission QCA (Rotor Head, Mast and Transmission). (7) Transmission Mounts and Dampers. (8) Primary Rotor Control Servo Cylinders. (9) Landing Gear. (0) Tail Boom. (11) Mission Antennas (EH-1H/x). (42) IR Exhaust Duct Assenbly. (13) IR Oi1 Cooler Shield. (24) Wire Strike Installation. change 4 344.1DMWR 55-1520-210 b. Detailed instructions for in- stalling the fuselage into the fixture are contained in chapter 4. c. For tailbooms requiring align- ment verification, the following parts are to be removed prior to placing the boom in the universal holding fixture (item 25, table 2-2). (1) Tadlboom elevators. (2) Drive shafting and cou- plings. (3) Drive shaft covers. (4) 420 gear box. (5) 90° gear box. » (6) Mission antennas. (EH-1H/ d. Detailed instructions for placing the tailboom into the holding fixture are contained in DMVR 55-1560- 222. 3-+11.3. General Damage Limits for Air- frame Structural Repair. a. Definitions: Structural damage is classified as minor or major. (1) Minor damage is that vhich can be repaired by burnishing or in somé cases does not require repair. (2) Major damage is that which is serious enough that a patch insertion or part replacement is required. b. Types of Damage and Repair Limits. (2) Minor dents in plain and formed sheet metal must be smooth and free from cracks. (Small surface cracks which indicate that the metal was deformed excessively). Small dents to 1/4 inch diameter and not exceeding 3-4.2 Change 4 25 percent of the diameter in-depth and dents between 1/4 and 1/2 inch diameter not exceeding 10-percent of diameter in depth are satisfactory without repair. (2) All dents exceeding limit: for minor dents must be repaired by patching, insertion or replacement. Dented forgings and castings shall be replaced. Dented extrusions used as fittings and control supports must be replaced. (3) Minor nicks, scratches, and chafing can be removed by burnishing, followed by polishing (to remove tools marks) and blending to a smooth con— tour. Burnishing will be accomplished with a stone or burr of at least 1/2 inch diameter unless clearance problems require the use of smaller cutting tools. On all areas (excluding radii), burnishing shall be limited to no more than 10 percent of the original metal thickness. Nicks and scratches in radius can be burnished to a depth equal to 5 percent of the thinner sec- tion. (4) All nicks, scratches and chafing exceeding the above limitations are major and must be repaired by patching, insertion or part replacement. Major nicks, scratches and chafing on forgings, castings, fittings and support brackets require replacement unless special limits appear for a specific part. (5) All cracks in sheet metal and rolled and extruded shapes must be repaired by removing the cracked material and making a patch or inser- tion repair as required. Part replace- ment should be used where it is cost effective or where the repairs would be unsightly. Cracked forgings and castings must be replaced. (6) Minor corrosion: Large area corrosion which can be completelyRemove without removing over 5 percent of the original thickness acceptable. When the part exhibits large area corrosion on both sides of an area (web, flange, etc.), the total reduction of the original metal thickness is 5 percent. Corrosion exceeding the limits herein stated shall be repaired by patching insertion or parts replacement. a, Isolated spots of corrosion which have maximum major spots of 2-1/2 inches of 1/2 of the least dimension open area of skin or web,whichever is less, can be completely removed provided no more than 10 percent of the original metals: thickness is removed. Spots must be separated by 5 inches of sound, unre- paired metal. b. Isolated spots on longitudinal members: When the spot is on leg or web of an angle, zee, channel, etc., the spot must be completely burnished out. Up to a maximum of 10 percent of the original metal thickness may be removed. When the spot extends across two or more elements of a cross section, i.e., the spot must be completely burnished out. Up toa maximum to 5 percent of the original metal thickness may be removed. NOTE Minor corrosion is repaired by removing corrosion, treating metal surface with appropriate chemical and then painting. Major corrosion shall be repaired by patching insertion or by parts replace- ments. c. Loose Rivet: rivets. d. Missing Rivets. ing rivets. e. Field Repair. Replace repairs that do not meet the criteria of this DMWR (i.e., type and thickness of re~ pairs material). Only weak field re~ pairs can remain provided they are neat in appearance and meet the minimum re~ quirements of this DMWR. Replace loose Replace all DMWR 55~1520-210 3-11.4 Acceptance of Repairs The presence of temporary structural repairs performed by field maintenance organizations is a factor that influ- ences the decision to return an aircraft for Depot Maintenance. In order that they may distinguish from temporary repairs, Non-standard repairs that they are approved by engineering authority shall be marked as such. a, Inspect prior structural repairs for compliance with the provisions of this DMWR. Submit all instances of noncompliance to the proper engineer- ing authority for approval. Repairs failing such approval shall be removed and reapplied in accordance with either the provisions of the DMWR or specific. engineering instructions. b. Acceptable repairs shall be iden- tified by noting the location of repair and the approving authority on DA Form 2408-15. c. Permanently label any acceptable repair that is both visible and exceeds the scope of field maintenance. The label shall read "nonstd rep auth by: (Approving Document Identifier. e.g., _ ‘AED-A0999, DMWR 55-1520-210, etc.). ‘Affix the label on or near the repair in such a manner that it can be viewed during access for routine field main~ tenance. Do not affix labels to the aircraft exterior. The provisions of this sub-paragraph apply only to the following structures: (1) Doorposts, F.S. 63-75 (2) Cargo door tracks (3) Main Beam panels, F.S. 102-211 (4) Bulkhead panels, F.S. 166 (5) Service deck panels, F.S. 155-241 (6) Roof deck panels, F.S. 63-166 (7) Bulkhead panels, F.S. 178 (8) Lower panels, F.S. 102-155, B.-L. 14-30 R/H & L/H (label inside access cover). (9) Bulkhead panel, F.S. 211 3-11.5. Definition of Inspections. a. "Penetrate Inspection: A nonde- structive method of inspection in ac~ cordance with MIL-I 6866B. Type. I ~ fluorescent dye type is normally used op Change 7 3-4.3