TM 55-1520-210-23-2

TM 55-1520-210-23-2
TECHNICAL MANUAL
AVIATION UNIT AND INTERMEDIATE

MAINTENANCE INSTRUCTIONS
ARMY MODEL UH-1H/V/EH-1H/X
HELICOPTERS
This manual supersedes TM 55-1520-210-23-2, 20 February 1979, including all changes.
HEADQUARTERS, DEPARTMENT OF THE ARMY

30 SEPTEMBER 1987
TM 55-1520-210-23-2
Personnel performing operations, procedures,

and practices which are included or implied in this
technical manual shall observe the following warnings.
Disregard of these warnings and precautionary
information can cause serious injury, or death.
Warnings, cautions, and notes are used to emphasize

important and critical instructions and are used for
the following conditions:
An operating procedure, practice, etc., which,

if not correctly followed, could result in personal
injury or loss of life.
An operating procedure, practice, etc., which, if not

strictly observed, could result in damage to or destruction
of equipment.
NOTE
An operating procedure, condition, etc., which

it is essential to highlight.
NOISE
Sound pressure levels in this helicopter during some operating conditions exceed the Surgeon General hearing
conservation criteria, as defined in TB MED 501. Hearing protection devices, such as aviator helmet or ear plugs
are required to be worn by all personnel in and around the helicopter during its operation.
ELECTROLYTE
Corrosive Battery Electrolyte (Potassium Hydroxide). Wear rubber gloves, apron, and face shield when handling
leaking batteries. If potassium hydroxide is spilled on clothing, or other material wash immediately with clean
water. If spilled on personnel, immediately start flushing the affected area with clean water. Continue washing
until medical assistance arrives.
TOXIC POISONS
Turbine fuels and lubricating oils contain additives which are poisonous and readily absorbed through
the skin. Do not allow them to remain on skin longer than necessary.
HANDLING HYDRAULIC FLUID (MIL-H-83282)
Prolonged contact with liquid or mist can irritate eyes and skin. After any prolonged contact with skin,
immediately wash contacted area with soap and water. If liquid contacts eyes, flush immediately with
clear water. If liquid is swallowed, do not induce vomiting, get immediate medical attention. Wear rub-
ber gloves when handling liquid. If prolonged contact with mist is likely, wear an apporopriate
respirator. When fluid is decomposed by heating, toxic gases are released.
a
TM 55-1520-210-23-2
STARTING HELICOPTER
Starting and operation of the helicopter will be performed only by authorized personnel in accordance with AR 95-1.
GROUNDING HELICOPTER
The helicopter should be electrically grounded when parked. Turn off all power switches before making electrical
connections or disconnections. Serious burns and electrical shock can result from contact with exposed electrical wires
or connectors.
Before removing any engine ignition system component, ground the leads to dissipate any stored voltage in ignition
unit.
FIRE EXTINGUISHER
Exposure to high concentrations of fire extinguishing agent or decomposition products should be avoided. The liquid
should not be allowed to come into contact with the skin, as it may cause frost bite or low temperature burns.
ARMAMENT
Loaded weapons, or weapons being loaded or unloaded, shall be pointed in a direction which offers the least exposure
to personnel or property in the event of accidental firing. Personnel shall remain clear of hazardous area of all loaded
weapons.
ANY ROTATION OF THE GUN ARMAMENT SUBSYSTEM BARRELS WILL CAUSE THE GUN TO FIRE. Upon
landing, immediately alert personnel to probable presence of live rounds in the gun. Summon armament repairman to
clear weapon.
FUELING AND DEFUELING

When refueling helicopter, the refueling vehicle or forward air refueling unit must be parked a minimum of 20 feet from
the helicopter. Before starting the fueling operation, always insert fueling nozzle grounding chain of fuel truck ground
wire into GROUND-HERE receptacle located on the right side of the helicopter aft of the cabin area. Refer to FM 10-68.
When defueling, turn off all electrical switches and disconnect external power from the helicopter. The helicopter must
be electrically grounded prior to defueling.
RADIOACTIVE MATERIALS
Self-luminous dials and ignition units may contain radioactive materials. If such an instrument or unit is broken or
becomes unsealed, avoid personal contact. Use forceps or gloves made of rubber or polyethylene to pick up contami-
nated material. Place materials and gloves in a plastic bag. Seal bag and dispose of it as radioactive waste in
accordance with AR755-15 and TM 3-261 (Refer to TB 43-0108). Repair procedures shall conform to requirements
in AR700-52.
CLEANING SOLVENTS
Cleaning solvents may be flammable and toxic. Use only in well ventilated areas. Avoid inhalation of vapor and skin
contact. Do not use solvents near open flame or in areas where very high temperatures prevail. Solvents with a flash
point greater than 100 F (38 C) should not be used unless otherwise specified.
ROTOR BLADES
Personnel will stay clear of rotor blades during operation. Refer to Chapter 1 for rotor blade dimensions and clearances.
b Change 14
TM 55-1520-210-23-2
C 16
URGENT
CHANGE HEADQUARTERS
DEPARTMENTS OF THE ARMY
No. 16 WASHINGTON, D.C., 8 April 2004
Aviation Unit and Intermediate

Maintenance Instructions

HELICOPTERS
DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited.
TM 55-1520-210-23-2, dated 30 September 1987, is changed as follows:
1. Remove and insert pages as indicated below. New or changed text material is indicated by a vertical bar in
the margin. An illustration change is indicated by a minute pointing hand.
Remove Pages Insert Pages
A through E/(F blank) A through E/(F blank)

i and ii i and ii
10-1 and 10-2 10-1 and 10-2
10-43 and 10-44 10-43 and 10-44
11-1 and 11-2 11-1 and 11-2
11-85 through 11-88 11-85 through 11-88
11-88.1/(11-88.2 blank)
12-9 and 12-10 12-9 and 12-10
12-17 and 12-18 12-17 and 12-18
13-15 and 13-16 13-15 and 13-16
14-65 and 14-66 14-65 and 14-66
(14-81 blank)/14-82
2. Retain this sheet in front of manual for reference purposes.

TM 55-1520-210-23-2
C 16
By order of the Secretaries of the Army:
Official:
PETER J. SCHOOMAKER
General, United States Army
Chief of Staff
JOEL B. HUDSON
Administrative Assistant to the
Secretary of the Army
0407102
DISTRIBUTION:
To be distributed in accordance with Initial Distribution Number (IDN) 311408, requirements for
TM 55-1520-210-23-2.
TM 55-1520-210-23-2
C 15
CHANGE HEADQUARTERS
NO. 15 } DEPARTMENT OF THE ARMY

WASHINGTON, D.C., 30 May 2003


HELICOPTERS
TM 55-1520-210-23-2, 30 September 1987, is changed as follows:
1. Remove and insert pages as indicated below. New or changed text material is indicated by a vertical bar in the
margin. An illustration change is indicated by a miniature pointing hand.
Remove pages Insert pages
A through E/(F blank) A through E/(F blank)

7-63 and 7-64 7-63 and 7-64
8-44.1 and 8-44.2 8-44.1 and 8-44.2
9-31 and 9-32 9-31 and 9-32
10-43 and 10-44 10-43 and 10-44
11-37 and 11-38 11-37 and 11-38
11-41 and 11-42 11-41 and 11-42
11-89 and 11-90 11-89 and 11-90
14-103 and 14-104 14-103 and 14-104
By Order of the Secretary of the Army:
ERIC K. SHINSEKI
Official: General, United States Army
Chief of Staff
JOEL B. HUDSON
0309004
DISTRIBUTION:
To be distributed in accordance with Initial Distribution Number 311408, requirements for TM 55-1520-210-23-2.
TM 55-1520-210-23-2
C 14
CHANGE HEADQUARTERS
NO. 14 } DEPARTMENT OF THE ARMY

WASHINGTON, D.C., 1 November 2001


HELICOPTERS
TM 55-1520-210-23-2, 30 Spetmeber 1987, is changed as follows:
1. Remove and insert pages as indicated below. New or changed text material is indicated by a vertical bar in the
margin. An illustration change is indicated by a miniature pointing hand.
a and b a and b
A through D A through E/(F blank)
7-11 through 7-14 7-11 through 7-14
––––– 7-14.1 / (7-14.2 blank)
––––– 7-26.1 / (7-26.2 blank)
7-31 and 7-32 7-31 and 7-32
7-43 and 7-44 7-43 and 7-44
7-55 and 7-56 7-55 and 7-56
7-59 and 7-60 7-59 and 7-60
7-60.3 / (7-60.4 blank) 7-60.3 / (7-60.4 blank)
7-61 and 7-62 7-61 and 7-62
7-65 and 7-66 7-65 and 7-66
7-69 and 7-70 7-69 and 7-70
7-71 and 7-72 7-71 and 7-72
7-72.1 and 7-72.2 7-72.1 and 7-72.2
7-72.5/(7-72.6 blank) 7-72.5/(7-72.6 blank)
7-73 and 7-74 7-73 and 7-74
7-79 and 7-80 7-79 and 7-80
7-81/ (7-82 blank) 7-81/(7-82 blank)
8-5 and 8-6 8-5 and 8-6
8-19 and 8-20 8-19 and 8-20
8-29 and 8-30 8-25 and 8-30
9-1 and 9-2 9-1 and 9-2
9-25 and 9-26 9-25 and 9-26
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––––– 9-26.1 / (9-26.2 blank)

9-27 and 9-28 9-27 and 9-28
9-31 and 9-32 9-31 and 9-32
9-33 through 9-37 / (9-38 blank) 9-33 through 9-37 / (9-38 blank)
10-19 and 10-20 10-19 and 10-20
10-25 through 10-30 10-25 through 10-30
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11-27 and 11-28 11-27 and 11-28
11-35 through 11-38 11-35 through 11-38
11-43 and 11-44 11-43 and 11-44
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11-59 through 11-64 11-59 through 11-64
11-71 and 11-72 11-71 and 11-72
11-77 and 11-78 11-77 and 11-78
11-89 and 11-90 11-89 and 11-90
----------- 11-90.1/(11-90.2 blank)
11-99 and 11-100 11-99 and 11-100
----------- 11-100.1/(11-100.2 blank)
11-107 through 11-112 11-107 through 11-112
----------- 11-112.1/(11-112.2 blank)
11-113 and 11-114 11-113 and 11-114
11-117 through 11-120 11-117 through 11-120
11-123 and 11-124 11-123 and 11-124
----------- 11-124.1/(11-124.2 blank)
11-131 and 11-132 11-131 and 11-132
--------- 11-132.1/(11-132.2 blank)
11-143 and 11-144 11-143 and 11-144
12-11 and 12-12 12-11 and 12-12
12-17 and 12-18 12-17 and 12-18
13-3 and 13-4 13-3 and 13-4
13-23 and 13-24 13-23 and 13-24
14-1/(14-2 blank) 14-1/(14-2 blank)
(14-61 blank)/14-62 (14-61 blank)/14-62
14-103 and 14-104 14-103 and 14-104
14-109 and 14-110 14-109 and 14-110
--------- 14-110.1 and 14-110.2
--------- 14-110.3/(14-110.4 blank)
14-111 and 14-112 14-111 and 14-112
16-25 and 16-26 16-25 and 16-26
17-1/(17-2 blank) 17-1/(17-2 blank)
TM 55-1520-210-23-2
C14
Official:
ERIC K. SHINSEKI
Chief of Staff
JOEL B. HUDSON
0123404
DISTRIBUTION:
To be distributed in accordance with Initial Distribution Number 311408, requirements for
TM 55-1520-210-23-2.
URGENT TM 55-1520-210-23-2
C13
CHANGE HEADQUARTERS
DEPARTMENT OF THE ARMY
No. 13 WASHINGTON, D.C., 1 May 2001

ARMY MODEL UH-1H/V/EH-1H/X HELICOPTERS

DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited
1. Remove and insert pages as indicated below. New or changed text material is indicated by a vertical bar
in the margin. An illustration change is indicated by a miniature pointing hand.
--- A thru D
9-85 and 9-86 9-85 and 9-86
ERIC K. SHINSEKI
Chief of staff

Secretary of the Amy
0110902
DISTRIBUTION:
To be distributed in accordance with Initial Distribution Number (IDN) 311408,
requirements for TM 55-1520-210-23-2.
URGENT TM 55-1520-210-23-2
C12
CHANGE HEADQUARTERS
No. 12 WASHINGTON, D.C., 5 August 1997


9-93 and 9-94 9-93 and 9-94

------------ 9-94.1 and 9-94.2
DENNIS J. REIMER
Chief of staff

Secretary of the Amy
03867
DISTRIBUTION:
To be distributed in accordance with DA Form 12-31-E, block no. 1408 requirements for
TM 55-1520-210-23-2.
TM 55-1520-210-23-2
C 10
CHANGE HEADQUARTERS
NO. 10 WASHINGTON, D.C., 22 July 1996

ARMY MODEL UH-I1HNIEH-1HIX HELICOPTERS
1. Remove and insert pages as indicated below New or changed text material is indicated by a vertical bar
in the margin An illustration change is indicated by a miniature pointing hand.
i and ii i and ii
7-43 and 744 743 and 7-44
7-59 and 740 7-59 and 740
9-15 and 9-16 9-15 and 9-16
9-31 and 9-32 9-31 and 9-32
9-32.1 and 9-32.2 9-32.1 and 9-32.2
9-101 and 9-102 9-101 and 9-102
10-15 through 10-18 10-15 through 10-18
10-29 and 10-30 10-29 and 10-30
10-30.11(10-30.2 blank) 10-30.1/(10-30.2 blank)
10-35 and 10-38 10-35 and 10-36
1043 and 10-44 1043 and 1044
10-45 and 10-46 1045/(1046 blank)
11-7 and 11-6 11-7 and 11-8
11-17 and 11-18 11-17 and 11-18
11-99 and 11-100 11-99 and 11-100
11-100.1/(11-100.2 blank)
11-101 11-101 and 11-102
11-115 and 11-116 11-115 and 11-116
11-121 and 11-122 11-121 and 11-122
124.1/(12-4.2 blank) 12-4.11/(124.2 blank)
12-5 and 12-6 12-5 and 12-6
14-103 and 14-104 14-103 and 14-104
17-11/(17-2 blank) 17-1/(17-2 blank)
Index 3 and Index 4 Index 3 and Index 4
Electronic 2028 Instructions
2. Retain this sheet In front of manual for reference purposes.
DENNIS J. REIMER
Chief of Staff

DISTRIBUTION:
To be distributed in accordance with DA Form 12-31-E, block no. 1408 requirements for
TM 55-1520-210-23-2.
URGENT
TM 55-1520-210-23-2
C9
CHANGE HEADQUARTERS
NO. 9 WASHINGTON, D.C., 15 February 1996


HELlCOPTERS
7-69 and 7-70 7-69 and 7-70

----- 7-70.3/(7-70.4 blank)
7-73 and 7-74 7-73 and 7-74
14-1/(14-2 blank) 14-1/(14-2 blank)
By Order of the Secretary of the Army
DENNIS J. REIMER
Chief of Staff
YVONNE M. HARRISON
secretary of the Army
01332
DISTRIBUTION:
To be distributed in accordance with DA Form 12-31-E, block no. 1408, requirements for
TM 55-1520-210-23-2.
TM 55-1520-210-23-2
C8
CHANGE HEADQUARTERS
NO. 8 WASHINGTON, D.C., 31 July 1995


HELlCOPTERS
DISTRIBUTION STATEMENT A Approved for public release; distribution is unlimited
8-41 and 8-42 8-41 and 8-42

------ 8-44.1 through 8-44.7/(8-44.8 blank)
8-45 and 8-46 8-45 and 8-46
Index 5 and Index 6 Index 5 and Index 6

DENNIS J. REIMER
Official: Chief of Staff
Acting Administrative Assistant to the

00481
DISTRIBUTION:
TM 55-1520-210-23-2.
TM 55-1520-210-23-2
C7
CHANGE HEADQUARTERS
NO. 7 WASHINGTON, D. C., 1 March 1995


HELlCOPTERS
7-2.1/(7-2.2 blank) 7-2.1/(7-2.2 blank)

7-3 and 7-4 7-3 and 7-4
7-7 and 7-8 7-7 and 7-8
7-13 and 7-14 7-13 and 7-14
7-21 and 7-22 7-21 and 7-22
7-41 and 7-42 7-41 and 7-42
7-67 and 7-68 7-67 and 7-68
---- 7-68.1/(7-68.2 blank)
7-70.1/(7-70.2 blank) 7-70.1 and 7-70.2
7-72.5/(7-72.6 blank) 7-72.5/(7-72.6 blank)
7-73 and 7-74 7-73 and 7-74
8-41 and 8-42 8-41 and 8-42
8-47 through 8-54 8-47 through 8-53/(8-54 blank)
8-55 8-55/(8-56 blank)
9-17 and 9-18 9-17 and 9-18
9-21 and 9-22 9-21 and 9-22
9-23 and 9-24 ----
9-31 and 9-32 9-31 and 9-32
9-32.1 and 9-32.2 9-32.1 and 9-32.2
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9-39 and 9-40 9-39 and 9-40

9-43 and 9-44 9-43/(9-44 blank)
9-51 and 9-52 (9-51 blank)/9-52
9-65 and 9-66 9-65 and 9-66
9-93 and 9-94 9-93 and 9-94
9-103 and 9-104 9-103 and 9-104
10-29 and 10-30 10-29 and 10-30
10-30.1/(10-30.2 blank) 10-30.1/(10-30.2 blank)
10-43 and 10-44 10-43 and 10-44
---- 10-44.1/(10-44.2 blank)
11-5 and 11-6 11-5 and 11-6
11-19 and 11-20 11-19 and 11-20
11-33 and 11-34 11-33 and 11-34
11-85 and 11-86 11-85 and 11-86
11-89 and 11-90 11-89 and 11-90
11-93 and 11-94 11-93 and 11-94
11-99 and 11-100 11-99 and 11-100
11-100.1/(11-100.2 blank) 11-100.1/(11-100.2 blank)
11-103 and 11-104 11-103 and 11-104
11-121 and 11-122 11-121 and 11-122
12-15 through 12-18 12-15 through 12-18
13-17 and 13-18 13-17 and 13-18
13-21 and 13-22 13-21 and 13-22
13-23 and 13-24 13-23 and 13-24
14-45 and 14-46 14-45/(14-46 blank)
14-63 and 14-64 14-63 and 14-64
16-23 through 16-26 16-23 through 16-26
16-57 and 16-58 16-57 and 16-58
16-59 and 16-60 (16-59 blank)/16-60
16-61 through 16-64 16-61 through 16-64
17-1/(17-2 blank) 17-1/(17-2 blank)
lndex 9 through lndex 12 lndex 9 through lndex 12
2. Retain these sheets in front of manual for reference purposes.

TM 55-1520-210-23-2
C7
GORDON R. SULLIVAN
Official: General, United States Army
Chief of Staff

07993
DISTRIBUTION:
TM 55-1520-210-23-2.
URGENT
NOTICE : THIS CHANGE HAS BEEN PRINTED AND DISTRIBUTED OUT OF SEQUENCE. IT
SHOULD BE INSERTED IN THE MANUAL AND USED. UPON RECEIPT OF THE
EARLIER SEQUENCED CHANGE . ENSURE A MORE CURRENT CHANGE PAGE IS
NOT REPLACED WITH A LESS CURRENT PAGE.
TM 55-1520-210-23-2
C 6
CHANGE HEADQUARTERS
NO. 6 WASHINGTON, D.C., 30 April 1993

1. Remove and insert pages as indicated below. New or changed text material is
indicated by a vertical bar in the margin. An illustration change is indi-
cated by a miniature pointing hand.
7-7 and 7-8 7-7 and 7-8

7-72.1 through 7-72.4 7-72.1 through 7-72.4
7-72.5/(7-72.6 blank) 7-72.5/(7-72.6 blank)
7-73/(7-74 blank) 7-73 and 7-74
9-33 and 9-34 9-33 and 9-34
9-93 and 9-94 9-93 and 9-94
10-9 and 10-10 10-9 and 10-10
10-15 through 10-18 10-15 through 10-18
10-29 and 10-30 10-29 and 10-30
10-30.1/(10-30.2 blank)
10-31 and 10-32 10-31 and 10-32
10-43 and 10-44 10-43 and 10-44
11-1 and 11-2 11-1 and 11-2
11-15 and 11-16 11-15 and 11-16
11-27 and 11-28 11-27 and 11-28
12-3 and 12-4 12-3 and 12-4
14-101 through 14-104 14-101 through 14-104
2. The following pages are not applicable to Change 6. These pages were not
assembled in proper order in previous changes.
7-43 and 7-44 7-43 and 7-44

7-67 and 7-68 7-67 and 7-68
9-35 and 9-36 9-35 and 9-36
10-1 and 10-2 10-1 and 10-2
TM 55-1520-210-23-2
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10-13 and 10-14 10-13 and 10-14

10-35 and 10-36 10-35 and 10-36
11-13 and 11-14 11-13 and 11-14
11-17 and 11-18 11-17 and 11-18
11-31 and 11-32 11-31 and 11-32
11-121 and 11-122 11-121 and 11-122
13-23 and 13-24 13-23 and 13-24
GORDON R. SULLIVAN
MILTON H. HAMILTON
03418
DISTRIBUTION:
To be distributed in accordance with DA Form 12-31-E, block no. 1408, require-
ments for TM 55–1520–210-23–2.
TM 55-1520-210-23-2
C 5
CHANGE HEADQUARTERS
NO. 5 WASHINGTON, D.C., 31 March 1993

1. Remove and insert pages as indicated below. New or changed text material
is indicated by a vertical bar in the margin. An illustration change is indi-
cated by a miniature pointing hand.
i and ii i and ii
7-9 and 7-10 7-9 and 7-10
7-13 and 7-14 7-13 and 7-14
7-42.1/(7-42.2 blank) 7-42.1/(7-42.2 blank)
7-69 and 7-70 7-69 and 7-70
------------------ 7-70.1/(7-70.2 blank)
7-71 and 7-72 7-71 and 7-72
7-77 and 7-78 7-77 and 7-78
7-81 7-81/(7-82 blank)
9-1 and 9-2 9-1 and 9-2
9-15 and 9-16 9-15 and 9-16
9-39 and 9-40 9-39 and 9-40
9-45 and 9-46 9-45 and 9-46
9-67 and 9-68 9-67 and 9-68
------------------ 9-84.1/(9-84.2 blank)
9-85 and 9-86 9-85 and 9-86
9-101 and 9-102 9-101 and 9-102
10-1 and 10-2 10-1 and 10-2
10-5 and 10-6 10-5 and 10-6
10-23 and 10-24 10-23 and 10-24
10-35 and 10-36 10-35 and 10-36
10-51 and 10-52 10-51 and 10-52
11-13 and 11-14 11-13 and 11-14
11-17 through 11-22 11-17 through 11-22
11-35 and 11-36 11-35 and 11-36
11-43 and 11-44 11-43 and 11-44
11-51 and 11-52 11-51 and 11-52
11-55 and 11-56 11-55 and 11-56
11-71 and 11-72 11-71 and 11-72
11-77 and 11-78 11-77 and 11-78
11-85 and 11-86 11-85 and 11-86
11-93 and 11-94 11-93 and 11-94
11-99 and 11-100 11-99 and 11-100
TM 55-1520-210-23-2
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11-103 and 11-104 11-103 and 11-104
11-117 and 11-118 11-117 and 11-118
11-121 and 11-122 11-121 and 11-122
11-135 through 11-138 11-135 through 11-138
11-143 and 11-144 11-143 and 11-144
12-17 and 12-18 12-17 and 12-18
13-23 and 13-24 13-23 and 13-24
14-105 and 14-106 14-105 and 14-106
14-109 14-109 through 14-112
2. THE FOLLOWING PAGES IN THIS CHANGE ARE CHANGE 6 PAGES. REMOVE THE CORRESPONDING
I CHANGE 6 PAGES AND REPLACE THEM WITH THE CHANGE 6 PAGES INCLUDED IN THIS CHANGE.
WHEN CHANGE 6 WAS ORIGINALLY ISSUED, CERTAIN ADDITIONAL CHANGES REQUIRED ON
THESE PAGES WERE INADVERTENTLY OMITTED. THE CHANGE 6 PAGES INCLUDED IN THIS
CHANGE INCORPORATE ALL DATA THAT SHOULD HAVE BEEN INCLUDED IN CHANGE 6.
7-72.1 through 7-72.5/(7-72.6 blank). 7-72.1 through 7-72.5/(7-72.6

10-29 and 10-30 blank)
14-101 and 14-102 10-29 and 10-30
14-101 and 14-102
GORDON R. SULLIVAN
MILTON H. HAMILTON
05231
DISTRIBUTION:
To be distributed in accordance with DA Form 12-31-E, block no. 1408, require-
ments for TM 55-1520-210-23-2.
TM 55-1520-210-23-2
C4
CHANGE HEADQUARTERS

ARMY MODEL UH-1H/V/EH-1H/X HELICOPTER
is indicated by a vertical bar in the margin. An illustration change is indicated
by a miniature pointing hand.
7-9 and 7-10 7-9 and 7-10

7-17 and 7-18 7-17 and 7-18
------ 7-40.1/7-40.2
7-41 and 7-42 7-41 and 7-42
7-42.1/7-42.2 7-42.1/7-42.2
7-49 and 7-50 7-49 and 7-50
------- 7-50.1/7-50.2
7-59 and 7-60 7-59 and 7-60
------- 7-60.1 through 7-60.3/7-60.4
7-72.1 and 7-72.2 7-72.1 and 7-72.2
7-73 through 7-76 7-73/7-74
8-1 and 8-2 8-1 and 8-2
8-5 and 8-6 8-5 and 8-6
8-19 and 8-20 8-19 and 8-20
8-25 and 8-26 8-25 and 8-26
8-35 and 8-36 8-35 and 8-36
8-41 and 8-42 8-41 and 8-42
8-45 and 8-46 8-45 and 8-46
9-31 and 9-32 9-31 and 9-32
------- 9-32.1 and 9-32.2
9-81 and 9-82 9-81 and 9-82
9-87 and 9-88 9-87 and 9-88
9-97 and 9-98 9-97 and 9-98
10-1 and 10-2 10-1 and 10-2
10-11 through 10-14 10-11 through 10-14
10-17 through 10-20 10-17 through 10-20
10-23 and 10-24 10-23 and 10-24
10-27 and 10-28 10-27 and 10-28
10-35 and 10-36 10-35 and 10-36
TM 55-1520-210-23-2
C 4
10-39 and 10-40 10-39 and 10-40

10-43 and 10-44 10-43 and 10-44
11-13 and 11-14 11-13 and 11-14
11-17 and 11-18 11-17 and 11-18
11-21 and 11-22 11-21 and 11-22
11-31 and 11-32 11-31 and 11-32
11-41 and 11-42 11-41 and 11-42
11-49 through 11-52 11-49 through 11-52
11-77 and 11-78 11-77 and 11-78
11-85 and 11-86 11-85 and 11-86
11-99 and 11-100 11-99 and 11-100
11-113 and 11-114 11-113 and 11-114
11-121 and 11-122 11-121 and 11-122
12-3 and 12-4 12-3 and 12-4
------ 12-4.1/12-4.2
12-15 and 12-16 12-15 and 12-16
13-13 and 13-14 13-13 and 13-14
13-23 and 13-24 13-23 and 13-24
14-107 and 14-108 14-107 and 14-108
GORDON R. SULLIVAN
GeneraI, United States Army
MILTON H. HAMILTON
01409
DISTRIBUTION :
To be distributed in accordance with DA Form 12-31, AVUM and AVIM requirements
for TM 55-1520-210-23-2.
URGENT
TM 55-1520-210-23-2
C 3
CHANGE HEADQUARTERS
NO. 3 WASHINGTON, D.C., 21 February 1991

14-63 and 14-64 14-63 and 14-64

— - - 14-64.1/14-64.2
14-99 through 14-102 14-99 through 14-102
CARL E. VUONO
THOMAS F. SIKORA
Brigadier General, United States Army
The Adjutant General
DISTRIBUTION :
To be distributed in accordance with DA Form 12-31-E, block no. 1408, AVUM and
AVIM maintenance requirements for TM 55-1520-210-23-2.
URGENT
TM 55-1520-210-23-2
C2
CHANGE HEADQUARTERS

i and ii i and ii
7-1 and 7-2 7-1 and 7-2
- - - - 7-2.1/7-2.2
7-15 and 7-16 7-15 and 7-16
7-19 and 7-20 7-19 and 7-20
7-43 and 7-44 7-43 and 7-44
7-49 and 7-50 7-49 and 7-50
7-72.3 and 7-72.4 7-72.3 and 7-72.4
7-73 and 7-74 7-73/7-74
7-77 and 7-78 7-77 and 7-78
8-15 and 8-16 8-15 and 8-16
8-35 and 8-36 8-35 and 8-36
9-9 and 9-10 9-9 and 9-10
9-31 and 9-32 9-31 and 9-32
- - - - 9-32.1 and 9-32.2
10-1 and 10-2 10-1 and 10-2
--- - 10-2.1/10-2.2
10-11 through 10-14 10-11 through 10-14
10-21 and 10-22 10-21 and 10-22
10-29 through 10-36 10-29 through 10-36
10-39 and 10-40 10-39 and 1.0-40
10-43 and 10-44 10-43 and 10-44
10-49 and 10-50 10-49 and 10-50
11-7 and 11-8 11-7 and 11-8
11-11 through 11-18 11-11 through 11-18
11-31 and 11-32 11-31 and 11-32
- - - - 11-32.1/11-32.2
11-41 and 11-42 11-41 and 11-42
11-77 through 11-80 11-77 through 11-80
11-89 and 11-90 11-89 and 11-90
11-93 and 11-94 11-93 and 11-94
11-99 and 11-100 11-99 and 11-100
TM 55-1520-210-23-2
C 2
11-100.1/11-100.2 11-100.1/11-100.2
11-113 and 11-114 11-113 and 11-114
11-121 and 11-122 11-121 and 11-122
11-129 through 11-132 11-129 through 11-132
11-139 through 11-142 11-139 through 11-142
12-3 and 12-4 12-3 and 12-4
12-7 and 12-8 12-7 and 12-8
12-17 and 12-18 12-17 and 12-18
13-1 and 13-2 13-1 and 13-2
13-15 and 13-16 13-15 and 13-16
13-19 through 13-24 13-19 through 13-24
14-1 and 14-2 14-1/14-2
14-61 and 14-62 14-62
14-65 and 14-66 14-65 and 14-66
14-97 and 14-98 14-98
14-101 through 14-104 14-101 through 14-104
16-1 and 16-2 16-1 and 16-2
17-1/17-2 17-1/17-2
- - - - Index-1 through Index-12
- - - - Index-13/Index-14
CARL E. VUONO
WILLIAM J. MEEHAN II
DISTRIBUTION:
for UH-1H, UH-1V, Helicopter Utility, EH-1H Helicopter, Electronic Countermeasure
and EH-1X Helicopter, Electronic Countermeasure and Intercept.
URGENT
TM 55-1520-210-23-2
C1
CHANGE HEADQUARTERS
NO. 1 WASHINGTON, D.C., 4 November 1988


- - - 7-42.1/7-42.2
7-43 and 7-44 7-43 and 7-44
7-55 and 7-56 7-55 and 7-56
- - - 7-72.1 through 7-72.5/7-72.6
7-73 and 7-74 7-73 and 7-74
7-79 and 7-80 7-79 and 7-80
8-19 and 8-20 8-19 and 8-20
11-99 and 11-100 11-99 and 11-100
- — - 11-100.1/11-100.2
12-3 and 12-4 12-3 and 12-4
CARL E. VUONO
R. L. DILWORTH
DISTRIBUTION :
for UH-1H, UH-1V, Helicopter, Utility, EH-1H, Helicopter, Electronic Countermeasure
and EH-1X Helicopter, Electronic Countermeasure & Intercept.
URGENT
TM 55-1520-210-23-2
TECHNICAL MANUAL HEADQUARTERS

No. 55-1520-210-23-2 WASHINGTON, D. C., 30 September 1987

NOTE :
This manual is printed in three volumes as follows:
TM 55-1520-210-23-1, consisting of Table of Contents, preface, chapters 1

through 6.
TM 55-1520-210-23-2, consisting of Table of Contents, chapters 7 through 17.
TM 55-1520-210-23-3, consisting of Table of Contents, appendix A through F,

and Index.
The appendices and index are applicable to all volumes.

TM 55-1520-210-23-2
TECHNICAL MANUAL HEADQUARTERS

NO. 55-1520-210-23-2 WASHINGTON, D.C., 30 September 1987
AVIATION UNIT AND INTERMEDIATE MAINTENANCE INSTRUCTIONS

ARMY MODEL UH-IHNIEH-IHIX HELICOPTERS
REPORTING OF ERRORS
You can improve this manual. If you find any mistakes or if you know of a way to improve the procedures, please let us
know. Mail your letter, DA Form 2028 (Recommended Changes to Publications and Blank Forms) located in the back of
this manual directly to: Commander, U.S. Army Aviation and Missle Command, ATTN: AMSAM-MMC-MA-NP, Redstone
Arsenal, AL 35898-5000. A reply will be furnished to you. You may also provide DA Form 2028 information to
AMCOM via e-mail, fax, or the World Wide Web. Our fax number is: DSN 788-6546 or Commercial 256-842-6546. Our
e-mail address is: [email protected]. Instructions for sending an electronic 2028 may be found at the back of this
manual immediately preceding the hard copy 2028. For the World Wide Web use: https://amcom2028.redstone.army.mil.
DISTRIBUTION STATEMENT A: Approved for public release; distribution Is unlimited.
TABLE OF CONTENTS
Page
CHAPTER 1 INTRODUCTION
Section I Servicing........................................................................................................................ 1-1
II Lubrication .................................................................................................................... 1-50
III Handling, Jacking, Mooring, Hoisting, and Sling Loading ....................................... 1-54
IV Inspection Requirements............................................................................................. 1-66
V Overhaul and Retirement Schedule ............................................................................ 1-110
VI Flight Safety Critical Aircraft Parts (FSCAP) Program.............................................. 1-115
CHAPTER 2 AIRFRAME
Section I Fuselage ........................................................................................................................ 2-1
II Tailboom ........................................................................................................................ 2-193
CHAPTER 3 AUGHTING GEAR

Section I Landing Gear................................................................................................................. 3-1
II Skids/Struts ................................................................................................................... 3-30
III Floats ............................................................................................................................. 3-30
IV Skis................................................................................................................................. 3-30
V Brakes ............................................................................................................................ 3-30
CHAPTER 4 POWER PLANT

Section I Power Plant ................................................................................................................... 4-1
II Cooling System............................................................................................................. 4-13
III Air Induction System.................................................................................................... 4-13
IV Exhaust System ............................................................................................................ 4-42.7
V Oil System ..................................................................................................................... 4-44
VI Ignition System ............................................................................................................. 4-61
VII Power Controls ............................................................................................................. 4-41
VIII Quick Change Assembly (AVIM) ................................................................................. 4-86
Change 16 i
TM 55-1520-210-23-2
TABLE OF CONTENTS (Cont)
Page
CHAPTER 5 ROTORS
Section I Main Rotor System ....................................................................................................... 5-1
II Main Rotor Hub ............................................................................................................. 5-16
III Main Rotor Blades ........................................................................................................ 5-38.1
IV Main Rotor Controls ..................................................................................................... 5-53
V Tail Rotor System ......................................................................................................... 5-104
VI Tail Rotor Hub and Blade Assembly........................................................................... 5-107
VII Tail Rotor Hub and Controls........................................................................................ 5-119
VIII Tail Rotor Blades .......................................................................................................... 5-132
XI Tracking Procedures .................................................................................................... 5-138
CHAPTER 6 DRIVE TRAIN SYSTEM
Section I Main Driveshaft ............................................................................................................. 6-1
II Clutch............................................................................................................................. 6-29
III Main Transmission ....................................................................................................... 6-29
IV Tail Rotor Driveshaft .................................................................................................... 6-1162
V Intermediate Gearbox................................................................................................... 6-138
VI Tall Rotor Gearbox ....................................................................................................... 6-148
VII Oil Systems ................................................................................................................... 6-167
CHAPTER 7 HYDRAULIC AND PNEUMATIC SYSTEMS
Section I Hydraulic System.......................................................................................................... 7-1
II Pneumatic System (Not Applicable) ........................................................................... 7-81
CHAPTER 8 INSTRUMENT SYSTEMS
Section I Instrument Maintenance .............................................................................................. 8-1
II Engine Instruments ...................................................................................................... 8-2
III Flight Instruments ........................................................................................................ 8-22
IV Navigation Instruments................................................................................................ 8-33
V Miscellaneous Instruments.......................................................................................... 8-37
VI Instrument Panels......................................................................................................... 8-51
CHAPTER 9 ELECTRICAL SYSTEMS
Section I Direct Current Power Distribution System................................................................. 9-1
II Alternating Current Power Distribution System ........................................................ 9-41
III Starting System............................................................................................................. 9-52
IV Ignition System ............................................................................................................. 9-54
V Lighting Provisions ...................................................................................................... 9-56
VI Miscellaneous Equipment............................................................................................ 9-94
CHAPTER 10 FUEL SYSTEM
Section I Fuel Cells ....................................................................................................................... 10-1
II Fuel Systems................................................................................................................. 10-11
CHAPTER 11 FLIGHT CONTROLS
Section I Controls Surfaces......................................................................................................... 11-1
II Flight Control Components ......................................................................................... 11-1
ii Change 10
TM 55-1520-210-23-2
TABLE OF CONTENTS (Cont)
Page
CHAPTER 12 UTILITY SYSTEMS
Section I Fire Detector System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1
II Windshield Wiper System . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . 12-5
III Rear View Mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . 12-20
CHAPTER 13 ENVIRONMENTAL CONTROL SYSTEM
Section I Heating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 13-1
II Air Cooling System . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . 13-15
III Winterization Equipment ........ . . . . . . . . . . . . . . .. . . . . . . . . . . . . . 13-18
CHAPTER 14 HOIST AND WINCHES
Section I Personnel Rescue Hoist . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1
II Cargo Suspension Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-98
CHAPTER 15 AUXILIARY POWER PLANTS

(Non applicable) .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1
CHAPTER 16 MISSION EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-1
CHAPTER 17 EMERGENCY EQUIPMENT .. . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-1
APPENDIX A REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
APPENDIX B MAINTENANCE ALLOCATION CHART

Section I Three Levels of Maintenance Concept . . . . . . . . . . . . . . . . . . B-1
II Maintenance Allocation Chart . . . . . . . . . . . . . . . . . . . . . . . . B-6
III Tools and Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-79
IV Remarks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-105
APPENDIX C AIRCRAFT INVENTORY MASTER GUIDE . . . . . . . . . . . . C-1
APPENDIX D ILLUSTRATED FIELD MANUFACTURE ITEMS LIST . . . . . . . . . . . D-1
APPENDIX E STORAGE OF AIRCRAFT

Section I General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1
II Flyable Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-4
III Short Term Storage . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . E-5
IV Intermediate Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-11
APPENDIX F WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . F-1
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index 1
iii/(iv blank)
TM 55-1520-210-23-2
CHAPTER 7
HYDRAULIC AND PNEUMATIC SYSTEMS
Section I. HYDRAULIC SYSTEM
7-1. HYDRAULIC SYSTEM. armament. The components are located in the pylon
aft of the basic system equipment. The external stores
couplings are located on the right and left sides of the
NOTE fuselage just above the landing skid attachment
points.
The use of any alcohol in cleaning
components which contact hydraulic 7-3. Operation — Hydraulic System. a. System
fluids is prohibited. Formation of a pressure (figure 7-2) of 950 to 1000 psig is produced
polymeric residue can result which by the variable delivery, pressure compensated
could impair mechanical operation of pump, mounted on the main transmission and driven
the components. at 0.65 engine drive shaft speed. Fluid is drawn from
the resevoir by the hydraulic pump and pumped to
the system through a check valve and a filter to a
NOTE normally-open, solenoid-operated system shutoff
valve. When the HYD CONTROL switch is ON, this
All preformed packings and threads valve is open and system pressure is supplied to all
will have a light film of hydraulic fluid four of the flight control power cylinders. Each power
(C130) or (C131) applied prior to as- cylinder assembly includes a servo vaIve which is
sembly. Ensure that parts are clean. mechanically controlled by the flight control linkages.
When the linkage moves any servo valve control lever
down, the cylinder retracts and when the linkage
7-2. Description — Hydraulic System. a. The moves the lever up the cylinder extends. When the
flight control hydraulic system provides power to lever IS centered, system pressure is applied equally
operate flight control power cylinders. A gravity feed to both sides of the cylinder piston but the system
reservoir is used. The basic system includes a return port is shut off and cylinder does not move in
variable delivery axial-piston pump, reservoir, filter, either direction. Irreversible valves are provided for
relief valve, solenoid valve, directional flow check each main rotor power cylinder to prevent feedback.
valves, servo valves, irreversible valves, power When system pressure drops to approximately 500
cylinders, pressure switch, low pressure caution psi, a spring loaded sequence valve (view A),
light, couplings for connection of a ground test stand sheet 2 in the irreversible valve closes and blocks
and connecting lines and a control switch located on both the system pressure and system return ports
the pedestal (figure 7-1 ). trapping fluid under 500 psi in the power cylinder
servo valve and irreversible valve. Each irreversi-
b. The pump is located on the transmission ble valve incorporates a check valve to isolate
sump case and is accessible through a removable surge pressure produced in the power cylinders
panel on right side of pylon island. Access to the from the system pressure lines. A differential re-
gravity feed reservoir is by opening transmission lief valve opens automatically to relieve pressures
fairing on cabin roof. The ground test stand couplings in excess of 500 psi differential. The irreversible
are located in the engine compartment on the right valves also incorporate another feature which al-
side. lows the power cylinders to be operated manual-
ly. The same function is performed by the check
c. Additional equipment for helicopters with valve which interconnects the system pressure
provisions for external stores includes a solenoid line to the system return line adjacent to the tail
valve in the pressure line, a filter and check valve in rotor power cylinder. When no system pressure is
the return line, and couplings with quick-disconnect available and the power cylinders are operated
fittings for connection of external stores and manually, fluid flows directly through the irrevers-
Change 2 7-1
TM 55-1520-210-23-2
Figure 7-1. Hydraulic System — Flight Controls (Sheet 1 of 2)
7-2
TM 55-1520-210-23-2
ible valve or the tail rotor check valve from the cylinder
return part to the cylinder pressure. Hence the cylinder
pumps fluid from one side of the piston to the other
without attempting to pump fluid through the entire
system. The pressurized reservoir hydraulic system is
no longer approved for use in UH-1 helicopters.
b. A line-mounted pressure switch is provided in
the system pressure line to sense the system
pressure. The switch closes a circuit to the caution
Change 7 7-2.1/(7-2.2 blank)

TM 55-1520-210-23-2
Figure 7-1. Hydraulic System — Flight Controls (Sheet 2 of 2)
7-3
Figure 7-2. Hydraulic System Schematic (Gravity Feed) (Sheet 1 of 2)
TM 55-1520-210-23-2
7-4 Change 7
TM 55-1520-210-23-2
Figure 7-2. Hydraulic System Schematic (Gravity Feed) (Sheet 2 of 2)
panel when the system pressure drops below 400 (1) Scope — Limits described are only for
psig and causes the HYD PRESSURE caution light and components in service in helicopter hydraulic
the MASTER CAUTION light to be illuminated. When systems. Intent is to minimize replacement of
pressure is increasing, the switch should open at 900 hydraulic components which are still serviceable.
psig maximum.
(a) These limits may differ from those
contained in various military specifications for
c. On helicopters, serial nos. 63-12956 thru 65- components, which are intended to control quality,
10135, 65-12773 thru 65-12776, 65-12847 thru 65- assembly, and proper functioning of the components
12852, and 65-12857 thru 65-12895, with for procurement. Components in service sometimes
provisions for externally mounted armament, develop leakage rates in excess of specification limits,
pressure is supplied to a normally-open solenoid without necessarily becoming detrimental to the
valve which is controlled by a switch on an armament system or failing to provide reliable operation.
control panel. When the valve is open, hydraulic fluid
is supplied to the external couplings on each side of (b) These limits are not to be used as basis
the helicopter. When external hydraulic equipment is for acceptance or rejection of components of any
connected, fIuid used to operate the equipment is bench functional test or systems on new helicopters.
returned through a filter and check valve to the (c) These limits are not applicable to self-
hydrauIic reservoir. contained closed-compartment hydrauIic units such
as viscous dampers, liquid springs, or oleo struts.
d. The following provides guide lines for (2) Causes of Leakage — Some seepage is
allowable external leakage of in-service hydraulic normally present, since static or dynamic seals are
system components, and some methods of not functionally perfect, due to such causes as
measuring such leakage. follows:
7-5
TM 55-1520-210-23-2
(a) A film of hydraulic fluid being retained by it is also possible to have enough components with
metal surfaces, such as piston rods, and thus carried allowable leakages that their combined leakage
past seals. This film is necessary for seal lubrication. should be classified as excessive.
(b) Pressure and temperature variations

affecting seals. (4) Leakage Checks — Measurement of
leakage rates, for classification according to Table 7-1
(c) Seals tending to take a permanent set can be performed as follows:
after a period of time.
(a) When hydraulic systems have remained
(3) Classification of Leakage — External in static unpressurized condition for an appreciable
leakages of hydraulic fluid can be broadly classified as period of time, leakage checks should not be
excessive or allowable. performed immediately after starting operation.
Activate systems and operate components several
(a) Excessive Leakage: Fluid leakage such times, then wipe off any leaked hydraulic fIuid before
that hydraulic reservoir level may be dangerously making leakage checks.
lowered or depleted during normal operation, or a fire
hazard may be created, or air-worthiness of (b) Where location of a component does not
helicopter may be otherwise compromised. permit direct observation, it is possible to measure
leakage on a flat surface (either part of structure
(b) Allowable Leakage: Fluid leakage such below or a panel temporarily positioned for that
that quantity lost is insignificant, will have no purpose). Wipe surface clean and place a drop of fluid
detrimental effect on helicopter operation, and on area, allow to stabilize, then outline area with soft
correction does not warrant maintenance time lead pencil before wiping off fluid. Pressurize and
involved. cycle the component to observe leakage rate,
comparing wetted surface to marked one-drop area.
(c) General: Leakage usually shows as a
seepage, stain, or wet area. It is possible for allowable
leakage or seepage to collect in a cavity or depression (c) Where fluid dropping from a component
in adjacent structure over a period of time and falsely can be directly observed, pressurize and cycle the
indicate excessive leakage. Accumulation on a flat component until a drop falls free. Continue operating,
area or a white-painted surface often appears to be observing time until next drop to determine leakage
excessive, though actually being allowable. However, rate.
Table 7-1. Allowable Leakage for In-Service Hydraulic Components
COMPONENT FUNCTION LEAK TYPE LEAKAGE RATE (Max.)
FLIGHT Rod Seal D 1 drop/20 full stroke cycles

CONTROLS S-D 1 drop/15 min.
ACTUATORS End Cap S 2 drops/day
Valve Input D 1 drop/5 cycles
S-D 1 drop/5 min.
Pressure Switch S-D 1 drop/5 min.
Valve Body (Weep Hole) S-D 1 drop/5 min.
PUMP Output Shaft D 8 drops/min.

S-D 1 drop/min.
Housing (Mating Surfaces) S 2 drops/day
SWIVELS Low Pressure S 1 drop/15 min.

High Pressure D 1 drop/5 cycles
S 1 drop/15 min.
7-6
TM 55-1520-210-23-2
Table 7-1. Allowable Leakage for In-Service Hydraulic Components (Cont)
COMPONENT FUNCTION LEAK TYPE LEAKAGE RATE (Max.)
VALVES Body (Weep Hole) S 2 drops/day

Manual Stem D 1 drop/5 cycles
S-D 1 drop/15 min.
Dump Valve S 2 drops/day
FITTINGS Flared or Flareless S None

Compression Seal S 1 drop/30 min. (less if
readily accessible)
NOTES: 1. Leaks Types: D = Dynamic

S = Static
S-D = Static leakage through dynamic seals.
2. Approx. 20 drops -1 cubic centimeter.
3. Components in static condition, as in parked aircraft, are allowed maximum leakage of two
drops per seal or packing per day.
(d) For tests requiring long periods of time and Premaintenance requirements for testing of hy-
where fluid can drop, wipe surface clean and dry draulic system
without using a solvent. Use a clean blotter or white
cloth after system has operated or has been idle the
required period of time. Conditions Requirements
7-4. Testing - Hydraulic System. Testing of the Model All

hydraulic system may be accomplished by attaching a
hydraulic test stand to the test connectors (located on Part No. or Serial No. All
right side of helicopter, forward of engine) and auxiliary
power unit in accordance with the following Special Tools None
procedures. Premaintenance requirements for testing
of hydraulic system are as follows: Test Equipment Hydraulic Test
Stand
Support Equipment Auxiliary Power

Unit Work Stand
Minimum Personnel Two

Use of hydraulic ground test equipment, Required
with any flight control tube disconnected,
may result in damage to swashplate, Consumable Materials (C130 or C131)
scissors and sleeve assemblies. (C155)
Special Environmental Temperature/

Conditions Dust Free/
Well Ventilated
Area
Change 6 7-7
TM 55-1520-210-23-2
a. Using auxiliary power unit and hydraulic test ing with hydraulic power. Change over from mechani-
stand, functional test hydraulic system as follows: cal to hydraulic operation should occur at 500 psig
minimum.
NOTE
(b) Reduce pressure to zero.
Adjust hydraulic test stand pressure to (c) Check for irreversibility by moving each
1175 psig. Adjust rate of flow to 6 GPM. servo valve control lever to up (extend) or down
(retract), then apply approximately 100 pounds force
(1) Apply 1050 psig pressure to system and to the power cylinder extension tube and try to move
maintain for at least 15 minutes; meanwhile make cylinder in direction opposite to servo valve position.
following checks. Cylinder should not move.
(a) Leakage: Observe all portions of (d) After pressure has been reduced to zero
system for external leakage. Repair as necessary. for 3 minutes, examine irreversible valve and servo
valve on each cylinder for evidence of leakage.
(b) Clearance: Slowly cycle all controls to
limits of stroke and observe movement of hydraulic (6) When test is complete, remove auxiliary
servo cylinders. Clearances of all moving parts should power unit, refill and bleed system as necessary:
be such that no fouling can occur. Check flexible
connections carefully to be sure chafing or pinching of (7) Disconnect hydraulic test stand from
hoses does not occur, and that vibration does not ground test coupling.
loosen attaching fittings.
(8) Attach return line from reservoir to hydraulic
(2) Check operation of HYD PRESSURE cau- test stand coupling.
tion panel light.
NOTE
(a) Apply electrical power to helicopter.
(b) Position HYD control switch to on. When a hydraulic test stand is not avail-
able, the transmission-driven hydraulic
pump can be used to perform opera-
(c) Slowly decrease hydraulic test stand
tional checks and to bleed the hydraulic
pressure. Light should illuminate when pressure
system. Operation of the engine shall
reaches 600 to 400 psig.
be performed in accordance with
instructions contained in TM
(d) Slowly increase pressure. Caution panel 55-1520-210-10.
light should extinguish when pressure reaches 700 to
900 psig.
b. Perform operational checks and bleed hydrau-
lic system as follows:
(3) With system pressure at 1050 psig, place
HYD CONTROL switch to OFF to test operation of
solenoid valve. Actuate cyclic, collective, and tail rotor
controls, Caution panel light should illuminate, and
more force should be required to operate controls if
valve closed properly to shutoff hydraulic power assis-
tance. Full movement of cyclic at lower rotor
rpm may damage the main driveshaft.
(4) Check operation of pressure relief valve in
hydraulic system. While operating pressure is slowly (1) Start and ground-run the helicopter TM
increased, place hand on relief valve to determine 55-1520-210-10).
when it opens. Valve should open between 1100 and
1200 psig.
NOTE
(5) Check operation of each irreversible valve.
Ensure the hydraulic system has been
(a) Slowly increase hydraulic pressure until bled and serviced (paragraphs 7-6 and
it can be determined that control systems are function- 7-8).
7-8 Change 7
TM 55-1520-210-23-2
(2) Increase engine speed to 6000 RPM. Make the b. Remove fitter element from filter assembly (para-
following checks: graph 7-48). Install bowl on filter head and tighten.
(a) Observe all hydraulic fittings and components c. Connect hydraulic test stand hoses to inlet and out-
for evidence of external leakage. let test fittings on the helicopter.
(b) Repair or replace components and fittings as d. Inspect complete hydraulic system for attachment
necessary to correct leakage. and security of components.
(c) Slowly cycle all (fore and aft, lateral and collec- e. Set hydraulic test stand pressure to 1175 psig and
tive) controls and observe movements of hydraulic flush for five minutes to dean the system.
cylinder assemblies. No fouling should occur.
f. Throughout the operation observe all portions of sys-
(d) Check flexible hoses and hose connections to tem for evidence of external leakage.
ensure that pinching and chafing of hoses does not recur.
g. Shut down hydraulic test stand and connect hoses
(e) Place HYD CONTROL switch to OFF. to irreversible valves and cylinders. Service aircraft reser-
Solenoid valve should energize and dose. Caution panel voir to overflow with dean hydraulic fluid.
HYD PRESSURE light should illuminate, and more force
should be required to operate the controls. h. Install new filter element, tighten bowl and secure
with Iockwire (C155).
(3) Refill and bleed system as necessary (paragraphs
7-6 and 7-8). i. Bleed system (paragraph 7-6).
7-5. Flushing-Hydraulic System. The complete j. If contamination still exists in the hydraulic system
system must be thoroughly flushed as follows: after the system has been flushed, the system must be
reflushed to include the collective, cyclic, and tail rotor ac-
tuator assemblies. Flushing of the collective, cyclic and tail
rotor actuator assemblies can only be accomplished at the
next higher maintenance by complete disassembly and
Prolonged contact with liquid or mist can irritate reassembly.
eyes and skin. After any prolonged contact with
skin, immediately wash contacted area with soap 7-6. Bleeding-Hydraulic System. a. Using helicop-
and water. If liquid contacts eyes, flush immedi- ter power (refer to TM 55-1520-210-1 O), bleed hydraulic
ately with dear water. If liquid is swallowed, do not system as follows:
induce vomiting; get immediate medical attention.
Wear rubber gloves when handling liquid. If
prolonged contact with mist is likely, wear an ap-
propriate respirator. When fluid is decomposed by
heating, toxic gases are released.
Full movement of cyclic at lower rotor rpm may
damage the main driveshaft.
(1) Start and ground-run helicopter (TM 55-1520-

210-10) 0
Ensure hydraulic fluid in test stand is same type (2) Cycle tail rotor pedals and cyclic and collective
fluid as in aircraft. controls a minimum of 10 times with main rotor turning at
engine idle. Shut down engine.
NOTE
(3) Service reservoir to overflow with hydraulic
Prior to flushing hydraulic system functionally fluid (C130 or C131).
check hydraulic test stand to insure that it is
operating properly. Install new filter elements in b. Using hydraulic test stand, bleed hydraulic system
the test stand. Fill test stand reservoir to capacity as follows:
with dean hydraulic fluid. Inspect test stand pres-
sure and return hoses. (1) Connect hydraulic test stand to connectors (lo-
cated right side of helicopter, forward of engine). With
a. Disconnect hoses from three irreversible valves and hydraulic test stand operating, decrease hydraulic test
from tail rotor control boost cylinder. Connect hoses stand pressure to 1000 psig.
together using part number MS21916D5-4 reducers. Cap
ports to irreversible valves to prevent entry of dirt.
Change 5 7-9
TM 55-1520-210-23-2
(2) Cycle tail rotor pedals and cyclic and NOTE

collective controls a full stroke a minimum of 10 times
to bleed air from system.
Ensure that all normal operational checks
(3) Fill reservoir to overflow with hydraulic have been performed prior to using the
fluid (C136 or C131). following table 7-2. Any malfunctions
not Iisted require assistance of next
7-7. Troubleshooting — Hydraulic System. higher level of maintenance.
Conditions, test and inspections, and corrective
actions for the hydraulic system are as follows:
Table 7-2. Troubleshooting of Hydraulic System
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. Rotor tends to turn when operating hydraulic test stand (on UH-1H/V serial numbers 62-2106
through 64-13901 only).
Check valve (4, figure 7-1) in pressure line of pump not seating or installed backward.
STEP 1. Check valve (4, figure 7-1) in pressure line of pump not seating or installed backward.
Replace check valve or remove and replace with correct flow direction (paragraphs 7-28 and
7-32).
2. Pump noisy.
Pump case drain incorrectly installed on bottom of pump, causing air entrapment. Inherent noise
of the newer pump P/N PV3-044-8 is considerably greater than the older yoke type. The noise
does not indicate a pump malfunction, but is characteristic of the design.
Install property (paragraph 7-24).
3. Excessive feedback to controls.
STEP 1. Air in system.
Bleed system (paragraph 7-6).
STEP 2. Rotor not properly adjusted.
Track and adjust rotor (paragraph 5-123).
STEP 3. Loose cylinder bearing housing retaining nut or loose bushing set adjustment nut.
Replace cylinder assembly (paragraph 7-71 or 7-84).
Check adjustment on bushing sat nut (not applicable for KSP 6099-1 bearing) (paragraph 7-70,
steps g. and h).
7-10
TM 55-1520-210-23-2
Table 7-2. Troubleshooting of Hydraulic System (Cont)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
STEP 4. Internal leakage in irreversible valve.
Replace irreversible valve (paragraph 7-102).
STEP 5. Loose or worn hydraulic cylinder bearing housing mounting studs.
Check condition of studs. Check for stripped threads. Tighten nuts and/or replace mounting studs.
(AVIM.)
Tighten nuts and/or replace mounting studs. (AVIM.)
STEP 6. Excessive wear to KSP 6099-1 bearing.
Replace bearing (paragraph 7-72).
4. Cyclic/collective cylinder binds or does not operate smoothly.
Excessively tight cylinder support bushing set adjustment nut (not applicable to KSP 6099-1 bearing).
Lubricate cylinder support bearing, or adjust retainer nut (figure 1-2 or refer to paragraph 7-70,
steps g. and h.).
5. Collective control stick will not stay in position.
Friction adjusted to low on collective stick.
Adjust friction (paragraph 11-27).
6. Tail rotor feedback in pedals.
Tail rotor servo mounting bearing loose or worn.
Replace bearing (paragraph 11-187 and figure 11-44).
7. High frequency vibration or chatter.
Damper bearing in bellcrank to tail rotor quadrant worn or deteriorated.
Replace bearing (paragraph 11-187 and figure 11-44).
8. Hydraulic system too hot.
STEP 1. Broken line.
Repair line, replace pump and flush system (paragraphs 7-21 and 7-5).
Change 14 7-11
TM 55-1520-210-23-2
Table 7-2. Troubleshooting of Hydraulic System (Cont)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
STEP 2. Pump delivers excessive pressure.

Replace pump (paragraph 7-21).
STEP 3. Relief valve stuck open.

Replace valve and pump (paragraphs 7-41 and 7-21 ).
STEP 4. Pump case drain incorrectly installed.
Install properly (paragraph 7-23).
STEP 5. Check valve in irreversible valve sticking open.

Replace irreversible valve and pump (paragraphs 7-102 and 7-21).
9. Hydraulic control switch inoperative.

STEP 1. Faulty switch.
Replace switch (paragraph 9-5).
STEP 2. Faulty connections.

Repair connections (paragraph 9-5 and figure F33).
STEP 3. Defective wiring.

Replace wiring (paragraph 9-5 and figure F33).
STEP 4. Defective solenoid valve.
Replace solenoid valve (paragraph 7-62).

STEP 5. No hydraulic pressure.
Refer to caution panel worded segment HYD PRESSURE lighted indication of trouble.
10. Caution panel worded segment HYD PRESSURE illuminated.

STEP 1. Caution light system malfunction.
Perform operational check of HYD. PRESSURE light (paragraph 9-169).
STEP 2. Hydraulic pump failure.

Replace hydraulic pump (paragraph 7-21).
7-12
TM 55-1520-210-23-2
Table 7.2. Troubleshooting of Hydraulic System (Cont)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
11. Hydraulic oil leaks.
STEP 1. Worn gaskets, seals, or preformed packings.
Replace gaskets, seals, or preformed packings
Do not tighten leaky flareless fittings.
STEP 2. Leaking fittings.

Replace with new tube or hose assembly if nut, sleeve, or tubing or hose is defective.
STEP 3. Improper tightening, presence of foreign matter, or defective part.
Clean and remove all foreign matter.
NOTE
Threads of tube and hose connectors and fittings will have hydraulic fluid (C130 or C131) applied
to them prior to torquing. Do not torque with threads dry. Hydraulic fluid serves as a seal also after
fluid drys.
Tighten fitting nut with wrench until a sharp increase in torque is noted. Do not overtorque.
NOTE
If there is any doubt that the point of sharp torque increase has been reached, rapidly loosen and
tighten the nut several times (use light torque) until certain that increase in torque is due to the sleeve
and tube touching the fitting seat and is not due to thread friction.
Tighten nut and additional 1/6 of a turn (one hex flat), from point of sharp torque increase.
If leak is present, tighten nut additional 1/6 of a turn.
If leak still persists, remove tube or hose assembly and install new tube or hose assembly.
Change 7 7-13
TM 55-1520-210-23-2
7-8. Servicing — Hydraulic System. Service reser- g. Remove two nuts (19), six washers (2) and four
voir (9, figure 7-3) to overflow with hydraulic fluid (C130 bolts (1). Lift reservoir (9) from cabin roof.
or C131) (paragraph 1-9).
7-12. Disassembly — Hydraulic Reservoir.
7-9. HYDRAULIC RESERVOIR. a. Remove cap assembly (6, figure 7-3), adapter (4)
and strainer (5) from reservoir (9).
7-10. Description — Hydraulic Reservoir. The gravi-
ty feed hydraulic reservoir is a non-pressurized, magne- b. Remove baffle (22) from reservoir (9); remove
sium allow unit with an approximate capacity of 5.3 pints preformed packing (25), ring (24) and nut (23) from baffle
at overflow, 2.5 pints at refill level and is mounted on the (22).
cabin roof, under the right side of transmission cowling. c. Remove fitting (13) from reservoir (9); remove
The reservoir has a filler cap, a filler screen, an internal preformed packing (10), ring (11) and nut (12) from fitting
baffle, a fluid level sight gage plug, a vent screen, an (13).
overflow scupper, a drain plug, and connections for suc-
tion, return, and pump bypass lines (figure 7-3). d. Remove fitting (18) from reservoir (9); remove
preformed packing (17) from fitting (18).
e. Remove lockwire securing sight plug (7) to reser-
CAUTION voir (9). Remove preformed packing (8) from sight plug
Protective covers shall be installed on all (7).
open ports and lines. f. Remove vent screen (3) from reservoir if screen
is clogged or damaged.
7-11. Removal — Hydraulic Reservoir.
7-13. Cleaning — Hydraulic Reservoir.
a. Open transmission cowling (2, figure 2-18) and
engine cowls (6 and 7) for access. a. Flush interior of reservoir (9, figure 7-3) with sol-
vent (C261) and air dry with clean filtered compressed
b. Deleted. air.
c. Using a suitable container, remove plug (16) from
reservoir (9). Drain a small quantity of hydraulic fluid from WARNING
bottom of reservoir and inspect for contaminants. If con-
taminants are evident, flush system (paragraph 7-5). Re- Cleaning materials are flammable and tox-
move preformed packing (15) from plug (16). ic. Avoid skin contact and breathing of sol-
vent vapors.
d. Disconnect hose assembly (20) from fitting (18).
Install covers to fitting (18) and hose assembly (20). Protective goggles will be worn when
blowing with compressed air. Do not allow
e. Disconnect tube assembly (14) from fitting (13). more than 5 psi air pressure to come in
Install protective covers to fitting (13) and tube assembly contact with skin.
(14).
b. Clean strainer (5), vent screen (3), outside of
f. Disconnect tube assembly (21) from baffle (22). reservoir, and all fittings with solvent (C261) and air dry
Install protective cover to tube assembly (21). Protect with clean, filtered compressed air. Flush inside of reser-
baffle (22) from foreign material. voir with clean hydraulic fluid (C130 or C131).
7-14 Change 14
TM 55-1520-210-23-2
Premaintenance Requirements for Hydraulic 7-14. Inspection — Hydraulic Reservoir.

Reservoir
a. Inspect reservoir (9, figure 7-3) as follows:
Conditions Requirements (1) Inspect cap assembly (6) and baffle (22) for
Model All damage. No cracks allowed to baffle (22). If a crack in the
Baffle is suspected, refer to TM 1-1520-256-23, Techni-
Part No. or Serial No. All
cal Manual Aviation Unit Maintenance (AVUM) and Avi-
Special Tools None ation Intermediate Maintenance (AVIM) manual nonde-
structive inspection procedures for UH-1 helicopter
Test Equipment Fluorescent Penetrant
series.
Method
Support Equipment None
Required
Consumable Materials None
Special Environmental None
Conditions
References TM 1-1520-256-23
Change 14 7-14.1/(7-14.2 blank)

TM 55-1520-210-23-2
1. Bolt
2. Washer 8. Preformed packing 14. Tube assembly 20. Hose assembly
3. Vent screen 9. Reservoir 15. Packing 21. Tube assembly
4. Adaptor 10. Preformed packing 16. Drain valve 22. Baffle
5. Stralner 11. Ring 17. Preformed packing 23. Nut
6. Cap assembly 12. Nut 18. Fitting 24. Ring
7. Sight plug 13. Fitting 19. Nut 25. Preformed packing
26. Nut
27. Cap
FIGURE 7-3. Reservoir - Hydraulic System - Removal and Installation

Change 2 7-15
TM 55-1520-210-23-2
(2) Inspect strainer (5) and vent screen (3) for 7-15. Repair or Replacement — Hydraulic Reser-
rust, corrosion, cleanliness, cuts, and breaks. No dam- voir.
age allowed.
a. Any parts that fail inspection requirements out-
lined in above paragraph 7-14 require replacement with-
(3) Inspect sight plug (7), hose assembly (20),
out repair. For repair of corrosion damage to parts, refer
tube assemblies (14 and 21) and plug (16) for thread
to TM 1-1500-204-23 series.
damage, cracks, dents, leaks, corrosion and loose, miss-
ing or improperly installed hardware. No cracks allowed. b. Parts containing cracks require replacement
For treatment of corrosion, refer to TM 1-1500-204-23 without repair.
series.
c. Replace sight plug (7, figure 7-3) if discolored.
(4) Damage limits for each boss, port, or fitting d. Replace all preformed packings and rings.
are as follows:
7-16. Assembly — Hydraulic Reservoir.
(a) Depth — one-third of thread. NOTE
Flareless tubing connections shall be
(b) Length — one-third of pitch diameter.
tightened as follows:
(c) Number of repairs: two per segment. Tighten MS 21921 nut 1/6 to 1/3 turns (1/2
hex flats) past the point of sharp torque
(d) No cracks allowed. If a crack in the fit- rise on all sizes and materials for all types
ting is suspected, refer to TM 1-1520-256-23, Technical of fittings or tubes.
Manual Aviation Unit Maintenance (AVUM) and Aviation
Intermediate Maintenance (AVIM) manual nondestruc- The 1/6 to 1/3 turns (performed after the
tive inspection procedures for UH-1 helicopter series. preset operation) is the final installation
torque.
(5) Maximum depth of repairable mechanical a. Install vent screen (3, figure 7-3) if removed, to
damage (reference nicks, scratches, gouges, dents, reservoir (9) and point stake at three places (radial loca-
etc.) to the reservoirs (9) is 0.040 inch deep after clean- tion is unimportant).
up. No cracks allowed.
b. Install strainer (5) in reservoir (9). Apply a thin film
(6) Corrosion damage to reservoirs (9) shall not of primer (C312) to threads of adapter (4) and install
exceed 0.020 inch in depth prior to cleanup and 0.040 adapter to reservoir (9).
inch in depth after cleanup. c. Install preformed packing (8) on sight plug (7) and
install sight plug to reservoir. Secure sight plug to reser-
(7) Inspect sight plug (7) for discoloration. Any voir with lockwire (C155).
discoloration is not acceptable.
d. Place packing (17) on fitting (18) and install fitting
(8) Inspect system for leaks. to reservoir (9).
e. Install nut (12), ring (11), and packing (10) to fit-
(9) Inspect plug (16) and cap assembly (6) for ting (13) and install fitting to reservoir.
proper locking and safetying.
f. Install nut (23), ring (24) and packing (25) to baffle
(10) Inspect drain lines for obstruction. (22) and install baffle to reservoir.
g. Insure drain valve (16) is closed.
b. Drain a small quantity of hydraulic fluid from bot-
tom of reservoir and inspect for contaminants. If contami- h. Install cap assembly (6) to reservoir (9).
nants are evident, flush system (paragraph 7-5).
7-17. Installation — Hydraulic Reservoir.
c. Inspect reservoir (9) and attaching components a. Apply tape (C278) to lower side of mounting pads
for cleanliness and proper security. of reservoir (9, figure 7-3).
7-16 Change 14
TM 55-1520-210-23-2
b. Install reservoir with four bolts (1), six washers (2) d. Remove protective cover from tube assembly
and two nuts (19). (21) and connect tube assembly to baffle (22).
NOTE e. Remove protective cover from tube assembly

(14) and connect tube assembly to fitting (13).
Bolt (1) with holes in head will be installed
in hole of mounting pad adjacent to (drain) f. Remove protective cover from hose assembly
plug (16). Refer to table 1-5 for proper (20) and connect hose assembly to fitting (18).
torquing of all fluid connections prior to g. Service reservoir to overflow with hydraulic fluid
installation. (C130 or C131).
h. Bleed hydraulic system (paragraph 7-6).
c. Place nut (26) and packing (27) on drain valve
(16) and install in drain hole of reservoir. Tighten nut to i. Close transmission cowling (2, figure 2-18) and
prevent leak. Install cap (27) on valve (16). right engine cowls (6 and 7).
Change 14 7-17
TM 55-1520-210-23-2
7-18. Painting — Hydraulic Reservoir. Touch-up re- Premaintenance Requirements for Hydraulic
pair areas with primer (C312) or primer (C206). Pump
7-19. HYDRAULIC PUMP. Conditions Requirements

Model All
7-20. Description — Hydraulic Pump. The hydraulic
pump (2, figure 7-1) is a variable-delivery, axial-piston
unit mounted on a geared drive pad at right side of trans- Special Tools None
mission accessory drive adjacent to the rotor tachometer
generator. Four external parts of the hydraulic pump are
provided for connecting suction, pressure, pump lubrica- Method
tion, and for seepage drain. Eddy Current Inspection
Unit
NOTE
Maximum allowable leakage for in-service
components of the hydraulic pump is as Minimum Personnel Two
follows: Required
Output shaft — dynamic — 8 drops/minute
Output shaft — static (through seal) — 1 Special Environmental None
drop/minute Conditions
Housing (mating surfaces) — static — 2 References TM 1-1520-256-23
drops/day
7-22. Inspection — Hydraulic Pump.
7-21. Removal — Hydraulic Pump.
a. Inspect pump assembly (13) for evidence of leak-
a. Remove right access door (24, figure 2-18) from age.
pylon island in cabin area. Provide a suitable container
to catch hydraulic fluid and place container under plug b. Inspect pump assembly (13) for cracks, corro-
(16, figure 7-3). sion, dents, deep scratches or damage to splines of
shaft. If damage is found, send pump to next higher main-
b. Remove lockwire from plug (16). tenance level. No cracks allowed. If a crack in the pump
Assembly is suspected, refer to TM 1-1520-256-23,
c. Remove plug (16) and drain fluid from reservoir Technical Manual Aviation Unit Maintenance (AVUM)
(9). and Aviation Intermediate Maintenance (AVIM) manual
d. Disconnect hose assemblies from fittings (figure nondestructive inspection procedures for UH-1 helicop-
7-4). Install protective covers on hoses. ter series.
(1) Hose (8) from fitting (9). c. Inspect all fittings, nuts, and hoses for deteriora-
tion, cracks, corrosion, dents, and thread damage. No
(2) Hose (18) from fitting (17). cracks allowed. If a crack in any of the Hydraulic System
Components is suspected, refer to TM 1-1520-256-23,
(3) Hose (19) from fitting (20). Technical Manual Aviation Unit Maintenance (AVUM)
(4) Hose (24) from fitting (1). and Aviation Intermediate Maintenance (AVIM) manual
nondestructive inspection procedures for UH-1 helicop-
e. Remove fitting (17) from pump assembly (13) ter series.
and remove packing (14), ring (15) and nut (16) from
d. Inspect pump assembly, nuts and hose and tube
fitting.
assemblies for security.
f. Remove fitting (20) from pump assembly (13) and
7-23. Repair or Replacement — Hydraulic Pump.
remove packing (23), ring (22) and nut (21) from fitting.
a. Replace unserviceable fittings (1, 9, 17 and 20,
g. Remove fitting (1) from pump assembly (13) and figure 7-4), hoses (8, 18, 19 and 24) and nuts (2, 3, 10,
remove packing (6), ring (5) and nut (2) from fitting. 16 and 21).
h. Remove fitting (9) from pump assembly (13) and b. Replace all packings (6, 12, 14, and 23), rings (5,
remove packing (12), ring (11) and nut (10) from fitting. 11, 15 and 22), and gasket (7).
i. Cap all open ports of pump assembly (13). c. Replace pump assembly (13) if damage limits are
exceeded or malfunction occurs, and forward pump to
j. Remove four nuts (3), eight washers (4), pump depot maintenance.
assembly (13) and gasket (7) from transmission.
d. Any cracks to pump assembly requires replace-
k. Remove container. ment of pump.
7-18 Change 14
TM 55-1520-210-23-2
7-24. Installation. sharp torque rise on all sizes and ma-

NOTE terials for all types of fittings or
Flareless tubing connections shall be tubes.
tightened as follows: The 1/6 to 1/3 turns (performed after
Tighten MS21921 nut 1/6 to 1/3 presetting operation) is the final in-
turns (1-2 HEX flats) past the point of stallation torque.
Table 7-4. Hydraulic Pump Installation Data
PUMP LINE LOCATIONS

CASE SEAL PRESSURE
PUMP DRAIN DRAIN LINE PUMP INLET
AA60321R Top Bottom-Inboard ****Top-Outboard ***Bottom-right
AA60321RA Top Bottom-Inboard ****Top-Outboard ***Bottom-right
AA65321RA Top Bottom-Inboard ****Top-Outboard ***Bottom-right
PV3-044-8 Top Bottom-Inboard Top-Outboard Bottom
AP2V-55 and
AP2V-77 Top Bottom-Inboard Top-Outboard Bottom
57049 **Top *Bottom-inboard Top-Outboard Bottom
* Connect to inlet marked UH-1D.
** Connect to case drain marked UH-1B.

*** Remove pump inlet fitting from pump and reinstall fitting facing to
the right when required.
**** Assemble an MS21916D16-12 reducer and an MS28778-12 preformed
packing in pressure line before installation in helicopter.
a. If replacing pump assembly, remove case e. Install nut (2), ring (5), and packing (6) on
drain plug from new pump and drain shipping fitting (1) and install fitting on pump assembly (13).
preservation fluid.
f. Install nut (21), ring (22), and packing (23) on
b. Refill pump assembly with clean hydraulic fitting (20) and install fitting on pump assembly(13).
fluid (C130 or C131) and install case drain plug. g. Install nut (16), ring (15), and packing (14) on
Secure case drain plug wih Iockwire (C155). fitting (17) and install fitting on pump assembly(13).
c. Remove protective caps from all open ports. h. Apply grease (C129) or compound (C47) to
pump shaft splines and splines of quill pad.
d. Install nut (10, figure 7-4), ring (11), and
packing (12) to fitting (9) and install fitting to pump i. Position gasket (7) and pump assembly (13) on
assembly (13). studs of drive pad on right side of transmission sump
7-19
TM 55-1520-210-23-22
1. Fitting 9. Fitting
2. Nut 17. Fitting
10. Nut 18. HOSe Assembly
3. Nut 11. Ring
4. Washer 19. Hose Assembly
12. Preformed packing 20. Fitting
5. Ring 13. Pump Assembty
6. Preformed packing 21. Nut
14. Preformed packing 22. Ring
7. Gasket 15. Ring
8. Hose assembly 23. Preformed packing
16. Nut 24. Hose Assembly
Figure 7-4. Hydraulic Pump Removal Installation

case, engaging pump shaft in splined gearshaft (4) Hose (24) to fitting (1).
Install eight washers (4) and four nuts(3) Torque nuts
(3) 120 TO 145 Inch-pounds. k. Fill hydraulic reservoir (9, figure 7-3) to
normal level with clean hydraulic fluid (C130) or
j. Remove protective cover from hose C131).
assembles (8), (18), (19), and (24) Connect hose
assemblies to fittings.
(1) Hose (8) to fitting (9) NOTE

(2) Hose (18) to fitting (17). With pump installed, placarded plug is
Iocated on top, left side, outboard
(3) Hose (19) to fitting (20). portion of piston chamber.
7-20 Change 2
TM 55-1520-210-23-2
NOTE h. Disconnect tube assemblies from upper and low-

The following paragraph applies to er end of check valve (18, figure 7-1) and remove check
AA-60321 series pumps only. valve.
l. On gravity feed system, locate and remove plac-

arded plug from top of pump piston chamber. Trapped air Premaintenance Requirements for Check Valve
will be expelled from piston chamber when hydraulic fluid
drains from plug port. After air is expelled, replace plug, Conditions Requirements
and secure with lockwire (C155). Model All
m. Bleed and test hydraulic system (paragraphs 7-4 Part No. or Serial No. All
and 7-6).
Special Tools None
7-25. Test Procedures - Hydraulic Pump. Test Equipment Fluorescent Penetrant
Method
a. Start and ground run helicopter at flight idle (TM
55-1520-210-10). Functionally check operation of hy- Support Equipment None
draulic pump assembly (13, figure 7-4). Minimum Personnel Re- Two
b. Check for leakage of fittings or hose connections. quired
7-26. CHECK VALVES.
Conditions
7-27. Description - Check Valves. Five check valves
(figure 7-1) (four in hydraulic system and one in arma- References TM 1-1520-256-23
ment system) allow fluid to flow, one direction only, in
lines during movement of flight controls. 7-29. Inspection - Check Valves. Inspect check
valves for cracks, corrosion, thread damage, evidence of
7-28. Removal - Check Valves. leakage and security. No cracks allowed. If a crack in the
Check Valves is suspected, refer to TM 1-1520-256-23,
a. Remove soundproofing blanket and access door Technical Manual Aviation Unit Maintenance (AVUM)
(81, figure 2-18) from pylon island in cabin area. and Aviation Intermediate Maintenance (AVIM) manual
NOTE nondestructive inspection procedures for UH-1 helicop-
ter series.
A small amount of fluid will seep while
breaking torque on tube and hose assem- 7-30. Repair or Replacement - Check Valves.
bly connectors and will require placing a
container under check valve. a. Any evidence of cracks requires replacement of
part. No repairs allowed.
b. Disconnect pump assembly hose from top of
check valve (4, figure 7-1), located right, forward side of WARNING
cargo hook lift beam. Install protective cap on hose as-
sembly. Use spray paint and chemical film material
c. Remove check valve (4) from fitting (tee). Re- in a well ventilated area. Avoid contact and
move preformed packing from check valve. breathing spray mist.
b. Minor nicks, scratches, dents or corrosion to ex-
d. Disconnect tube from check valve (4.1) and
ternal surface of check valve is acceptable, provided
check valve from fitting (tee).
damaged area is smoothed out using 600 grit sandpaper
e. Remove lower, aft, fuselage door. Disconnect (C234) to original finish and touched-up with chemical
tube assemblies from forward and aft end of check valve film material (C62) followed with a light coat (by brush) of
(12) and remove check valve. primer (C312) or primer (C206). Any corrosion to internal
area or threads of check valve requires replacement of
f. Disconnect tube assembly from top of check part.
valve (13) and remove check valve from bulkhead fitting
(tee). Remove preformed packing from check valve (13). c. Check security of check valves.
NOTE d. Replace check valve when there is evidence of

fluid leakage (reference pin holes in valve body, due to
The following procedural steps f. and g. internal corrosion damage) or corrosion damage to
pertain to helicopters with armament pro- threads.
visions installed only.
e. Replace check valve when malfunctioning oc-
g. Remove access door (80, figure 2-18). curs.
Change 14 7-21
TM 55-1520-210-23-2
7-31. Test Procedures — Check Valves. Perform op- j. Install check valve (4.1) in fitting (tee) and connect
erational check of hydraulic system (paragraph 7-4). tube to check valve.
k. Install access door (81, figure 2-18).
7-32. Installation — Check Valves.
7-33. GROUND TEST CONNECTIONS.
CAUTION
7-34. Description — Ground Test Connections. Two
Ensure that directional flow arrow is point- ground test connections (figure 7-5) are provided for con-
ing in right direction prior to installation nection of hydraulic test stand to functionally check hy-
(view A through D, figure 7-1). draulic and flight control systems.
NOTE 7-35. Removal — Ground Test Connections.
All fluid connections will be properly
torqued in accordance with table 1-5. a. Open right-side lower engine cowl (7, figure
2-18). Disconnect coupling half (9, figure 7-5) from cou-
NOTE pling half (11). Place protective cover on coupling half (9).
If hydraulic system for external armament b. Provide a container and place under connectors
hook-up is not incorporated in helicopter, of tube assemblies (14 and 15) to catch fluid and discon-
proceed to step c. nect tube assemblies from fittings (13 and 16).
a. Position and install check valve (18, figure 7-1) c. Remove screws (1), washers (2), nuts (3), and
between upper and lower tube assemblies as shown in bracket (18).
view D.
d. Remove test connectors and attaching compo-
b. Connect and secure upper and lower tube as- nents from brackets (6 and 18) as follows:
sembly to check valve (18).
(1) Remove fitting (16) from fitting (23) and re-
c. Install access door (80, figure 2-18). move preformed packing (17) from fitting.
d. Install packing to end of check valve (13, figure (2) Remove fitting (13) from fitting (24). Re-
7-1) that will be adjacent to fitting (tee). Position check move preformed packing (12) from fitting (13).
valve (13) as shown in View B and install check valve to (3) Remove screws (4) and washers (5) from
top side of outboard bulkhead fitting (tee). bracket (6) and remove bracket (6) from bracket (18).
e. Connect and secure tube assembly to check (4) Break torque on nut (27); remove fitting (24)
valve (13). preformed packing (25), ring (26) and nut (27) from cou-
f. Position and install check valve (12) as shown in pling half (7).
View C by connecting forward and aft tube assemblies. (5) Remove screws (8) attaching coupling half
g. Install access door (53, figure 2-18) to forward (7) to bracket (6) and remove coupling half.
fuselage. (6) Break torque on nut (20); remove fitting
h. Install packing on end of check valve (4, figure (23), preformed packing (22), ring (21) and nut (20) from
7-1) which installs adjacent to fitting (tee). Position and coupling half (11).
install check valve (4) as shown in View A to top side of (7) Remove screws (10) attaching coupling half
fitting (tee). (11) to bracket (18) and remove coupling half.
i. Connect and secure pump hose assembly to top (8) Remove coupling half (9) from hose assem-
of check valve (4). bly.
7-22 Change 14
TM 55-1520-210-23-2
1. Screw 10. Screw 19. Cap assembly

2. Washer 11. Coupling half 20. Nut
3. Nut 12. Preformed packing 21. Ring
4. Screw 13. Fitting 22. Preformed packing
5. Washer 14. Tube assembly 23. Fitting
6. Bracket 15. Tube assembly 24. Fitting
7. Coupling half 16. Fitting 25. Preformed packing
8. Screw 17. Preformed packing 26. Ring
9. Coupling half 18. Bracket 27. Nut
Figure 7-5. Hydraulic Test Connections — Removed and Installed
7-23
TM 55-1520-210-23-2
Premaintenance Requirements for Ground Test

Connections WARNING
Use spray paint and chemical film material

Conditions Requirements in a well ventilated area. Avoid contact and
Model All breathing spray mist.
Part No. or Serial No. All c. Minor corrosion on exterior surfaces of tube as-
Special Tools None semblies, fittings, brackets or coupling halves is allowed,
Test Equipment Fluorescent Penetrant provided damaged areas are polished out with 600 grit
Method sandpaper (C234), treated with chemical film material
Support Equipment None (C62), followed with a light coat of primer (C312) or prim-
er (C206).
Required d. Any evidence of leaks to coupling halves requires
Consumable Materials None replacement of part.
Special Environmental None e. Replace all preformed packings.
Conditions
References TM 1-1520-256-23 7-38. Installation — Ground Test Connections.
a. Install coupling half (9, figure 7-5) to hose assem-
7-36. Inspection — Ground Test Connections. bly.
a. Visually inspect coupling halves (7, 9 and 11, fig- b. Position coupling half (11) to bracket (18) and
ure 7-5), cap assembly (19) and brackets (6 and 18) for install screws (10).
cracks. No cracks allowed. If a crack in any of the Cou- c. Install nut (20), ring (21), packing (22) and fitting
pling Halves, Cap Assembly, or Brackets of the Ground (23) to coupling half (11).
Test Connections is suspected, refer to TM d. Position coupling half (7) to bracket (6) and install
1-1520-256-23, Technical Manual Aviation Unit Mainte- screws (8).
nance (AVUM) and Aviation Intermediate Maintenance e. Install nut (27), ring (26), packing (25) and fitting
(AVIM) manual nondestructive inspection procedures for (24) to coupling half (7).
UH-1 helicopter series.
f. Position bracket (6) to bracket (18) and install
b. Inspect fittings (13, 16, 23 and 24), coupling half screws (4) and washers (5).
(7, 9 and 11) and cap assembly (19) internally and exter- g. Install packing (12) on fitting (13). Install fitting
nally for evidence of corrosion. (13) to fitting (24).
h. Install packing (17) on fitting (16). Install fitting
c. Inspect brackets (6 and 18) for damage in accor- (16) to fitting (23).
dance with the following limits:
i. Position bracket (18) and install screws (1), wash-
(1) No cracks allowed. ers (2) and nuts (3).
j. Connect tube assembly (14) to fitting (13).
(2) Surface imperfections: (Nicks, scratches, k. Connect tube assembly (15) to fitting (16).
corrosion, etc.) shall be blended into the surrounding l. Disconnect hydraulic test stand from test connec-
surface. Minimum acceptable wall thickness after clean- tions. Connect coupling half (9) to coupling half (11) and
up is 0.032 inch. Cleanup area not critical. ensure that both coupling halves are locked securely.
(3) Edge chamfer or dent: 0.060 maximum m. Connect cap assembly (19) to coupling half (7)
depth. and ensure that cap assembly is locked.
n. Bleed hydraulic system (paragraph 7-6).
d. Inspect coupling halves (7, 9 and 11) and con- o. Check ground test connectors and attaching
nections of attaching tube assemblies (14 and 15) for components for leakage.
evidence of leakage.
p. Close right lower engine cowl (7, figure 2-18).
7-37. Repair or Replacement — Ground Test Con- 7-39. RELIEF VALVE.

nections.
7-40. Description — Relief Valve. A relief valve, lo-
a. Any cracks or damaged threads to test couplings cated on forward side of cargo hook lift beam (figure 7-6)
or attaching components requires replacement of part. relieves system pressure in excess of 1175 psi into the
return circuit to prevent damage to the system or compo-
b. No corrosion allowed to interior areas of coupling nents. This relief valve acts as a safety device that moni-
half, fittings or tube assemblies. Replace corroded parts. tors system pressure and must not be used to adjust
No corrosion allowed on threaded area of parts. system pressure.
7-24 Change 14
TM 55-1520-210-23-2
1. Tube assembly 9. Tube assembly 16. Bolt

2. Tube assembly 10. Bolt 17. Preformed packing
3. Electrical connector 11. Preformed packing 18. Ring
4. Electrical connector 12. Fitting 19. Fitting
5. Washer 13. Preformed packing 20. Washer
6. Spacer 14. Relief valve 21. Bolt
7. Nut 15. Washer 22. Bolt
8. Tube assembly
Figure 7-6. Hydraulic Relief Valve — Removal and Installation
218-260 O - 88 - 2 7-25
TM 55-1520-210-23-2
7-41. Removal — Relief Valve. 7-42. Inspection — Relief Valve.

a. Remove access door (81, figure 2-18). a. Visually inspect relief valve (14, figure 7-6), bolt
a.1. Disconnect electrical connections (3 and 4) from (10) and fitting (12) for cracks, deep gouges or scratches.
pressure switch and solenoid valve. No cracks allowed. If a crack in the Relief Valve, Bolt, or
Fitting is suspected, refer to TM 1-1520-256-23, Techni-
b. Disconnect tube assemblies (1, 2, 8 and 9, figure cal Manual Aviation Unit Maintenance (AVUM) and Avi-
7-6) from hydraulic unit and cap all openings. ation Intermediate Maintenance (AVIM) manual nonde-
c. Remove bolts (16) and washers (15). structive inspection procedures for UH-1 helicopter
series.
d. Remove bolts (21) and washers (20).
b. Visually inspect relief valve (14) and bolt (10) for
e. Remove bolts (22), washers (5), and spacers (6)
thread damage or corrosion.
attaching filter assembly to lift beam and remove filter
assembly. c. Visually inspect tube assemblies for nicks,
f. Place hydraulic unit on work bench. Remove lock- scratches, thread damage, dents or corrosion.
wire from bolt (10). Remove bolt (10), preformed packing d. Visually inspect relief valve for evidence of leak-
(11), fitting (12) and preformed packing (13) from relief age.
valve (14).
g. Remove preformed packing (13) from bolt (10) 7-43. Repair or Replacement — Relief Valve.
and remove bolt from fitting (12). Remove preformed
packing (11) from bolt (10). a. Replace packings (11, 13 and 17, figure 7-6) and
ring (18).
h. Break torque on nut (7) and remove relief valve
(14) from hydraulic unit. b. Replace relief valve (14) when malfunction oc-
curs.
i. Remove preformed packing (17) and ring (18)
from fitting (19). c. Any cracks to relief valve (14), bolt (10), fitting
j. Cap open ports of valve (14). (12) requires replacement of part.
WARNING
Premaintenance Requirements for Relief Valve
Conditions Requirements Use paint and chemical film material in a
well ventilated area. Avoid skin contact
Model All and breathing spray mist.
d. Minor corrosion, scratches or gouges to the ex-
Special Tools None ternal surface of relief valve are allowed, provided dam-
aged areas are polished out with 600 grit sandpaper
(C234) to original finish and treated with chemical film
Method
material (C62) followed with a light application (by brush)
Support Equipment None of primer (C312) or primer (C206).
Minimum Personnel Two e. Replace bolt (10), fitting (12) or relief valve (14)
Required when corrosion exists in internal area of components.
f. Any corrosion damage to threaded areas of parts
Special Environmental None requires replacement of part.
Conditions
g. Any evidence of leakage to the relief valve (14)
References TM 1-1520-256-23 requires replacement of part.
7-26 Change 14
TM 55-1520-210-23-2
7-44. Test Procedures — Relief Valve. (paragraph d. Position hydraulic unit to forward side of cargo
7-4). hook lift beam and install bolts (21) and washers (20).
7-45. Installation — Relief Valve. e. Install bolts (16) and washers (15) to relief valve
(14) and bracket on cargo lift beam.
a. Install ring (18, figure 7-6) and packing (17) to
fitting (19). f. Install bolts (22), washers (5) and spacers (6) to
b. Remove protective covers from ports of relief filter assembly and bracket on cargo lift beam.
valve (14) and thread relief valve onto fitting (19). Tighten
nut (7) against relief valve. g. Remove protective dust covers and connect tube
assemblies (1, 2, 8 and 9).
c. Install packing (11), fitting (12) and packing (13)
on bolt (10), and install bolt and assembled parts to ports h. Connect electrical connector (3) to pressure
of relief valve (14). Secure bolt (10) with lockwire (C155). switch and secure with lockwire (C154).
Change 14 7-26.1/(7-26.2 blank)

TM 55-1520-210-23-2
i. Connect electrical connector (4) to sole- (8) Place assembly on workbench. Break
noid valve and secure with Iockwire (C154). torque on nut (8) and remove fitting (6) and pressure
switch from solenoid valve, Remove preformed
j. Install upper access panel and soundproofing packing (9), ring (19) and nut (8) from fitting (6)
blanket.
7-46. HYDRAULIC FILTER (9) Break torque on nut (15) and remove filter
ASSEMBLY. assembly (21) from fitting (14).
7-47. Description — Hydraulic Filter Assem- (10) Remove preformed packing (20), ring (18)
bly. The hydraulic filter assembly is a non by- and nut (15) from fitting (14).
pass assembly (21, figure 7-7) that has a filter (11) Break torque on nut (25) and remove
element with a filtering capability of at least 15 fitting (26) from filter assembly (21) Remove
micron absolute. A red indicator is provided, to preformed packing (23), ring (24) and nut (25) from
raise, when differential pressure across the ele- fitting (26).
ment exceeds 70 plus or minus 10 psi and the
indicator button is visible through a window on NOTE
the pylon island in the cabin areas. The filter Filter element replacement procedures
assembly is located on forward side of cargo. are typical for both P/N MS28720-6 and
hook lift beam. An additional filter. assembly 205-076-03-4-6 filter, assemblies, 205-
without red indicator (17, figure 7-1) Is installed 076-034-7 filter element may be used in
in helicopters that have armament provisions. lieu of 206-076 -034-3 filter element,
7-48. Removal — Hydraulic Filter Assembly. a. (12) When replacement of filter element is
Remove filter assembly (21, figure 7-7) as follows: required, disassemble filter assembly as follows:
(1) Remove access door (81, figure 2-18).
NOTE
Three different filter assemblies are
available for use. Refer to figure 7-7,
sheet 2 differences and determine which
filter is installed.
Ensure protective covers are installed on
all open ports to prevent entry of foreign (a) Remove Iockwire from bowl (30, figure
material. 7-7)
(2) Disconnect tube (1 and 2, figure 7-7) (b) Place a container under filter assembly
to catch fluid seepage. Remove bowl/element
(3) Disconnect tube assembly (10) Cover all from head assembly (35).
open ports.
(c) Drain fluid from bowl (30) and remove
(4) Remove lockwire from electrical connectors retainer (27) and element (29) from bowl.
(3 and 7) and remove electrical connectors (d) Remove preformed packing (28) from
element (29).
(5) Remove bolts (13) and washers (12) (e) Remove two backup rings (36) and
attaching relief valve to bracket on lift beam. preformed packing (37) from head assembly (35).
(6) Remove bolts (22), washers (4), and (13) If indicator assembly (31) is being
spacers (5) attaching filter assembly (21) to bracket on replaced, remove indicator assembly as follows:
lift beam.
(a) Remove Iockwire, from indicator
(7) Remove bolts (17) and washers (16) assembly (31) and remove indicator from head
attaching solenoid valve to bracket and remove filter assembly (35).
assembly (21) and attached components.
7-27
TM 55-1520-210-23-2
1. Tube assembly 10. Tube assembly 19. Ring

2. Tube assembly 11. Fitting 20. Preformed packing
3. Electrical connector 12. Washers 21. Filter assembly
4. Washers 13. Bolts 22. Bolts
5. Spacers 14. Fitting 23. Preformed packing
6. Fitting 15. Nut 24. Ring
7. Electrical connector 16. Washers 25. Nut
8. Nut 17. Bolts 26. Fitting
9. Preformed packing 18. Preformed packing
Figure 7-7. Hydraulic Filter Assembly – Removal and

Installation (Sheet 1 of 2)
7-28
TM 55-1520-210-23-2
DETAIL A
(Bendix Part No. 056448 Shown)
27. Retainer 31. Indicator assembly 35. Head assembly
28. Preformed packing 32. Back up ring 36. Back up ring
29. Element assembly 33. Preformed packing 37. Preformed packing.
30. Bowl 34. Preformed packing
Figure 7-7. Hydraulic Filter Assembly – Removal and
(b) Remove preformed packings (33 and 34) (6) Remove preformed packing (8), ring (10)
and backup ring (32) from indicator assembly (31). and nut (11) from fitting (12).
(7) When replacement of filter ele-
NOTE ment is required, disassemble filter
assembly in accordance with paragraph
The following removal procedures apply 7-48, step a. (12).
to helicopters that have armament
provisions. NOTE
b. Remove filter assembly (6, figure 7-8) as When ambient temperatures are be-
follows: low +20 degrees F (-6.7 degrees
C) the indicator buttons may ex-
(1) Remove access door (73, figure 2-18). tend. Reset button after fluid
warms up.
(2) Place a container under fiter assembly (6,
figure 7-8) to catch fluid seepage. Disconnect tube 7-49. Inspection — Hydraulic Filter Assembly. a.
assemblies (3 and 13). Cover all open ports. Inspect filter assembly for internal or external
corrosion damage.
(3) Remove nuts (1), washers (2 and 8). and
bolts (7) from filter assembly (6), and remove filter b. Inspect filter assembly for security.
assembly.
(4) Remove fitting (4). Remove preformed c. Inspect filter assembly for cracks. Maximum
depth of nicks, scratches, dents and corrosion: 0.015
packing (5) from fitting.
inch after cleanup. Thread damage: one-third of
(5) Break torque on nut (11) and remove fitting thread. Length: one-quarter inch cumulative.
(12) from filter assembly (6).
d. Inspect ports of filter assembly for thread
damage.
7-29
TM 55-1520-210-23-2
1. Nut 6. Filter assembly 10. Ring

2. Washers 7. Bolts 11. Nut
3. Tube assembly 8. Washers 12. Fitting
4. Fitting 9. Preformed packing 13. Tube assembly
5. Preformed packing
Figure 7-8. Hydraulic Filter Assembly (Helicopter Serial Numbers
(63-12956 through 65-12895) – Removal and Installation
e. Disassemble and inspect filter assembly

internally for contamination.
f. Inspect attaching components for damage.
7-30
TM 55-1520-210-23-2
(a) Install backup ring (32, figure 7-7) and

packing (33) on indicator assembly (31).
(b) I n s t a l l p a c k i n g ( 3 4 ) o n i n d i c a t o r
Cleaning materials are flammable and assembly (31) and install indicator assembly to head
toxic. A v o i d s k i n c o n t a c t a n d assembly (35).
breathing of solvent vapors.
(c) Install two backup rings (36) and packing
7-50. Cleaning — Hydraulic Filter Assembly. (37) into grooves in head assembly (35).
Wipe exterior surface of filiter assembly with a
soft cloth dampened with solvent (C261).
NOTE
When ambient temperature is below 20 NOTE

degrees F (-6.7 degrees C) the indicator
buttons may extend. Reset button after Filter elements shall be considered
fluid warms. unserviceable if cracked, torn, sepa-
rated, deteriorated, corroded, crushed,
7 - 5 1 . Repair of Replacement — Hydraulic Fil- or collapsed.
ter Assembly. a. All UH-1 helicopters use filter
elements (29, figure 7-7) rated at 15 micron.
These filter elements need to be changed only if
the indicator button on the module is tripped or
every 3rd and 6th phase inspection, whichever
occurs first.
b. If the red indicator button extends remove (d) Install packing (28) in element assembly
and replace filter element. Reset the button; (29). Place element assembly in bowl (30) and install
operate the hydraulic system until normal oper- retainer (27) into groove in bowl (30).
ation temperature is obtained.
c. R e p l a c e a l l p e r f o r m e d p a c k i n g s a n d ( i f (e) I n s t a l l b o w l ( 3 0 ) o n h e a d a s s e m b l y
required) backup rings. (35) and secure with Iockwire (C155).
d. Replace filter assembly when evidence of
corrosion exists in internal area of filter. (2) Install packing (5, figure 7-8) on fitting (4)
e. Check for proper security of filter assem- and install fitting at IN port of filter assembly (6).
bly.
f. Any cracks to the filter assembly requires
(3) Install nut (11), ring (10) and packing (9) on
replacement of part. Replace without repair.
fitting (12), position fitting (12) (pointing down) and
g. C o n t a m i n a t i o n : F l u s h h y d r a u l i c s y s t e m
install fitting at OUT port of filter assembly (6).
and replace all filter elements.
7-52. Installation — Hydraulic Filter Assembly. a.
Install Part No. MS28720-6 or Part No. 205-076-034- (4) Position filter assembly (6) to bracket and
5 filter assembly (6, figure 7-8) as follows: install bolts (7), washers (8 and 2), and nuts (1).
(1) If replacement of filter element (29, fig-

(5) R e m o v e covers from tube assemblies (3
ure 7-7, detail A) or replacement of indicator
and 13).
assembly (31) was required, assemble filter
assembly (6) as follows:
(6) C o n n e c t tube assembly (3) to fitting (4).
NOTE
(7) C o n n e c t tube assembly (13) to fitting (12).
Three different filter assemblies are
available for use. Refer to figure 7-7 for
differences and determining which filter (8) S e r v i c e and bleed hydraulic system
is installed. (paragraph 7-6).
7-31
TM 55-1520-210-23-2
(9) Install access door (73, figure 2-18). will then be illuminated. The pressure switch should open
at 800 plus or minus 100 psig increasing pressure.
(10) Lower and secure center troop seats.
b. Install Part No. MS28720-6 or Part No. 7-55. Removal — Pressure Switch.
205-076-034-5 filter (21, figure 7-7) as follows: a. Remove access door (81, figure 2-18).
(1) If replacement of filter element (29, figure b. Ensure that all electrical power is OFF.
7-7) or replacement of indicator assembly (31) was re-
quired, assemble filter assembly (21) in accordance with c. Remove lockwire and electrical connector (1, fig-
preceding step a.(1). ure 7-9) from pressure switch (2).
(2) Install nut (25), ring (24) and packing (23) on d. Position a small container under pressure switch
fitting (26) and install fitting to IN port of filter assembly (2) to catch fluid seepage and remove pressure switch
(21). from fitting.
(3) Install nut (15), and packing (18) and (20) on e. Remove packing (3) from pressure switch (2).
fitting (14).
f. Install protective dust cover to open ports of pres-
(4) Thread fitting (14) in OUT port of filter assure switch and fitting.
sembly (21) and tighten nut (15) against filter assembly.
Premaintenance Requirements for Pressure Switch
(5) Install nut (8), ring (19), and packing (9) on
fitting (6). Remove cover from port of solenoid valve and Conditions Requirements
install fitting (6) in solenoid valve. Tighten nut (8) against
Model All
solenoid valve.
(6) Install bolts (22), washers (4) and spacers
(5) to filter assembly (21). Position assembled hydraulic Special Tools None
unit to forward side of cargo lift beam and temporarily Test Equipment Fluorescent Penetrant
secure (finger tight) two bolts (22). Method
(7) Temporarily install (finger tight) bolts (17) Support Equipment None
and washers (16) to solenoid valve.
(8) Temporarily install (finger tight) bolts (13) Required
and washers (12) to relief valve.
(9) Secure bolts (13, 17 and 22). Special Environmental None
(10) Remove covers from connectors of tube as- Conditions
semblies (1, 2, and 10). References TM 1-1520-256-23
(11) Install tube assembly (1) to fitting (26).
(12) Install tube assembly (2) to fitting (6). 7-56. Inspection — Pressure Switch.
(13) Install tube assembly (10) to fitting (11). a. Inspect pressure switch (2, figure 7-9) for evi-
dence of fluid leakage.
(14) Install electrical connector (3) to pressure
switch and secure electrical connector with lockwire b. Inspect pressure switch (2) for corrosion (inter-
(C154) nally and externally). No internal corrosion allowed. Max-
imum depth of external corrosion after cleanup: 0.010
(15) Install electrical connector (7) to solenoid inch.
valve and secure electrical connector with lockwire
(C155). c. Inspect pressure switch (2) for cracks or thread
damage. No cracks allowed. Maximum thread damage:
(16) Install access door (81, figure 2-18). Depth — one third of thread, Length — one quarter inch
cumulative. If a crack in the Pressure Switch is sus-
7-53. PRESSURE SWITCH. pected, refer to TM 1-1520-256-23, Technical Manual
Aviation Unit Maintenance (AVUM) and Aviation Inter-
7-54. Description — Pressure Switch. A pressure mediate Maintenance (AVIM) manual nondestructive in-
switch is provided in the hydraulic system pressure line spection procedures for UH-1 helicopter series.
to sense the system pressure. The pressure switch d. Maximum depth of nicks and scratches, 0.010
closes a circuit to the caution panel when pressure is at inch after cleanup. No dents allowed.
500 plus or minus 100 psig decreasing pressure, and the
HYD PRESSURE caution light and master caution light e. Inspect pressure switch (2) for security.
7-32 Change 14
TM 55-1520-210-23-2
1. Electrical connector 4. Solenoid valve

2. Pressure switch 5. Relief valve
3. Preformed packing 6. Filter assembly
Figure 7-9. Hydraulic Pressure Switch — Removal and Installation
7-33
TM 55-1520-210-23-2
7-57. Repair or Replacement —Pressure Switch. e. Apply hydraulic pressure to system. Check
a. Any evidence of leakage to body of pressure switch pressure switch for proper operation and leakage.
(2, figure 7-9) requires replacement of part.
f. Install access door (81, figure 2-18).
b. Replace packing (3).
7-60. SOLENOID VALVES.
c. Any corrosion to internal area, or threads of
pressure switch (2), requires replacement of part. No 7-61. Description — Solenoid Valves. Two
repairs allowed. solenoid valves (3 and 18, figure 7-10) are used. One
is located on forward side of cargo lift beam and the
other (on helicopters with armament provisions) is
located on aft side of cargo lift beam.
7-62. Removal — Solenoid Valves. a. Remove

access door (81, figure 2-18).
Use spray paint and chemical film
material in a well ventilated area. Avoid b. Remove left and right soundproofing blankets
skin contact and breathing of spray mist. and left and right pylon doors (23 and 24).
c. Remove hydraulic unit from helicopter
(paragraph 7-41, steps b. through j).
d. Polish corrosion, nicks or scratches to ex-
ternal area of pressure switch (2) in accordance d. Disconnect tube assembly (10, figure 7-10)
with limits in paragraph 7-56 with 600 grit sand- from fitting (7) and install protective cover on tube
paper (C234) to original finish and touched-up assembly connector.
with chemical film material (C62) followed with
a light application of primer (C312) or primer e. Break torque on nut (11) and remove solenoid
(C206). valve (3) from fitting (12).
e. Cracks, or malfunction to the pressure switch
(2) requires replacement of part. No repairs allowed. f. Remove packing (8) and ring (9) from fitting
(12).
f. Any dents to pressure switch (2) requires
replacement of part. No repair allowed. g. Break torque on nut (14) and remove solenoid
valve (3) from fitting (13).
g. When replacing pressure switch, ensure
proper security. h. Remove packing (5) and ring (4) from fitting
(13).
7-58. Test Procedures — Pressure Switch.
Perform operational check of pressure switch (2) i. Remove fitting (7) and packing (6) from
(paragraphs 7-3 and 7-4). solenoid valve (3).
7-59. Installation — Pressure Switch. a. Remove j. Install protective covers on open ports of
covers from ports of pressure switch (2, figure 7-9) solenoid valve (3).
and fitting.
b. Install packing (3) to fitting. NOTE
c. Install pressure switch (2) to fitting.
Cargo hook may have to be removed
d. Install electrical connector (1) to pressure prior to performing the following
switch (2) and secure with Iockwire (C154). procedures (paragraph 14-151).
7-34
TM 55-1520-210-23-2
1. Electrical connector 6. Preformed packing 11. Nut

2. Lift beam 7. Fitting 12. Fitting
3. Solenoid valve 8. Preformed packing 13. Fitting
4. Ring 9. Ring 14. Nut
5. Preformed packing 10. Tube assembly
Figure 7-10. Hydraulic Solenoid Valves — Removal and

7-35
TM 55-1520-210-23-2
15. Electrical connector 20. Washer 25. Preformed packing

16. Fitting 21. Preformed packing 26. Plug
17. Preformed packing 22. Ring 27. Tube assembly
18. Solenoid valve 23. Nut 28. Tubs assembly
19. Bolt 24. Fitting 29. Tube assembly
Figure 7-10. Hydraulic Solenoid Valves — Removal and

7-36
TM 55-1520-210-23-2
k. If helicopter has armament provisions installed, structive inspection procedures for UH-1 helicopter
remove solenoid valve (18) as follows: series.
(1) Position a small container under solenoid b. Inspect internal and external areas of solenoid
valve (18) to catch fluid seepage and disconnect tube valve for corrosion damage.
assemblies (27, 28 and 29). c. Inspect solenoid valve for nicks, scratches, or
(2) Remove bolts (19) and washers (20) attach- thread damage.
ing solenoid valve (18) to lift beam and remove solenoid d. Inspect solenoid valve for security.
valve.
7-64. Repair or Replacement—Solenoid Valves.
(3) Install protective covers to connectors of
tube assemblies (27, 28 and 29). a. Any cracks to solenoid valves (3 or 18, figure
7-10) requires replacement of part.
(4) Break torque on nut (23) and remove fitting
(24) from solenoid valve (18).
WARNING
(5) Remove packing (21) and ring (22) from fit-
ting (24). Use spray paint and chemical film material
(6) Remove fitting (16) from solenoid valve in a well ventilated area. Avoid skin con-
(18). tact and breathing of spray mist.
(7) Remove packing (17) from fitting (16). b. Corrosion damage to internal area or threads of
solenoid valve (3 or 18) requires replacement of part.
(8) Remove plug (26) from bottom part of sole- Minor corrosion, scratches or nicks, to external area of
noid valve (18). solenoid valve is acceptable, provided damage is com-
pletely polished to original finish with 600 grit sandpaper
(9) Remove packing (25) from plug (26). (C234), touched-up with chemical film material (C62),
(10) Install protective covers on all open ports of followed with a coat of primer (C312) or primer (C206).
solenoid valve (18). c. Replace solenoid valve (3 or 18) when malfunc-
tion exists.
Premaintenance Requirements for Solenoid Valves
7-65. Test Procedures — Solenoid Valves. Perform
Conditions Requirements
operational check of solenoid valve (3 or 18, figure 7-10).
Model All (TM 55-1520-210-10).
Part No. or Serial No. All 7-66. Installation—Solenoid Valves.
Special Tools None NOTE
Test Equipment Fluorescent Penetrant If armament provisions are not installed in
Method hydraulic system, proceed to following
Support Equipment None step m.
Minimum Personnel Two Cargo hook will have to be removed prior

Required to performing the following procedures
(paragraph 14-142).
a. Remove protective covers from ports of solenoid
Special Environmental None valve (18, figure 7-10).
Conditions
b. Install packing (25) to plug (26).
c. Install plug (26) in bottom port (number 3) of sole-
noid valve (18).
7-63. Inspection—Solenoid Valves.
d. Install packing (17) to fitting (16).
a. Inspect solenoid valve (3 or 18, figure 7-10) for
e. Install fitting (16) port (number 2) of solenoid
cracks. No cracks allowed. If a crack in the solenoid
valve (18).
valves is suspected, refer to TM 1-1520-256-23, Techni-
cal Manual Aviation Unit Maintenance (AVUM) and Avi- f. Install nut (23), ring (22) and packing (21) to fitting
ation Intermediate Maintenance (AVIM) manual nonde- (24).
Change 14 7-37
TM 55-1520-210-23-2
g. Install and position fitting (24) (with tee down) and 7-68. Description—Hydraulic Servo Cylinder As-
secure nut (23). sembly (Cyclic Control). Two hydraulic cylinder as-
semblies (6 and 33, figure 7-11) are incorporated to re-
h. Remove protective covers from tube assemblies duce effort required for fore and aft and lateral control
(27, 28 and 29). and to reduce feedback or forces from main rotor. The
pilot-operated linkage terminates at the servo valve (fig-
i. Position solenoid valve (18) (with fitting (24) point- ures 7-12 and 7-13) when hydraulic power is ON. There
ing toward left side) to aft side of cargo lift beam and are two types of hydraulic cylinder assemblies that may
install bolts (19) and washers (20). be installed on the aircraft. One is the type which incorpo-
rates a servo cylinder and irreversible valve combination
and the other is a servo cylinder in itself that functions
j. Connect tube assemblies (27, 28 and 29) to sole-
identically to the servo/irreversible valve unit. These two
noid valve. (Refer to table 1-5 for proper torque on fluid
assemblies may be used either in pairs or mixed. Due to
connectors.)
the complexity of the newer servo cylinder, PN
205-076-056-107, few repairs are authorized below de-
k. Install electrical connector (15) to top of solenoid pot level. For this reason procedures for inspecting both
valve (18) and secure electrical connector with lockwire types of servo cylinders differ and are identified where
(C155). required. Installation instructions differ between the two
assemblies due to the geometry of the newer single valve
l. If solenoid valve (3) was not removed, bleed and assembly. Separate instructions are given for installa-
perform operational test of hydraulic system (paragraphs tion.
7-6 and 7-4).
7-68.1 Removal and Replacement—Hydraulic Servo
m. Install solenoid valve (3) as follows: Cylinder Assembly. Hydraulic servo cylinder assem-
blies (cyclic and collective) may be replaced without a
(1) Install packing (6) on fitting (7) and install rigging check, using the following procedures, providing
fitting (with pressure switch) to port (number 1) of sole- there are no other discrepancies in the flight control sys-
noid valve (3). tem which require a rigging check.
a. Remove the hydraulic servo cylinder assembly
(2) Install nut (14), ring (4) and packing (5) to from the helicopter. (Refer to paragraph 7-72 or 7-84.)
fitting (13). Position fitting (with pressure switch up) and
install fitting to port (number 2) of solenoid valve (3) and b. Measure and record dimension “A”, (refer to fig-
secure nut (14). ure 7-12) of removed cylinder assembly.
c. Remove tube assembly (5, figure 7-14), from ser-
(3) Install nut (11) ring (9) and packing (8) to vo cylinder assembly, reference paragraph 7-72a (5) thru
fitting (12).
(8).
(4) Install solenoid valve to fitting (12) and se- d. Install tube (5) on new servo cylinder assembly,
cure nut (11) against bottom of solenoid valve (3). refer to paragraph 7-76d.
e. Adjust hydraulic servo cylinder assembly to pre-
(5) Connect tube assembly (10) to fitting (7). viously recorded dimension “A” (see step b above).
(6) Install hydraulic unit to forward side of lift f. Insure that clevis (1) is properly aligned. Do not
beam (paragraph 7-45, steps d. through i). loosen nut (3).
g. Torque nut (6) (refer to figure 7-12).
7-67. HYDRAULIC SERVO CYLINDER ASSEMBLY h. Install boot (33) (refer to paragraph 7-76f and
(CYCLIC CONTROL). 7-89a).
NOTE i. Install hydraulic servo cylinder assembly (refer to

paragraph 7-78 or 7-91).
An improved servo cylinder (PN
205-076-056-107) has been developed to j. If during test flight a discrepancy is experienced,
replace the current servo cylinder and ir- perform a rigging check.
reversible valve.
7-69. Adjustment—Hydraulic Servo Cylinder As-
sembly (Cyclic Control).
The servos are functionally interchange-
able and may be used in mixed installa- a. Check clevis adjustment of 2.53 inches as shown
tions with the current servos. in figure 7-12.
7-38 Change 14
TM 55-1520-210-23-2
b. Check overall dimension A adjustment of hydrau- NOTE

lic cylinder assembly as shown in figure 7-12. Presence of KSP9046 shield and plastic
plug in the grease zerk port is the only
c. After final adjustment of length has been accom- indication, other than physical teardown,
plished, seal thread area, witness hole and area where of the presence of KSP6099 bearing.
tube body meets upper end fitting with sealant (C244) or
equivalent. See NOTE B, figure 7-12. Insure that no This bearing does not require the spring
weep holes exist after applying sealant. Check slot for scale torque check. The required friction
position sealing. has been built into this bearing during
manufacture and it requires no additional
Premaintenance Requirements for Hydraulic Servo adjustment. The bearing is designed to
Cylinder (cyclic control) Assembly gimbal freely, thus does not have the char-
acteristic tightness of the uniball bearing
which requires the spring scale torque
Conditions Requirements test. The rotational freedom of the KSP
Model All 6099-1 bearing should not be interpreted
as wear and the axial vertical movement
should not be considered as excessive
Special Tools None unless feedback is felt in the controls. The
bearing requires no lubrication and plugs
should be installed in the grease fitting
Method
(12) holes. Installation of the KSP 6099-1
Support Equipment None bearing requires that the bearing housing
Minimum Personnel Two retaining nut be torqued 1100 to 1180 inch-
Required pounds to secure it to the servo cylinder.
This torque does not affect the friction on
Consumable Materials None the housing. When the KSP 6099-1 bear-
References TM 1-1520-256-23 ing is installed, the KSP 9046-1 shield
must also be installed. Do not use (rubber)
boot (9) when installing shield on P/N
205-076-099 cylinder assembly.
7-70. Inspection — Hydraulic Servo Cylinder (Cyclic
Control) Assembly (Installed). Perform the following g. Remove hoses (19 and 20) from fittings (18) and
inspection functions with hydraulic cylinder assembly place suitable container under irreversible valve (22).
installed. Bottom (retract) hydraulic cylinder (6 and 33) and attach
a pound reading scale to clevis (on top of hydraulic cylin-
a. Inspect all parts of hydraulic cylinder assemblies ders). Check for smooth operation during extension
(6 and 33, figure 7-11) for damage, corrosion or pitting, (paragraph 7-73); a friction drag of 25 pounds or less is
and distorted threads (paragraph 7-73 and table 7-5). acceptable. If the friction drag is greater than 25 pounds,
the hydraulic cylinder should be allowed to warm up to
b. Inspect housing (11, figure 7-14) for looseness, 65°F - 90°F and be rechecked. If friction drag is greater
wear and proper installation. There must be no indication than 25 pounds after warm up, replace hydraulic servo
of binding. cylinder assembly.
h. Extend hydraulic cylinder in the full up position.
c. Inspect hydraulic cylinder assemblies (6 and 33,
Attach a pound reading spring scale to clevis (on top of
figure 7-11) for security.
hydraulic cylinders). Check the force required to move
d. Inspect hydraulic cylinder assemblies (6 and 33) the cylinder through full fore/aft and lateral travel as
for evidence of leakage. Any evidence of leakage to cyl- shown in view B, figure 7-14. If force is not within 1 TO 2.5
inders requires replacement of seals. pounds, retorque nut (10, figure 7-14) as follows:
NOTE
e. Inspect protective boots (9 and 33, figure 7-14) Spring scale drag check per view B will not
for cuts, holes, tears and deterioration. Replace boot if be required for 205-076-099 hydraulic cyl-
any of the above are evident. If boot (9 or 33) is dirty or inder assembly. Refer to NOTE preceding
oil soaked, remove boot (paragraph 7-72) and wash in- step g above.
side and outside of boot with a mild detergent and warm
water. Check bearing for friction. (1) Lubricate fitting (12). Using spanner wrench
(T2), torque nut (10) 400 TO 450 inch-pounds. Rotate
f. Disconnect hydraulic cylinders (6 or 33, figure cylinder assembly through full travel (see View B) several
7-11) from the control tubes (13 or 27) and swashplate times to ensure proper seating of bearing surfaces to
(paragraph 7-71). bushing set (see View A).
Change 14 7-39
TM 55-1520-210-23-2
IRREVERSIBLE VALVE USED ON SERVO CYLINDER

ASSY P/N 206-076-099-1 AND -3. NOT APPLICABLE
TO P/N 205-076-056-101 AND -103.
Figure 7-11. Hydraulic Cylinder Assemblies Fore and Aft and Lateral Cyclic Controls-
Removal and Installation (Sheet 1 of 4)
7-40 Change 4
TM 55-1520-210-23-2
Figure 7-11. Hydraulic Cylinder Assembles Fore and Aft and Lateral Cyclic Controls-
Change 4 7-40.1/(7.40.2 blank)

TM 55-1520-210-23-2
Figure 7-11. Hydraulic Cylinder Assembles Fore and Aft and Lateral Cyclic Controls-
Removal and installation (Sheet 3 of 4)
Change 4 7-41
TM 55-1520-210-23-2
SERVO CYLINDER ASSEMBLY P/N 205-076-099-1 AND -3
1. Bolt. 15. Cotter pin 29. Washer

2. Nut 16. Bolt 30. Nut
3. Washer 17. Preformed packing 31. Washer
4. Bolt 18. Fittings 32. Nut
5. Cotter pin 19. Hose assembly 33. Hydraulic cylinder
6. Hydraulic cylinder 20. Hose assembly 34. Nut
7. Nut 21. Preformed packing 35. Washer
8. Washer 22. Irreversible valve 36. Cotter pin
9. Nut 23. Preformed packing 37. Fittings
10. Washer 24. Cotter pin 38. Hose Clamp
11. Washer 25. Nut 39. Machine Screw
12. Bolt 26. Washer 40. Nut
13. Control tube 27. Control tube 41. Washer
14. Nut 28. Bolt
Figure 7-11. Hydraulic Cylinder Assemblies Fore and Aft and Lateral Cyclic
Controls-Removal and Installation (Sheet 4 of 4)
7-42 Change 7
TM 55-1520-210-23-2
NOTE A
Dimension A is obtained with valve in

neutral position.
NOTE B
After final adjustment, use sealing

compound (C244) or equivalent. to
completely. seal the tube assembly
threaded areas, slots,and witness holes
make sure no voids exist after drying.
Figure 7-12. Hydraulic Servo Cylinder Adjustment Dimensions
Change 5 7-42.1/(7-42.2 blank)

TM 55-1520-210-23-2
collective lever or swashplate assembly. When vertical

movement is detected at the uni-ball, retorque nut (10),
perform spring drag check and re-lube.
NOTE
It is permissible for the cylinder barrel to
turn within the housing assembly, pro-
vided there is no vertical movement of the
barrel. When vertical movement is de-
tected at the uniball, and the uniball is oth-
er than the KSP6099, the servo must be
removed from aircraft and returned to
AVIM for retorque and re-lube. If after re-
torquing per paragraph 7-70h(5) vertical
movement is detected, replace Hydraulic
Servo Cylinder Assembly.
(6) Install hoses (19 and 20, figure 7-11) to fit-
tings (22). Remove container.
i. Inspect linkage part for wear, elongated bolt
holes, cracks, nicks, and surface damage.
j. Inspect hydraulic cylinder servo valve for service-
ability.
(1) Inspect servo valve assembly (paragraph
7-73). Inspect servo valve for leakage.
(2) Inspect servo valve for nicks, scratches or
1. Screw 3. Bolt thread damage (paragraph 7-73).
2. Screw 4. Bolt (3) Inspect servo valve for cracks. No cracks
allowed.
Figure 7-13. Hydraulic Cylinder
(4) Inspect for deformity.
Servo Valve (Wire Drive Type)
(5) Visually inspect internal area of ports and
external surfaces of servo valve for corrosion damage.
(2) Loosen nut (10) and retorque to obtain 1 TO (6) Inspect servo valve and attaching compo-
2.5 pounds drag (see view B), by spring scale, on bear- nents for security.
ing. On part number 205-076-099 cylinder assembly,
torque nut (10) 1100 TO 1180 inch-pounds. (7) Inspect chamfered end of piston rod for
sharp edges.
NOTE
Locknut assembly used on cylinder as- (8) Check linkage set for sticking or binding.
sembly, P/N 205-076-099, requires one (9) Inspect housing for cracks. No cracks al-
positive safety only. lowed. If a crack in the housing is suspected, refer to TM
1-1520-256-23, Technical Manual Aviation Unit Mainte-
(3) After proper drag on bearing has been ac-
nance (AVUM) and Aviation Intermediate Maintenance
complished, secure nut (10) to housing (11) with lockwire
(AVIM) manual nondestructive inspection procedures for
(C155) in two places, one positive safety to prevent loos-
ening and one negative safety to prevent further tighten-
ing. (See detail D, figure 7-14). (10) Inspect bolts through arm lever for wear and
distortion, bolt to be fingertight only.
(4) Apply slippage marks (C141) from nut (10)
to housing (11). k. Check cotter pins for security.
(5) Connect control tube at bottom of the cylin- l. Inspect bearing housing and flange for elongation
der assembly and connect the cylinder assembly to the of holes.
Change 14 7-43
TM 55-1520-210-23-2
Figure 7-14. Hydraulic Cylinder Assembly - Disassembly and Assembly (Sheet 1 of 3)
7-44 Change 4
TM 55-1520-210-23-2
13. Retaining ring 17. Packing strip 21. Preformed packing

14. Retainer 18. Cylinder cap 22. Key
15. Wiper ring 19. Preformed packing 23. Nut
16. Preformed packing 20. Cap seal
Figure 7-14. Hydraulic Cylinder Assembly — Disassembly and Assembly (Sheet 2 of 3)
7-45
TM 55-1520-210-23-2
Figure 7-14. Hydraulic Cylinder Assembly - Disassembly and Assembly (Sheet 3 of 3)
7-46 Change 4
TM 55-1520-210-23-2
Figure 7-14.1 Hydraulic Cylinder Assembly P/N 205-076-099

Disassembly and Assembly (Sheet 1 of 2)
7-47
TM 55-1520-210-23-2
1. Shield Assembly 15. Retainer
2. Nut 16. Washer
3. Nylon Stop 17. Packing
4. Bushing Set (not shown) 18. Packing
5. Bearing (not shown) 19. Seal
6. Bearing KSP 6099-1 20. Cap
7. Fitting 21. Key
8. Plug 22. Nut
9. Housing 23. Seal
10. Washer 24. Seal
11. Nut 25. Rod Assy
12. Ring 26. Plug
13. Retainer 27. Plate
14. Scraper 28. Cylinder
29. Head Assy
7-14.1 Hydraulic Cylinder Assembly P/N 205-076-099

Disassembly and Assembly (Sheet 2 of 2)
7-48
TM 55-1520-210-23-2
m. Inspect hydraulic cylinder assembly for leaks at tion two (2, figure 7-13) in the servo lever need to be
all connections and fittings. With power on, seepage replaced to bring play below the 0.015 inch limit.
around piston rod seals is permissible but not to ex-
(c) If measured play is within limits, reconnect
ceed one drop for every 25 cycles. A cycle is defined
spring (12.1, figure 7-14) on servo cylinder.
as valve position neutral, to full up, to full down, to
neutral (figure 7-12 and 7-13). q. Check bearing retainer nut (view A, figure 7-14)
for looseness. If looseness is felt, torque bearing re-
n. Inspect upper cylinder tube (5, figure 7-14), at tainer nut in accordance with figure 7-12.
time of replacement of cyclic control hydraulic cylinder
(paragraph 7-76). 7-71. Removal-Hydraulic Servo Cylinder
Assembly (Cyclic Control).
o. Inspect moisture seal (sealant) on clevis on top
of control tube (5) for looseness or cracking (Note B, NOTE
figure 7-12). If the adhesive bond is broken, remove
tub assembly and inspect tube for corrosion and thread Ensure protective cover are installed on
damage. all open ports to prevent entry of foreign
material.
p. Inspect for play between Hydraulic Servo Lever
Assembly (Sloppy Link) and Drive Rod (Wire Drive) Premaintenance requirements for removal of
per steps below. hydraulic cylinder assembly (cyclic control)
NOTE Condition Requirements

Model All
This procedure is not applicable to servo cyl-
Part No. or Serial No. 204-076-026,
inder PN 205-076-056-107.
205-076-038,
205-076-099
(1) Disconnect control tubes (.13 and 27, figure 7-
11 and 11, figure 7-23) from the lever assembly of all Special Tools None
three (fore/aft, lateral and collective) servo cylinders. Test Equipment None
Remove spring (12. 1, figure 7-14) on collective servo. Support Equipment Maintenance
Work Stands
NOTE Minimum Personnel Two
Required
Check for play must be done on hydraulic le- Consumable Materials None
vers of all three servo cylinders. Special Environmental Dust Free/Well
Conditions Ventilated Area.
(2) Clamp a dial indicator to the flat surface of
the irreversible valve. Place stylus of the reaction arm . a. Hydraulic Servo Cylinder (6, figure 7-11.)Re-
at the bottom of lever at position two (2, figure 7-13), move hydraulic cylinder assembly in accordance with
directly under the attaching point of the drive rod. Hold the following procedures:
a pencil eraser against the drive rod to help in detect-
ing movement. Move lever up and down and measure (1) Open transmission cowling (2, figure 2-18) and
for play at the drive rod to servo lever attach point. left side engine cowls (6 and 7).
Reinstall spring (12.1, figure 7-14) on collective servo.
(2) Remove soundproofing blankets and left side
NOTE access doors (3 and 24) from pylon island in cabin
area.
Drive rod must not move up and down while
lever is being moved during measurement for (3) Remove soundproofing blanket and access
play. door (81 ) from pylon island in cabin area.
(3) Limitations and Corrective Action. (4) Remove cotter pin (15, figure 7-11 ), nut (1 4),
washers (11), and bolt (12) from control tube (13) and
(a) Measured play must not exceed 0.015 inch. disconnect control tube from bottom of servo valve.
(b) if measured play exceeds 0.015 inch, ei-

ther or both the shoulder screw and bearing at posi- Change 4 7-49
TM 55-1520-210-23-2 TM 55-1520-210-23-2
NOTE
and 20) to catch fluid seepage and disconnect hose
When disconnecting hydraulic hose assemblies assemblies from fittings of
(19 or 20), a small amount of fluid seepage Install covers to connectors of hose assemblies and
may occur and will require placing a container fittings.
under fittings of irreversible valve. Disconnec-
tion of hose assemblies not required if irre- (6) Remove cotter pin (5), nut (2), washer (3) and
versible valve is not being removed. bolt (4) from clevis of hydraulic cylinder assembly (6).
(5) Place a container under hose assemblies (19 (7) Remove nuts (9), washers (10), nut (7) and
and 20) to catch fluid seepage and disconnect hose washer (8) attaching hydraulic cylinder (6) to support
assemblies from fittings of irreversible valve. Install and remove hydraulic cylinder (6).
covers to connectors of hose assemblies and fittings.
b. Hydraulic Servo Cylinder (33, figure 7-11). Re-
(6) Remove irreversible valve from hydraulic servo move hydraulic servo cylinder assembly in accordance
valve (paragraph 7-94). with the following procedures:
(7) Install covers on open ports of irreversible (1) Open transmission fairing (2, figure 2-18) and
valve and hydraulic servo valve. open right side engine cowls (6 and 7).
(8) Remove cotter pin (5), nut (2), washer (3) and (2) Remove soundproofing blankets and right side
bolt (4) from clevis of hydraulic cylinder assembly (6). access doors (3 and 24) from pylon island in cabin
area.
(9) Remove nuts (9), washers (10), nut (7) and .
washer (8) attaching hydraulic cylinder (6) to support (3) Remove soundproofing blanket and access
and remove hydraulic cylinder (6). door (81 ) from pylon island in cabin area.
a.1. Hydraulic Servo Cylinder P/N 205-076-056-103 (4) Remove cotter pin (24, figure 7-11), nut (25),
(6, figure 7-11) washers (26) and bolt (28) from control tube and
disconnect control tube from bottom of servo valve.
Remove hydraulic cylinder assembly in accordance
with the following procedures:
(1) Open transmission cowling (2, figure 2-18) and

When disconnecting hydraulic hose assemblies
left side engine cowls (6 and 7).
(19 or 20), a small amount of fluid seepage
may occur and will require placing a small
(2) Remove soundproofing blankets and left side
container under fittings of irreversible valve.
access doors (3 and 24) from pylon island in cabin
area. (5). Place container under hose assemblies (19
and 20) to catch fluid seepage and disconnect hose
(3) Remove soundproofing blanket and access
assemblies from irreversible valve. Install protective
door (81 ) from pylon island in cabin area.
dust covers to connectors of hose assemblies and
fittings.
(4) Remove cotter pin (15, figure 7-11), nut (14),
washers (11), and bolt (12) from control tube (13) and
(6) Remove irreversible valve (paragraph 7-94).
(7) Remove cotter pin (36), nut (34), washer (35)
NOTE
and bolt (1) from clevis of hydraulic cylinder assembly
(33).
(8) Remove three nuts (32), three washers (31),
may occur and will require placing a container
nut (30) and washer (29) attaching hydraulic cylinder
under fittings of servo valve.
(33) to support and remove hydraulic cylinder (33).
(5) Place a container under hose assemblies (19
7-50 Change 4
TM 55-1520-210-23-2
b.1 Hydraulic Servo Cylinder PN 205-076-056-101 low for adequate clearance between any struc-
(33, figure 7-11). ture and wire bundle to prevent chafing. The
45 degree fittings provided for 205-076-056-
Remove hydraulic servo cylinder assembly in ac- 107 hydraulic connections should be discarded
cordance with the following procedures: and not used in this application.
(1) Open transmission fairing (2, figure 2-18) and

open right side engine cowls (6 and 7). 7-72. Disassembly—Hydraulic servo Cylinder
Assembly (Cyclic Control) (AVIM). a. Remove com-
(2) Remove soundproofing blankets and right side ponents from hydraulic cylinder (figure 7-14) as fol-
access doors (3 and 24) from pylon island in cabin lows:
area.
Premaintenance requirements for disassembly of
(3) Remove soundproofing blanket and access hydraulic servo cylinder assembly
door (81) from pylon island in cabin area.
Condition Requirements
(4) Remove cotter pin (24, figure 7-11), nut (25), Model All
washers (26) and bolt (28) from control tube (27) and
205-076-038,
204-076-064 and
NOTE 205-076-099
Special Tools (T25 or T62.1)
Test Equipment None
may occur and will require placing a small Support Equipment None
container under fittings of servo valve. Consumable Materiels None
Special Environmental Dust Free/Well
(5) Place a container under hose assemblies (19 Conditions Ventilated Area
and 20) to catch fluid seepage and disconnect assem-
blies from servo valve. Install protective dust covers to (1) Place hydraulic servo cylinder assembly on a
connectors of hose assemblies and fittings. clean workbench in dust free area.
(6) Remove cotter pin (36), nut (34), washer (35) (2) Remove Iockwire from nuts (3 and 10, figure
and bolt (1) from clevis of hydraulic cylinder assembly 7-14).
(33).
(3) Using a plastic scraper, so as not to damage
(7) Remove three nuts (32), three washers (31), the threads on clevis (1), clean sealant from top of nut
nut (30) and washer (29) attaching hydraulic cylinder (3) and threads of clevis (1).
(33) to support and remove hydraulic cylinder (33).
(4) Break torque on nut (3) and remove clevis
NOTE (1), lock (2) and nut (3) from tube assembly (5).
Servo cylinder PN 205-076-056-101 and 103. (5) Remove nut (25), washers (26) and screw
Due to increased physical size of servo, ma- (27) from upper clamp (24). Remove upper clamp (24)
neuvering the servo into position may seem from boot assembly (33).
harder than the old servo and may require
extending, contracting, and turning the servo (6) Remove nut (28), two washers (29) and screw
in relation to mount. Do not attempt to pry (30) from lower clamp (31). Remove lower clamp (31)
using a screwdriver or any hard object to posi- from flange (32).
tion servo. In some aircraft interference may
exist between the cylinder shield (P/N (7) Remove boot assembly (33) and swivel joint
KSP9064-5) and a wire bundle directly below flange (32) from tube assembly (5).
the angle structure that runs along right hand
beam assembly and the top of opening for (8) Remove nut (6), lock (7), and tube assembly
access cover. Wire bundle may be relocated (5) from piston rod (8).
to top side of angle by re-using and relocating
existing clamps. Care should be taken to al-
Change 4 7-50.1/(7-50.2 blank)
TM 55-1520-210-23-2
Figure 7-15. Hydraulic Cylinder Assembly P/N 100585-1 –

Disassembly and Assembly
7-51
TM 55-1520-210-23-2
1. Retaining ring 5. Glide ring 9. Locknut

2. Scraper retainer 6. Cap 10. Cap seal
3. Scraper 7. Preformed packing 11. Ring seal
4. Preformed packing 8. Tab washer
Figure 7-16. Hydraulic Cylinder Assembly P/N 100585-7 —

Disassembly and Assembly
7-52
TM 55-1520-210-23-2
NOTE (e) Remove packing (5) and two backups (7)

from cap (8).
Disassembly of servo cylinder, PN 205-076-
056, beyond this point is not authorized below (f) Remove packing (9) from cap (8).
depot level maintenance.
(g) Remove cap seal (13) and ring seal (12)
NOTE from piston rod.
Exercise piston rod to discharge residual fluid. (h) Remove tab washer (10) and locknut (11)
from cylinder assembly.
(9) Mount cylinder assembly in torque fixture (T25
or T62.1) (figure 7-17). (14) Hydraulic servo cylinder assembly P/N
100585-7. Remove components and disassemble cap
(6, figure 7-16) as follows:
NOTE
(a) Break torque on locknut (9), back locknut
Perform the following procedure only if tab away from cap (6).
Iockwasher (10, figure 7-15) or (8, figure 7-16) is in-
stalled. If nut (23, figure 7-14) is installed, proceed to (b) Remove cap (6) from cylinder assembly.
following step (12).
(c) Remove retaining ring (1), scraper retainer
(10) Carefully straighten tangs of tab washer (10, (2), scraper (3), packing (4) and glide ring (5) from
figure 7-15) or (8, figure 7-16). cap (6).
(11) Remove Iockwire from nut (23, figure 7-14) (d) Remove packing (7) from cap (6).
and break torque on nut.
(e) Remove cap seal (10) and ring seal (11)
(12) Remove cylinder cap from upper end of cyl- from piston rod.
inder assembly in accordance with applicable cylinder
assembly. Refer to steps (13), (14), and (15) as appli- (f) Remove tab washer (8) and locknut (9) from
cable. cylinder assembly.
(13) Hydraulic servo cylinder assembly P/N (15) Hydraulic servo cylinder assembly P/N
100585-1. Remove components and disassemble cap 105875. Remove component and disassemble cylin-
(8, figure 7-15) as follows: der cap (18, figure 7-14) as follows:
(a) Break torque on locknut (11), back locknut (a) Remove Iockwire from key (22) and nut (23),
away from cap (8). break torque on nut (23), back nut away from cylinder
cap (18).
(b) Unscrew cap (8) and remove cap from cyl-
inder assembly.
(c) Remove retainer ring (1), retainer (2) and

scraper (3) from cap (8).
(d) Remove felt strip (4) from cap (8).
Change 4 7-53
TM 55-1520-210-23-2
Flgure 7-17. Tool Application Hydraulic Cylinder Assembly Supported

in T100619-2 or T41000310-1 or T204-076-162-3 Torque Fixture
7-54
TM 55-1520-210-23-2
(b) Remove cylinder cap (18) from cylinder 7-73. Inspection—Hydraulic Cylinder Assembly
assembly. (Cyclic Control). (Table 7-5 and Figures 7-18 through
7-21.)
(c) Remove retaining ring (13), retainer
(14), wiper ring (15), packings (16 and 17) from cylinder
a. Tube assembly (5, figure 7-14). Inspect tube as-
cap (18).
sembly in accordance with the following inspection re-
(d) Remove packing (19) from cylinder cap quirements and limits outlined in figure 7-18 and table
(18). 7-5.
(e) Remove cap seal (20), packing (21),
(1) Inspect tube assembly (5) for thread dam-
key (22) and nut (23) from cylinder assembly.
age, abrasions and dents (figure 7-18).
(16) Hydraulic servo cylinder assembly. PN
20576-099. Remove KSP 6099-1 bearing (figure 7-14.1) (2) Inspect tube assembly (5) for cracks. No
as follows: cracks allowed. If a crack in the Hydraulic Servo Cylinder
Tube Assembly is suspected, refer to TM
a. Remove lockwire, loosen nut (11) and remove ser-
vohead (29). Set servo assembly aside.
b. Mount cylinder assembly in torque fixture (T-62.1, (AVIM) manual nondestructive inspection procedures for
figure 7-17). UH-1 helicopter series.
c. Unbend tabs of washer (16) and remove retainer
(15). Discard washer (16). (3) Check security of rivets and bonded seams.
NOTE (4) Inspect the internal threaded area of upper

Perform step d only if retainer (15) is to be and lower tube assembly (5) for corrosion damage.
overhauled.
b. Hydraulic Cylinder Assembly (AVIM).
d. Remove ring (12), retainer (13), and scraper (14)
from the retainer (15). (1) Inspect hydraulic cylinder assembly for
e. Remove assembled parts consisting of shield as- cracks. No cracks allowed. If a crack in the Hydraulic
sembly (1), nut (2), bearing (6), and housing (9) from Servo Cylinder Assembly is suspected, refer to TM
servo cylinder (28). 1-1520-256-23, Technical Manual Aviation Unit Mainte-
f. Mount housing (9) in retainer (T-62.2). Cut lockwire (AVIM) manual nondestructive inspection procedures for
on nut (2) and remove nut (2) using spanner wrench UH-1 helicopter series.
(T-2).
g. Remove bearing (6) from housing (9). (2) Inspect upper and lower end of hydraulic
cylinder assembly for evidence of leakage.
Premaintenance Requirements for Hydraulic Servo (3) Inspect external surfaces of hydraulic cylin-
Cylinder (cyclic control) Assembly der assembly and piston rod (8, figure 7-14) for nicks or
scratches (figure 7-19 and table 7-5).
(4) Inspect external surfaces of hydraulic cylin-
Model All der assembly and piston rod (8) for corrosion (figure 7-21
Part No. or Serial No. All and table 7-5). Maximum diameter of damage, after re-
pair, 0.0996 inch. Thread damage limits to piston rod are
Special Tools None as follows: (a) Depth—one-third thread. (b) Length—
Test Equipment Fluorescent Penetrant one-quarter inch circumlative each segment.
Method
Magnetic Particle Method c. Clevis.
Support Equipment None (1) Inspect clevis (1, figure 7-14) for corrosion.
Minimum Personnel One
Required (2) Inspect clevis (1) for cracks. No cracks al-
lowed.
Special Environmental None (3) Inspect clevis (1) in accordance with limits
Conditions outlined in figure 7-20 and table 7-5.
References TM 1-1520-256-23 (4) Inspect clevis (1) for security.
Change 14 7-55
TM 55-1520-210-23-2
d. Bearing Housing (AVIM). f. Boots.

(1) Inspect bearing housing (11, figure 7-14) for (1) Inspect boot assembly (33, figure 7-14) for
nicks, scratches, corrosion and sharp dents in accor- deterioration and tears.
dance with limits outlined in figure 7-21. (2) Inspect swivel joint flange (32) for tears.
(1.1) Inspect exterior surfaces only of bearing (3) Inspect boot assembly (33) for security.
housing (11, figure 7-14) installed on servo cylinder
205-076-056. g. Attaching Hardware.
(1) Inspect hydraulic cylinder assembly and at-
e. Nut Assembly (AVIM).
taching components for missing or loose hardware.
NOTE
(2) Inspect all attaching hardware to hydraulic
For nuts installed on servo cylinder P/N cylinder assembly for cracks or corrosion. No cracks al-
205-076-056 only external surfaces can be lowed. If a crack in any of the Hydraulic Cylinder Assem-
inspected. bly Components is suspected, refer to TM
(1) Inspect nut assembly (10, figure 7-14) for nance (AVUM) and Aviation Intermediate Maintenance
corrosion and thread damage. (AVIM) manual nondestructive inspection procedures for
(2) Inspect nut assembly (10) for cracks. No UH–1 helicopter series.
cracks allowed. (3) Inspect the Hydraulic Servo Cylinder caps
(3) Inspect nut assembly (10) for security. for cracks. No cracks allowed. If a crack in the cylinder
cap is suspected, refer to TM 1-1520-256-23, Technical
(4) Inspect nuts (3) and (6) for maximum thread Manual Aviation Unit Maintenance (AVUM) and Aviation
damage as follows: (a) Depth: One-third of thread, (b) Intermediate Maintenance (AVIM) manual nondestruc-
Length: 1.0 inch cumulative. tive inspection procedures for UH-1 helicopter series.
7-56 Change 14
Table 7-5. Inspection Requirements for Hydraulic Cylinder Assembly (AVIM)
7-57 TM 55-1520-210-23-2
Table 7-5. Inspection Requirments for Hydraulic Cylinder Assembly (AVIM) (Cont)
7-58 TM 55-1520-210-23-2
TM 55-1520-210-230-2
Table 7-5. Inspection Requirements for Hydraulic Cylinder Assembly (AVIM) (Cont)
FIGURE 7- METHOD
REFERENCE PARAGRAPH
AND OF INSPECTION
TYPICAL DEFECTS
INDEX *MAGNETIC
NO. NOMENCLATURE VISUAL PARTICLE **PENETRANT INSPECTION REPAIR REMARKS
15 8 Cap X X Cracks, corrosion, nick 7-73 7-75

or scratches.
15 10 Tab Washer X Cracks, corrosion, or bent 7-73 Replace if

damaged.
15 11 Lock Nut X X Cracks, thread damage 7-73 Replace if

and corrosion. damaged.
16 1 Retaining Ring X Cracks, corrosion, or bent. 7-73 Replace if

damaged.
16 2 Scraper Retainer X Cracks, corrosion, or wear. 7-73 Replace if worn

or damaged.
16 3 Scraper X Cracks or wear. 7-73 Replace if worn

or damaged.
16 5 Glide Ring X Cracks or wear. 7-73 Replace if worn

or damaged.
16 6 Cap X X Cracks, corrosion, nick, 7-73 Replace if

and scratches. damaged.
16 8 Tab Washer X Cracks, corrosion or bent. 7-73 Replace if

damaged.
16 9 Lock Nut X Cracks, corrosion or thread 7-73 Replace if

damage. damaged.
* Magnetic particle per MIL-I-1949 and TM 1-1500-204-23 series.
** Fluorescent penetrant per MIL-I-1949 and TM 1-1520-256-23.
Change 14 7-59
TM 55-1520-210-23-2
Table 7-5. Inspection Requirements for P/N 205-076-056 Cylinder Hydraulic Assembly (AVIM)
FIGURE 7- METHOD REFERENCE PARAGRAPH

AND OF INSPECTION
INDEX TYPICAL DEFECTS
NO NOMENCLATURE ’MAGNETIC REMARKS
VISUAL PARTICLE **PENETRANT INSPECTION REPAIR
14 1 Clevis X X Cracks, nicks, scratches 7-73 7-75 See figure

corrosion, thread damage 7-73
and security
14 2 Lock X X Cracks, corrosion, or. 7-73 7-75
14 3 Nut X X Cracks, corrosion and 7-73 7-75
14 4 Decal X Torn or cracked 7-73 Replace If See figure

damaged. 7-14
14 5 Tube Assembly X X Cracks, corrosion, bent 7-73 and 7-75 See figure
thread damage, loose or figure 7-18 7-18
missing rivets and deformed.
14 6 Nut X X Cracks, corrosion and 7-73 Replace If

thread damage. damaged.
14 7 Lock X Cracks, corrosion or 7-73 Replace If

bent damaged.
14 * Piston Rod X Cracks, corrosion, bent 7-73 See figure

scratches and thread damage 7-19
14 9 Boot X Cracks, tears and 7-73 7-75
14 10 Nut X Cracks, corrosion scratches 7-73 7-75

and thread damage
14 11 Housing X Cracks, corrosion, scratches 7-73 7-75 See figure

and thread damage Replace If 7-21
14 12 Fitting X Fracture/cracks Replace If

damaged.
7-60 Change 10
Table 7-5. Inspection Requirements for PN 205-076-056 Cylinder Hydraulic Cylinder Assembly (AVIM) (cent)
FIGURE 7- METHOD
AND OF INSPECTION REFERENCE PARAGRAPH
INDEX *MAGNETIC TYPICAL DEFECTS
No. NOMENCLATURE VISUAL PARTICLE ✩✩
PENETRANT INSPECTION REPAIR REMARKS
14 24 Clamp, Upper x Cracks, corrosion, scratches 7-73 Replace if

and bent. damaged.
14 31 Clamp, Lower x Cracks, corrosion, scratches 7-73 Replace if
and bent. damaged.
14 32 Swivel Joint x Cracked. 7-73 Replace if
Flange damaged
14 33 Boot Assembly x Tom or deteriorated 7-73 Replace if
damaged.
Change 4 7-60.1
TM 55-1520-210-23-2
TM 55-1520-210-23-2
(3) Inspect all attaching hardware to hydraulic cyl- (1) No cracks allowed.
inder assembly for security.
(2) Depth of repair for nicks, corrosion, and
h. Inspect holes in pilot input lever of servo valve scratches is 0.010 inch maximum. Number of repairs,
and clevis (1, figure 7-14) for elongation. not critical.
i. Inspect Part Number KSP 9046-1 bearing shield (3) Dents: 0.040 inch, Number of repairs, not
(on P/N 205-076-099 and PN 205-076-056 hydraulic critical.
cylinders only) in accordance with the following limits:
DAMAGE AREA AND REPAIR ZONES
TYPE OF DAMAGE I I
NICKS, SCRATCHES 0.005 INCH 0.006 INCH 0.010 lNCH

AND DENTS
CORROSION 0.0025 INCH 0.005 INCH 0.005 INCH
MAXIMUM AREA PER 0.25 SQ. IN. 0.10 SQ. IN. NOT CRITICAL
FULL DEPTH REPAIR
MAXIMUM NUMBER TWO PER NOT CRITICAL

OF REPAIRS SEGMENT
EDGE CHAMFER 0.020 INCH 0.020 INCH NOT

APPLICABLE
CRACKS — NONE ALLOWED
THREAD DAMAGE:
DEPTH: ONE-THIRD OF THREAD
LENGTH: ONE-QUARTER INCH
NUMBER: TWO PER SEGMENT
NOTES:
(1) The width of repair at any section shall not exceed one-third of the tube circumference.
(2) Material: 2024-T4 Al Aly, 1-1/2 OD X 0.083 wall thickness, per WW-T-785,Type 1,
Temp-T3.
Figure 7-18. Tube Assembly Damage Limits — Hydraulic CyIinder Assembly, P/N 204-076-267
7-60.2 Change 4
. . . ..-. .
TM 55-1520-210-23-2
NICKS AND SCRATCHES — DEPTH: 0.025 INCH

DENTS — DEPTH: 0.003 INCH
THREAD DAMAGE — DEPTH: 1/3 THREAD

LENGTH: 1/4 INCH CUMULATIVE EACH SEGMENT
BLEND AND POLISH OUT ALL IMPERFECTIONS:

MINIMUM DIAMETER AFTER REPAIR IS 0.996 INCH.
AREA A HOLE REPAIR: DEPTH: 0.0005 INCH
AREA: 1/4 CIRCLE (2 HOLES)
Blend and polish all nicks and scratches-depth 0.040 inch.
Figure 7-19. Hydraulic Cylinder Assembly (P/N 205-076-056) — Damage Limits (Sheet 1 of 2)
Change 14 7-60.3/(7-60.4 blank)

TM 55-1520-210-23-2

NO DAMAGE ALLOWED THIS SURFACE.

THREAD DAMAGE — DEPTH: 1/3 THREAD

LENGTH: 1/4 INCH CUMULATIVE EACH SEGMENT
BLEND AND POLISH OUT ALL IMPERFECTIONS:

MINIMUM DIAMETER AFTER REPAIR IS 0.996 INCH.
AREA A HOLE REPAIR: DEPTH: 0.0005 INCH
AREA: 1/4 CIRCLE (2 HOLES)
Blend and polish all nicks and scratches-depth 0.040 inch.
Figure 7-19. Hydraulic Cylinder Assembly (P/N 204-076-052) — Damage Limits (Sheet 2 of 2)
Change 14 7-61
TM 55-1520-210-23-2
NICKS, SCRATCHES, DENTS
DEPTH: 0.005 INCH DEPTH: 0.010 INCH

REPAIR AREA: 0.25 INCH REPAIR AREA: 0.25 INCH
NUMBER OF REPAIRS: ONE PER EAR NUMBER OF REPAIRS: NOT CRITICAL
THREAD DAMAGE
DEPTH: 1/3 THREAD

LENGTH: 1/4 INCH CUMULATIVE
EDGE CHAMFER
0.030 INCH MAXIMUM
HOLE REPAIR
DEPTH: 0.002 INCH

REPAIR AREA: 1/4 CIRCLE (TWO HOLES)
Figure 7-20. Clevis, Hydraulic Cylinder Assembly

(P/N 204-076-268) – Damage Limits
7-62
TM 55-1520-210-23-2
DAMAGE AREA REPAIR SYMBOLS

TYPE OF DAMAGE PARTICULAR GENERAL
NICKS, SCRATCHES, 0.020 IN.

AND SHARP DENTS 0.040 IN.
CORROSION 0.010 IN. 0.020 IN.

MAXIMUM AREA PER 0.10 SQ. IN.
FULL DEPTH REPAIR NOT CRITICAL
NUMBER OF REPAIRS NOT CRITICAL NOT CRITICAL

EDGE CHAMFER 0.040 IN. 0.060 IN.
BORE DAMAGE 0.002 INCH FOR 1/2 CIRCUMFERENCE
THREAD DAMAGE:
LENGTH: CUMULATIVE
NUMBER:
CRACKS NO CRACKS ALLOWED
Figure 7-21. Bearing Housing (P/N 204-076-201),

Hydraulic Cylinder — Damage Limits
7-63
TM 55-1520-210-23-2
7-74. Cleaning—Hydraulic Cylinder Assembly Premaintenance requirements for repair of

(Cyclic Control). hydraulic servo cylinder assembly
(cyclic control)
WARNING
Condition Requirements
Cleaning materials are flammable and toxic. Model All

Avoid skin contact and breathing of solvent
vapors.
205-076-038,
a. Immerse and clean all metallic parts in solvent 204-076-064 and
(C261). Pay particular attention to passages and 204-076-099
threaded areas. Special Tools None
b. Use a stiff-bristled, non-metallic brush mois- Test Equipment None
tened with solvent (C261) to remove caked dirt from
parts. Support Equipment None
Minimum Personnel Required One
WARNING
Consumable Materials (C1), (C62), (C68),
(C312), (C234)
Goggles will be worn when using compressed (C261)
air. Do not allow more than 5 psi air pressure
to come in contact with skin. Special Environmental Dust Free/Well
Conditions Ventilated Area
c. Dry all parts with compressed air at 15 psig
(maximum) pressure.
a. Deleted.
d. If parts are not to be placed into immediate use
after cleaning, flush parts with hydraulic fluid (C131), b. Service and bleed hydraulic system after re-
wrap with barrier material (C115) and place in a dust-free placing hydraulic cylinder assembly (paragraphs 7-6 and
container. 7-8).
e. Clean inner and outer areas of boot assembly c. Replace any lockwire and cotter pins removed.
(33, figure 7-14) with mild detergent soap (C101) and
warm water. Rinse thoroughly and allow to air dry or wipe
with clean cloth. d. Replace all packings and seals.
7-75. Repair or Replacement—Hydraulic Cylinder e. Replace tab washers (10, figure 7-15 and 8,
Assembly (Cyclic Control). figure 7-16) if unserviceable.
7-64 Change 15
TM 55-1520-210-23-2
(1) Deleted. Premaintenance requirements for repair of

hydraulic servo cylinder assembly (cyclic control)
(2) Deleted.
(3) Deleted. Condition Requirements
(4) Apply sealant (C245) to threaded portions Model All
of clevis and control tube (5) to seal tube when installing Part No. or Serial No. 205-076-056
clevis. Wipe away exposed sealant.
Test Equipment None
f. Cylinder Assembly.
(1) Any cracks or cylinder assembly requires
replacement of part. Tag and send damaged cylinder Minimum Personnel Required One
assembly to depot maintenance for overhaul. Consumable Materials
(2) Leakage from the cylinder assembly, in ex- Special Environmental Condi- Dust Free/Well
cess of that allowed in paragraph 7-70m., requires re- tions Ventilated Area
placement of part.
(3) Minor corrosion to external surfaces of cyl- a. Service and bleed hydraulic system after replac-
inder assembly may be repaired by sanding corroded ing hydraulic cylinder assembly (paragraphs 7-6 and
area with 600 grit sandpaper (C68) to original finish. 7-8).
(4) Minor nicks and scratches are acceptable, b. Replace any lockwire and cotter pins removed.
provided the damage area is sanded with 600 grit sand- c. Repair or replace all parts which prove defective.
paper (C68) to its original finish. Use polishing cloth (C1) Do not attempt to repair delicate parts or surfaces. Re-
or equivalent, to polish out minor scoring on aluminum place damaged parts rather than attempt difficult or ex-
parts. Thoroughly clean any polished parts with solvent tensive repairs.
(C261).
d. Repair components of hydraulic cylinder assem-
g. Clevis. Inspect clevis (1, figure 7-14) in accor- bly per steps below:
dance with limits outlined in figure 7-20 and table 7-5.
(1) Tube assembly (5, figure 7-14).
h. Bearing Housing—Inspect exterior surfaces only
in accordance with limits outlined in figure 7-21 and table
7-5. WARNING
i. Nut Assembly—Inspect exterior surfaces only in Use paint and chemical film material in a
accordance with limits outlined in paragraph 7-73 and well ventilated area. Avoid skin contact
table 7-5. and breathing of spray mist.
j. Boot. Any cracks, tears or deterioration to boot (a) Remove clevis polish nicks, corrosion
assembly (9 or 33, figure 7-14) requires replacement of and scratches with 600 grit sandpaper (C241) and treat
part. No repairs allowed. repair area with chemical film material (C62). Touch-up
k. Flange. Any damage to swivel joint flange (32) treated area with primer (C312) or primer (C206). See
requires replacement of part. figure 7-18 for damage limits.
l. Attaching hardware.Replace any damaged hard- (b) Any cracks to tube assembly 5, figure
ware. 7-14 requires replacement of part.
(c) Deleted.
7-75.1 Repair or Replacement—Hydraulic Cylinder
Assembly (Cyclic Control) PN 205-076-056. (d) Replace decal (4) when damaged.
Change 14 7-65
TM 55-1520-210-23-2
(e) Inspect the internal threaded area of upper a. Install KSP 6099-1 bearing (figure 7-14.1) on hy-
and lower tube assembly (5) fittings for corrosion dam- draulic cylinder assembly, P/N 205-076-099 as follows:
age (area A and B, figure 7-12). Replace tube assem-
bly if corrosion is found. If no corrosion is noted at NOTE
time of inspection, flush tube assembly (5, figure 7-
14) with primer (C312) as follows: Step (1) need not be completed unless re-
tainer (15) was disassembled.
NOTE
(1) Install scraper (14) in retainer (15) so that lip
on scraper faces away from threaded end of retainer.
For new cylinder assemblies that have tubes Then install retainer (13) on top of scraper (14). Then
attached, it is not necessary to remove the install snap ring (12) in outermost groove of retainer
tube in order to accomplish the flushing pro- with rounded side of ring facing scraper.
cedure. Remove the rod end or clevis (1) from
upper end of tube (5) and proceed with flushing (2) Mount housing (9) in retainer (T-62.2, figure
operation as outlined in following sub-step. In 7-17) and install bearing (6) into main bore of hous-
the event a replacement tube is not available, ing.
the tube may be continued in service by ap-
plying primer (C312) to the inner circumfer- (3) Screw nut (2) into housing assembly (9) finger
ence of the end fittings. By this application, tight
the corrosion will be temporarily retarded until
a replacement tube becomes available. (4) Torque nut (2) using spanner wrench (T-2) to
1100 to 1180 inch-pounds of torque.
NOTE
(5) Install Iockwire (C-155) on nut (2), only one
positive safety required.
Disassembly and Assembly of P/N 205-076-
056-107 is not authorized at AVUM or
(6) Slide shield (1) with the clamp installed and
AVIM. Paragraph 7-76 does not apply to this nut and bolt partially tightened onto servo cylinder (28).
assembly.
(7) Install bearing house (9) on servo cylinder (28).
7-76. Assembly-Hydraulic Servo Cylinder As-
sembly (Cyclic Control) (AVIM). (8) Install new tab washer (16) to fit into notches
on end of servo cylinder. (28)
Premaintenance requirements for assembly of
hydraulic servo cylinder assembly (cyclic control) (9) Install assembled retainer (15) on piston and
screw into cylinder tightened finger tight.
Model All (10) Torque retainer (15) 600 to 650 inch-pounds.
Bend tang of washer (16) that aligns with flat on re-
Part No. or Serial No. 204-076-026, tainer (15) against flat (See figure 7-12).
204-076-038,
204-076-064 and (11) Screw nut (11) onto piston rod (25) place
205-076-099 washer (10) on piston rod with tab facing away from
nut (11).
Special Tools (T24), (T25),
or (T62.1)
(12) With servo cylinder piston in the full extended
Test Equipment None position, carefully screw servohead (29) onto piston
rod to bottom then back off 1/2 to 1-1/2 turns, then
Support Equipment None tighten nut (11) against washer (10) finger tight.
Minimum Personnel One
Required (13) Align groove in threads on piston with notch
in servohead assembly. Tighten nut (11) on piston un-
Consumable Materials (C130 or C131) til it bottoms against servohead. Torque nut (11) 200
(C155) to 225 inch-pounds. Lockwire nut (11) with (C-155).
Special Environmental Dust Free/Well
Conditions Ventilated (14) Move shield (1) along the servo (28) until
contact is made by shield rubber against nut (2).
Tighten clamp and bolt on shield.
7-66 Change 4
TM 55-1520-210-23-2
b. Assemble and install cap (6, figure 7-16) to (7) Install cap (6) assembly to cylinder
hydraulic cylinder assembly PN 100585-7 as follows: assembly.
NOTE NOTE
All packings and ring seals will have Actual torque requirements is 400 TO
hydraulic fluid (C130 or C131) ap- 450 inch-pounds. Using torque fixture
plied to them prior to assembly. (T25) or torque fixture (T62.1) and a 10
inch torque wrench will provide the
(1) Install nut (9) and tab washer (8) on required torque while indicating 304 TO
cylinder assembly 380 inch-pound.
(8) Using a 10 inch torque wrench and torque

fixture (T25) or torque fixture (T62.1) torque locknut
Concave surface of ring seal (11) must be (9) 304 TO 380 inch-pounds to acquire 400 TO 450
against cap seal (10) (concave side up). inch-pounds. Bend tangs (minimum of two) of tab
washer against nut.
(2) Install ring seal (11) into groove in piston (9) Remove hydraulic cylinder assembly from
rod (8, figure 7-14). torque fixture (T25) or torque fixture (T62.1).
(3) Install cap seal (10, figure 7-16) on top of c. Assemble and install cap (8, figure 7-15) to
ring seal (11) and within packing groove. hydraulic cylinder assembly P/N 100585-1 as
follows:
(4) Install packing (7) into groove in large end NOTE
of cap (6).
All internal parts of cylinder as-
sembly wiII have hydraulic fluid
(C130 or C131 ) applied to them prior
Concave surface of glide ring (5) must be to assembly.
against packing (4) (concave side up). (1) Install locknut (11) and tab washer (10) on
cylinder assembly.
(5) Install scraper (3) into cap (6) (with lip on
scraper facing up) and secure with retaining ring (1)
(placing retaining ring in outermost groove in cap
with rounded side of retaining ring facing down).
(6) Install hydraulic cylinder assembly in

torque fixture (T25) or torque fixture (T62.1). Concave surface of ring seal (12) must be
against cap seal (13) (concave side up).
(2) Install ring seal (12) into groove on piston

rod (8, figure 7-14).
Groove in threaded area on cylinder must
align with notch in cap (6). If necessary, (3) Install cap seal (13, figure 7-15) on top of
beck off cap (6) to first notch for ring seal (12) and within packing groove.
alignment.
Change 2 7-67
TM 55-1520-210-23-2
(4) Install packing (9) into groove in large end servo and surrounding airframe. Tube assemblies
of cap (8). (204-076-267-1) are procured with both slots “1” and
“2”, however tube assemblies procured before
January 1994 have only one slot and will require the
above modification. Modify tube (item 5, figure 7-14)
as follows:
(1) Vibro Etch the number “1” as shown in
figure 7-22.1 next to the present slot in the upper end
Concave surface of glide ring (6) must be of tube.
placed opposite of backup (7) (concave
side up). (2) Machine one additional slot as shown in
figure 7-22.1. Being careful not to damage the threads.
(5) Install two backups (7), glide ring (6) and Break all sharp edges. Vibro etch the number “2” next
packing (5) into small end of cap (8). to this new slot.
(6) Install scraper ring (3) into cap (8) (with lip (3) Coat machined surface with epoxy poly-
on scraper facing up), retainer (2) and secure with amide primer and finish with black polyurethane paint.
retaining ring (1) (placing retaining ring in outermost
groove in cap with rounded side of retaining ring facing (4) Continue with assembly by placing lock (7,
down). figure 7-12), with Iockwire hole down inside nut (6).
Align lock with slot in piston rod (8) and thread nut (6)
and tube assembly (5) on piston rod (8).
e. Adjust hydraulic cylinder assembly in accor-

dance with dimension A, figure 7-12, and torque nut (6,
figure 7-14) 1500 TO 1800 inch-pounds and secure
Groove in threaded area on cylinder must with Iockwire (C155). Refer to paragraph 7-89 for
align with notch in cap (8). If necessary, details regarding the collective assembly.
back off cap (6) to first notch for align- f. Install preventive boot (33) or P/N KSP9046-1
ment. shield, on hydraulic cylinder assembly as follows
(205-076-099 cylinder assemblies only, refer to follow-
(7) Install hydraulic cylinder assembly in torque ing step g for installation procedures):
fixture (T25) or torque fixture (T62-1).
(1) Compress and insert swivel joint flange (32)
(8) Install assembled cap (8) to cylinder into lower end of boot and engage flange lip in collar.
assembly.
(2) Slip swivel joint flange (32) with boot (33)
down over tube assembly (5) and cylinder.
NOTE
(3) Position lower clamp (31) around swivel
Actual torque requirement is 400 TO 450 joint flange (32) and install screw (30), two washers
inch-pound. Using torque fixture (T25) (29) and nut (28).
or torque fixture (T62.1) and a 10 inch
torque wrench will provide the required (4) With piston rod (8) in full up position adjust
torque while indicating 304 TO 380 inch- boot assembly (33) 20 inches from top flange of tube
pounds. assembly (5) as shown in detail B. Position upper
clamp (24) around top of boot assembly (33) and install
(9) Using a 10 inch torque wrench and torque screw (27), two washers (26) and nut (25).
fixture (T25) or torque fixture (T62.1) torque locknut
(11) 304 TO 380 inch-pounds to acquire 400 TO 450 (5) Check for proper security of boot (9).
inch-pounds torque. Bend tangs (minimum of two) of
tab washer (10) against nut. NOTE
d. Assembly of servo cylinder assembly P/N The following step g. applies to P/N
205-076-056-101 requires the modification of tube 205-076-099 cylinders only.
assembly P/N 204-076-267-1. This modification is
only required on the left cyclic servo installation and g. Install shield to top of cylinder as follows (view
permits proper clearance after installation between A, figure 7-14):
7-68 Change 7
TM 55-1520-210-23-2
(1) Position shield to cylinder. dimension, which may be slightly changed during
rigging. When assembling the left cyclic servo cylinder
assembly the following is applicable:
(2) Install clamp, screw, and nut.
(1) If P/N 205-076-099-5 servo cylinder is
used, align slot in clevis with slot “1” in tube assembly.
h. Place lock (2) into nut (3). Align lock (2) with slot
in clevis (1) and thread nut (3) on clevis. (2) If PIN 205-076-056-107 servo cylinder is
used, align slot in clevis with slot “2” in tube assembly.
The adjustment of the clevis at 2.53 inches should be
attempted as close as possible. The exact measure-
ment may not be achieved.
NOTE
When assembling servo cylinder assem-
blies care should be taken that correct slot This is a mandatory inspection point.
is used in tube assembly depending on
which servo cylinder is being installed. j. Torque nut (3, figure 7-14) 480 TO 600 inch-
pounds and secure with Iockwire (C155).
k Deleted.
i. Install and position clevis (1) as shown in figure
7-14, to tube assembly (5) and set adjustment of clevis l. Remove hydraulic cylinder assembly from
at 2.53 inches as shown in figure 7-12. This is an initial torque fixture (T25) or torque fixture (T62.1).
Change 7 7-68.1/(7-68.2 blank)

TM 55-1520-210-23-2
(b) Cut lockwire on the test 2 port hexagonal

7-77. Lubrication - Hydraulic Servo Cylinder As- plug and slowly remove the plug and packing.
sembly (Cyclic Control). Apply grease to hydraulic
cylinder assembly (6 or 33, figure 7-11) in accordance (c) Manually pump the servocylinder
with figure 1-6. (P/N 205-076-099 and 205-076-056 through full range of motion for no less than 10 cycles.
do not require lubrication). Attention must be directed to the relative phasing of the
input lever and the cylinder movement in order to effect
7-78. Installation - Hydraulic Servo Cylinder As- manual pumping. Pumping is accomplished by moving
sembly (Cyclic Control). the valve head toward and away from the cylinder with
the input lever held in the direction of movement in each
case. Collect discharged fluid in a waste container. The
NOTE total amount of fluid discharged will vary from servo to
Servo units are preserved with servo, but the majority of the fluid will be discharged dur-
ing the first 5 to 6 actuations.
MIL-H-6083. Assure all preservation hy-
draulic oil is flushed from the unit with
MIL-H-83282 prior to installation. (d) Wipe area with a dean cloth, re-install
the packing (if original packing is damaged, replace with
MS28778-2, NSN 5330-00-803-7208) with plug.
a New Servocylinder Purge Procedure - Prior to
Torque plug to 40 TO 50 inch pounds.
installing a new (unused) servocylinder on an aircraft, it
is necessary to purge the MIL-H-6083 preservation
fluid from the assembly. Fluid purge can be accom- (e) Lockwire (using 0.020 lockwire) plug and
plished using one of the following two methods: apply torque seal stripe.
(1) if a hydraulic mule, hydraulic test stand, or b. Dispose of discharged fluid end proceed with
AGPU is available (must have MIL-H-83282 fluid): installation in accordance with TM 55-1520-210-23.
c. Install hydraulic cylinder assembly (33, figure

(a) Connect pressure line from mule to the
7-11) in accordance with the following procedures:
pressure port on the servo.
(b) Conned a hydraulic line from the servo NOTE

return port to a waste container. Do not allow preserva- An improved servo cylinder (P/N
tive fluid to contaminate mule or AGPU reservoir. 205-076-056-107) has bean developed to
replace the current servo cylinder and irre-
(c) Gradually apply pressure (approximate- versible valve. Servos are functionally in-
Iy 1000 PSl) to the servo with the mule. Operate the interchangeable and maybe used in mixed
put lever to stroke the cylinder to the fully extended end installations with current servos.
retracted positions. Repeat this process for 3 cycles
(extend, retract equals one cycle,while collecting the re- (1) Position servo valve as shown on view A-A
turn fluid in the waste container.) figure 7-11. Lower hydraulic cylinder assembly (33)
onto studs of cylinder support.
(2) Manual purge (if equipment in (1), is not
available): (a) Fore and Aft (right) Cyclic control the
right forward and left rear quadrant. Due to increased
(a) Locate test port number 2 (test 2) on ser- physical size of servo, maneuvering the servo into posi-
vo housing. tion may seem harder than the old servo and may re-
quire extending, contracting, and turning the servo in
relation to mount. Do not attempt to pry using a screw-
driver or any had object to position servo. In some air-
craft interference may exist between the cylinder shield
(P/N KSP9064-5) and a wire bundle directly below the
Some residual pressure may exist in the angle structure that runs along right hand beam assem-
internal accumulator. Therefore, remove bly and the top of opening for access cover. Wire bundle
the plug slowly. may be relocated to top side of angle by re-using and
Change 9 7-69
TM 55-1520-210-23-2
relocating existing clamps. Care should be taken to allow NOTE

for adequate clearance between any structure and wire Add washers (26) as necessary to achieve
bundle to prevent chafing. The 45 degree fittings pro- 1/32 inch or less sideplay between bol-
vided for P/N 205-076-056-107 hydraulic connections thead and hydraulic lever.
should be discarded and not used in this application.
(b) Lateral (left) Cyclic controls the left for- (6) Position control tube (27) to lever to servo
ward and right rear quadrant. As with fore and aft cyclic, valve and install bolt (28), two washers (26) and nut (25).
installation of servo in this application may seem harder Torque nut (25) to a maximum of 25 inch-pounds, bolt
and may require extending, contracting, and turning the must turn freely. Secure nut (25) with cotter pin (24).
servo in relation to mount. Servos should be position with
(7) Adjust servo cylinder assembly (paragraph
control input lever facing aft. This 180 degrees out from
7-69).
the old servo installation. In lateral cyclic application the
pressure port on servo should be relocated to alternate (8) Rig hydraulic cylinder assembly (33, figure
pressure port which is also located on the bottom of servo 7-1) to cyclic control system (paragraph 11-55).
housing. Original pressure port should be plugged. Also,
the 45 degree hydraulic fittings provided on servo should (9) Torque nut (3, figure 7-14) 480 TO 600 inch-
be positioned so that hydraulic lines are routed forward pounds and secure with lockwire (C 155)
of tube assembly P/N 204-001-018-27 but not chafing
the tube or structure. To prevent hydraulic lines from (10) After final adjustment, completely seal tube
chafing each other, a standoff should be used and posi- assembly thread areas (Note B, figure 7-12).
tion 5 to 6 inches from the end of hydraulic line using two
(11) Perform operational check and check for
(2) loop clamps (MS21122-5), one machine screw
leaks (paragraph 7-79) of hydraulic cylinder (6, figure
(MS27039-1-08), one self locking nut (MS21042L3) and
7-11).
one flat washer (AN960PD10L).
(2) Install washer (29), nut (30), washers (31) (12) Install access door (81, figure 2-18) and
and nuts (32). Tighten nuts (30 and 32) evenly using soundproofing blanket to pylon island in cabin area.
standard torque. Paint slippage marks.
(13) Install left side access doors (3 and 24) and
(3) Install irreversible valve (22) to servo valve. soundproofing blanket to left side of pylon island in cabin
(4) Check position of clevis (view A-A, figure area.
7-11) on hydraulic cylinder assembly and connect clevis (14) Close and secure left engine cowls (6 and
to swashplate assembly. Install bolt (1, figure 7-11), 7).
washer (35) and nut (34) and secure nut with cotter pin
(36). d. Install hydraulic cylinder assembly (P/N
(5) Remove covers from fittings (19) and install 205-076-056-103) (33, figure 7-11) in accordance with
hose assemblies (19 and 20) to fittings. the following procedure:
(1) Position servo valve as shown on view A-A
WARNING figure 7-11. Lower hydraulic cylinder assembly (33) onto
studs of cylinder support. Due to the larger size of this
Make sure bolt (28) can be rotated by hand servo assembly it may be necessary to extend or retract
after installation of washers (26), self- servo assembly and turn servo in relation to mount while
locking castellated nut (25), and cotter pin installing to permit servo cylinder to fit through cylinder
(24). support on the aircraft.
7-70 Change 14
TM 55-1520-210-23-2
VIEW LOOKING DOWN
NOTE NOTE
The above clevis position is for The above clevis position is for
the following hydraulic cylinder the following hydraulic cylinder
assemblies only. assemblies only.
PART NUMBER PART NUMBER
204-076-026-19 204-076-026-17
204-076-026-21 204-076-064-7
204-076-064-9 204-076-070-1
204-076-064-11 205-076-038-1
204-076-070-3 205-076-099-1
205-076-070-5
205-076-038-3
205-076-038-5
205-076-099-3
205-076-099-5
Figure 7-22. Positioning of Clevis to Servo Cylinder — Hydraulic Cylinder

Assembly (Cyclic Control)
Change 7 7-70.1
TM 55-1520-210-23-2
TUBE ASSEMBLY P/N 204-076-267-1

VIEW LOOKING DOWN FROM ABOVE. SIDE VIEW
Figure 7-22.1. Modification of Tube Assembly,

Left Cyclic
7-70.2 Change 7
TM 55-1520-210-23-2
NOTE (2) Install washer (29), nut (30), washers (31)

and nuts (32). Tighten nuts (30) and (32) evenly using
standard torque. Paint slippage marks.
On some aircraft interference may exist
between the cylinder shield (P/N
KSP9046-5) and a wire bundle which is Io- (3) Check position of clevis (view A-A, figure
cated below and attached to an angle 7-11) on hydraulic cylinder assembly and connect cle-
structure runnng fore and aft along the vis to swashplate assembly. Install bolt (1) figure 7-11
right hand beam assembly. This wire washer (35) and nut (34) and secure nut with cotter pin
bundle may be relocated to topside of the (36).
angle using and relocating existing
clamps Care should be taken to allow for (4) Discard 45 degree fittings provided on servo
adequate clearance between any structure cylinder and replace with straight fittings (18). Install
and wire bundle to prevent chafing. hose assemblies (19 and 20) to fittings (18).
Change 9 7-70.3/(7-70.4 blank)

TM 55-1520-210-23-2
WARNING CAUTION
Make sure bolt (28) can be rotated by hand Care should be taken that hose assem-
after installation of washers (26), self- blies are not chafing the control tube (13)
locking castellated nut (25), and cotter pin or any structure after installation.
(24).
NOTE
Add washers (26) as necessary to achieve WARNING
1/32 inch or less sideplay between bol-
thead and hydraulic lever.
Make sure bolt (2) can be rotated by hand
(5) Position control tube (27) to lever of servo after installation of washers (11), self-lock-
valve and install bolt (28), two washers (26) and nut (25). ing castellated nut (14), and cotter pin (15).
Torque nut (25) to a maximum of 25 inch-pounds, bolt
must turn freely. Secure nut (25) with cotter pin (24). NOTE
(6) Adjust servo cylinder assembly (paragraph Add washer (11) as necessary to achieve
7-69). 1/32 inch or less sideplay between bol-
thead and hydraulic lever.
(7) Rig hydraulic cylinder assembly (33, figure
7-11) to cyclic control system (paragraph 11-55).
(4) Position control tube (13) to lever of servo
(8) Torque nut (3, figure 7-14) 480 to 600 inch- valve and install bolt (12, figure 7-11), washers (11), and
pounds and secure with lockwire (C155). nut (14). Torque nut (14) to a maximum of 25 inch-pounds
(9) After final adjustment completely seal tube both (12) must turn freely. Secure nut (14) with cotter pin
assembly thread areas (Note B, figure 7-12). (15).
(10) Perform operational check (paragraph (5) Perform operational check and check for
7-79) and check hydraulic cylinder (33, figure 7-11) for leaks (paragraph 7-79) of hydraulic cylinder (6, figure
leaks. (Table 7-1). 7-11).
(11) Install access door (81, figure 2-18) and
soundproofing blanket to pylon island in cabin area. (6) Install access door (81, figure 2-18) and
soundproofing blanket to pylon island in cabin area.
(12) Install right access doors (3 and 24) and
soundproofing blanket to right side to pylon island in (7) Install left side access doors (3 and 24) and
cabin area. soundproofing blanket to left side of pylon island in cabin
(13) Close and secure right side engine cowls (6 area.
and 7).
(8) Close and secure left engine cowls (6 and
d.1. Install hydraulic cylinder assembly (6, figure 7).
7-11) in accordance with the following procedure:
(1) Position servo valve as shown in view A-A, e. Install hydraulic cylinder assembly (P/N
figure 7-11 and lower hydraulic cylinder assembly (6) 205-076-056-101) (6, figure 7-11) in accordance with the
onto studs of cylinder support. following procedure:
(2) Install washer (8), nut (7), washers (10) and
(1) Position servo valve as shown in view A-A,
nuts (9). Tighten nuts (7, and 9) evenly using standard
figure 7-11 and lower hydraulic cylinder assembly (6)
torque. Paint slippage marks.
onto studs of cylinder support. Due to the larger size of
(3) Check position of clevis of hydraulic cylinder this servo assembly it may be necessary to extend or
assembly (figure 7-22) and connect clevis to swashplate retract the servo assembly and turn servo in relation to
assembly and install bolt (4, figure 7-11), washer (3) and the mount while installing to permit servo cylinder to fit
nut (2). Secure nut with cotter pin (5). through cylinder support on the aircraft.
Change 14 7-71
TM 55-1520-210-23-2
(2) Install washer (8), nut (7), washers (10) and nuts (9) Close and secure left engine cowls (6 and 7).
(9). Tighten nuts (7, and 9) evenly using standard toque. Paint
slippage marks. 7-79. Operations Check — Hydraulic Cylinder
Assembly(Cyclic Control). a. Perform operational check
(3) Check position of clevis of hydraulic cylinder of hydraulic cylinder assembly (6 and 33, figure 7-11)
assembly (figure 7-22) and connect clevis to swashplate (paragraph 7-3).
assembly and install bolt (4, figure 7-11), washer (3) and nut
(2). Secure nut with cotter pin (5). b. Check hydraulic cylinder assembly (6 and 33) for
leaks (table 7-l).
(4) Relocate 45° fitting (37, figure 7-11) from pres-
sure port on servo to alternate pressure port on servo cylinder. 7-80. HYDRAULIC SERVO CYLINDER ASSEMBLY
Cap original pressure port with cap fitting removed from the (COLLECTIVE CONTROL).
alternate pressure port. Remove protective dust covers from
45° fitting (37) and install hose assemblies (19 and 20) to 7-81. Description — Hydraulic Servo Cylinder
fitting (37). Hose assemblies should be routed forward of the Assembly (Collective Control). There are two types of
control tube (13). Install a standoff consisting of items (38), hydraulic servo cylinder assemblies that may be used in the
(39), (40), and (41), figure 7-11, 5 to 6 inches from the end collective control. Both reduce feedback forces and assist
of hose assemblies to prevent chafing. collective pitch control of the main rotor. One uses a hydraulic
cylinder with an irreversible valve and the other incorporates
WARNING the irreversible feature within the servo cylinder itself.
Make sure bolt (12) can be rotated by hand after 7-82. Adjustment — Hydraulic Servo Cylinder
installation of washers (11), self-locking castel- Assembly (Collective Control). a. Adjust collective
lated nut (14), and cotter pin (15). hydraulic cylinder as shown in dimension A of figure 7-12
and paragraph 7-69.
CAUTION
b. Adjust clevis as shown in figure 7-12 and paragraph
Care should be taken that hose assemblies are not 7-69.
chafing the control tube (13) or any structure
after installation. c. Rig collective hydraulic cylinder after installation
procedures have been accomplished (paragraph 11-6).
CAUTION
d. When collective stick is creeping up during flight,
When installing or removing 45 degree fittings. bend tab (21, figure 7-23) down. Bend tab (21) up when
Make sure the screen does not fall out of the collective stick is creeping down.
hydraulic servo pressure port.
7-83. Inspection (Acceptance/Rejection Criteria) —
NOTE Hydraulic Servo Cylinder Assembly (Collective
Control). (Paragraph 7-70, 7-73, figures 7-18 through
Add washer (11) as necessary to achieve 1/32 7-21 and table 7-5).
inch or less sideplay between bolthead and
hydraulic lever.
7-84. Removal-Hydraulic Servo Cylinder Assembly
(Collective Control). a. Gain access to cylinder as fol-
(5) Position control tube (13) to lever of servo valve
lows:
and install bolt (12), figure 7-11, washers (11), and nut (14).
Torque nut (14) to a maximum of 25 inch-pounds bolt (12)
(1) Open transmission cowling (2, figure 2-18) and
must turn freely. Secure nut (14) with cotter pin (15).
left engine cowls (6 and 7).
(6) Perform operational check and check for leaks
(2) Remove cargo hook assembly (paragraph
(paragraph 7-79) of hydraulic cylinder (6, figure 7-11). 14-151).
(7) Install access door (81, figure 2-18) and sound-
(3) Remove soundproofing blanket and left access
proofing blanket to pylon island in cabin area.
doors (23 and 24).
(8) Install left side access doors (3 and 24) and
soundproofing blanket to left side of pylon island in cabin
area.
7-72 Change 5
TM 55-1520-210-23-2
b. Disconnect and remove cylinder assembly (6, (5) If necessary, remove droop compensator
figure 7-23) as follows: jackshaft assembly and bracket on cylinder support
(paragraph 4-129).
(1) While gaining access through cargo hook
opening, remove cotter pin (12), nut (13), washers (9) (6) Remove nuts (7) and washers (8).
and bolt (10) from lever of servo valve and remove tube (7) Remove nut (15) and washer (14).
assembly (11).
(8) Remove cotter pin (3), nut (2), washer (4)
NOTE and bolt (5) from clevis of hydraulic cylinder assembly
and disconnect clevis from trunnion bearing (1) of lever
When disconnecting hydraulic hose as- assembly.
semblies (16 and 17), a small amount of
fluid seepage may occur and will require (9) Carefully rotating hydraulic cylinder assem-
placing a small container under fittings of bly, lift hydraulic cylinder assembly from helicopter.
irreversible valve. (See detail A.) b.1. Hydraulic Servo Cylinder Assembly P/N
205-076-056-105.
(2) Disconnect hose assemblies (16 and 17)
from irreversible valve. (1) Open transmission cowling (2, figure 7-18)
and left engine cowls (6 and 7).
(3) Remove irreversible valve from hydraulic (2) Remove cargo hook assembly (paragraph
servo valve (paragraph 7-102). 14-285).
(4) Install protective covers to open ports of hy- (3) Remove soundproofing blanket and left ac-
draulic servo and irreversible valves. cess doors (23 and 24).
Change 14 7-72.1
TM 55-1520-210-23-2
7-85. Disassembly — Hydraulic Servo Cylinder As- proper clearance after installation between servo and
sembly (Collective Control) (AVIM). surrounding airframe. Modify tube (Item 5, figure 7-14) as
NOTE follows:
Disassembly procedures for collective hy- (1) Vibro etch the letter “A” as shown in figure
draulic cylinder assembly are same as cy- 7-23.1 next to the present slots in hex threaded end of
clic control hydraulic cylinder assembly, tube.
except for maintenance tasks outlined in (2) Machine two additional slots as shown in
the following steps. figure 7-23.1. Vibro etch the letter “B” next to these new
a. Remove nuts (18, figure 7-23) and bolts (20) from slots.
stops (19). (3) Cool machined surface with Epoxy Poly-
b. Remove stops (19) from piston rod of collective amide Primer and finish with Black Polyurethane Paint.
hydraulic cylinder assembly (6).
b. Tube assemblies (204-076-267-5) are procured
b.1. Remove spring (22). with both slots “A” and “B”, however tube assemblies
procured before November 1987 have only one set of
c. Disassemble hydraulic cylinder assembly (para-
slots and will require the above modifications.
graph 7-72).
7-86. Inspection — Hydraulic Servo Cylinder As- CAUTION

sembly (Collective Control) (AVIM). Inspect collective
hydraulic cylinder assembly in accordance with inspec-
When assembling servo cylinder assem-
tion limits outlined in paragraphs 7-70 and 7-73, figures
blies care should be taken that correct slot
7-18 through 7-21, and table 7-5.
is used in tube assembly depending on
7-87. Cleaning — Hydraulic Servo Cylinder Assem- which servo cylinder is being installed.
bly (Collective Control). (Paragraph 7-74). c. When assembling servo cylinder assembly per
para. 7-76 d. and e. the following is applicable to collec-
7-88. Repair — Hydraulic Servo Cylinder Assembly tive installation:
(Collective Control) (AVIM). For repairs or replace-
ment to components of collective hydraulic cylinder as- (1) If P/N 205-076-099-5 servo cylinder is used
sembly (paragraph 7-75). align slot in piston rod with slot “A” in tube assembly when
final adjustment is made.
7-89. Assembly — Hydraulic Servo Cylinder Assem-
bly (Collective Control). (2) If P/N 205-076-056-107 servo cylinder is
used align slot in piston rod with “B” in tube assembly
NOTE when final adjustment is made.
Assembly procedures for collective hy- This is a mandatory inspection point.
draulic cylinder assembly are same as cy-
clic control hydraulic cylinder assembly d. Discard 45° fittings (37, figure 7-11) provided and
(paragraph 7-76), except for maintenance replace with straight fittings (18, figure 7-11). Port A
tasks outlined in the following steps. should have plug installed. Ports B and C should have
hydraulic lines installed. (Figure 7-23.2).
a. Assembly of servo cylinder assembly P/N
205-076-056-105 requires the modification of tube as- e. Install irreversible valve to servo (not applicable
sembly P/N 204-076-267-5. This modification permits for P/N 205-056-105) (Paragraph 7-98).
7-72.2 Change 14
TM 55-1520-210-23-2
*TORQUE NUT TO 25 INCH POUNDS MAX.

BOLT MUST TURN FREELY
1. Trunnion bearing 5. Bolt 9. Washers 13. Nut

2. Nut 6. Cylinder assembly 10. Bolt 14. Washer
3. Cotter pin 7. Nut 11. Tube assembly 15. Nut
4. Washer 8. Washer 12. Cotter pin
Figure 7-23. Hydraulic Servo Cylinder Assembly (Collective Control) —

ALL DATA ON PAGES 7-75 THRU 7-77 INCLUDING FIGURES 7-24 THRU 7-26 AND TABLE
7-6 ARE DELETED.
Change 5 7-72.3
TM 55-1520-210-23-2
Figure 7-23. Hydraulic Servo Cylinder Assembly (Collective Control)

Removal and Installation (Sheet 2 of 2).
7-72.4 Change 6
TM 55-1520-210-23-2
Figure 7-23.1. Additional Slots in Tube Assembly
NOTES:
1. General position of serve using
slot “B” in Figure 7-23.1
2. Serve should clear adjacent structure

for its full travel with hydraulics on.
3. Ensure part “A” has a plug

installed. Part “B” and “C” have
hydraulic lines installed.
Figure 7-23.2. Position of servo,

P/N 205-076-056-105, in collective position,
looking up into hell hole
Change 14 7-72.5/(7-72.6 blank)

TM 55-1520-210-23-2
f. With piston rod (8, figure 7-14) in full up position, b. Install washers (8 and 14) and nuts (7 and 15) on
adjust boot assembly (33) 14.5 inches as shown in detail studs of cylinder support. Using standard torque, tighten
B. nuts evenly. Paint slippage marks.
g. Adjust and position clevis (1) 2.53 inches from NOTE
center of hole in clevis to top of tube assembly (5) as Protective dust covers in parts of servo
shown in figure 7-12. Torque nut (3, figure 7-14) 480 to valve will have to be removed prior to
600 inch-pounds and secure with lockwire (C155). hookup of clevis to trunnion bearing (1,
Check dimension A measurement of collective hydraulic figure 7-23) for release of cylinder pres-
cylinder assembly as shown in figure 7-12. sure while moving piston rod up or down.
c. Check position of clevis of servo valve (figure
CAUTION 7-22) and connect clevis of hydraulic cylinder assembly
(6, figure 7-23) to trunnion bearing (1) and install bolt (5),
Stops (19, figure 7-23) must be against washer (4) and nut (2), torque nut (2) (fig 5-5). Torque nut
nut. (2) (figure 7-23) to 100 TO 140 inch-pounds. Secure nut
(2) with cotter pin (3).
h. Install bolts (20, figure 7-23), stops (19) and nuts
(18) to piston rod and against nut.
WARNING
i. Install spring (22).
Make sure bolt (10) can be rotated by hand
7-90. Lubrication - Hydraulic Servo Cylinder Assem- after installation of washers (9), self-lock-
bly (Collective Control). Apply grease to collective hy- ing castellated nut (13), and cotter pin (3).
draulic cylinder assembly (6, figure 7-23) in accordance NOTE
with figure 1-6. P/N 205-076-099 and 205-076-056 do
not require lubrication. Add washers (9) as required to achieve
1/32 inch or less sideplay between bol-
7-91. Installation - Hydraulic Servo Cylinder Assem- thead (10) and hydraulic lever.
bly (Collective Control). Install collective hydraulic cyl- d. Position bearing of tube assembly (11) into lever
inder assembly (6, figure 7-23) in accordance with the of servo valve and install bolt (10), washers (9) and nut
following procedures. (13). Torque nut (13) to a maximum of 25 inch-pounds,
bolt (10) must turn freely. Secure nut (13) with cotter pin
NOTE
(12).
Servo units are preserved with
MIL-H-6083. Assure all preservative hy- e. Install irreversible valve to servo P/N
draulic oil is flushed from the unit with 205-076-099-5. (Not applicable to P/N
MIL-H-83282 prior to installation. Refer- 205-076-056-105.)
ence para 7-78a. f. Remove protective covers from hose assemblies
(16 and 17, figure 7-23).
a. Position servo valve as shown in detail C, figure
7-23 and lower collective hydraulic assembly (6) onto g. Install hose assemblies (16 and 17) to fittings
studs of cylinder support. located on bottom of either irreversible valve or servo
cylinder (P/N 205-076-056).
NOTE
h. Install droop compensator jackshaft and bracket
Figure 7-23.2 shows collective hydraulic
on cylinder support (paragraph 4-132).
cylinder assembly, P/N 205-076-056-105,
in proper position and clearances with i. Service and bleed hydraulic system (paragraph
surrounding structure. 7-6).
Change 14 7-73
TM 55-1520-210-23-2
j. Install left access doors (23 and 24, figure 2-18) tional check of hydraulic system (paragraph 7-3). With
and soundproofing blanket to pylon island in cabin area hydraulic test stand attached to hydraulic system, move
collective stick up and down and check hydraulic cylin-
der for leaks (table 7-1). Ensure that all parts of the Ser-
NOTE
vo Cylinder Assembly do not foul cabin structure. If foul-
Prior to adjustment of balance spring, ening does occur, check position of servo cylinder as
sure that collective system is inspected In shown in detail C, figure 7-23. During operational flight,
accordance with Chapter 11 of TM check collective stick for creeping up or down. Adjust
55-1520-210-23-2. spring on control cylinder servo valve if collective stick is
creeping (paragraph 7-82). Adjust servo cylinder
7-92. Operational Check - Hydraulic Servo Cylin- 204-076-056-109 balance spring by loosening nut (24)
der Assembly (Collective Control). Perform opera- and turning nut (26). Tighten nut (24) after adjustment.
ALL DATA ON PAGES 7-75 THROUGH 7-76 INCLUDING FIGURES 7-24 THROUGH 7-26 AND TABLE 7-26
ARE DELETED.
7-74 Change 9
TM 55-1520-210-23-2
DELETED
Change 7 7-75
TM 55-1520-210-23-2
DELETED
All data on pages 7-74 thru 7-78 including Figures 7-24 thru 7-26 and
Table 7-6 are deleted.
7-76 Change 7
TM 55-1520-210-23-2
Paragraphs 7-92.1 through 7-99 Deleted.
Change 5 7-77
TM 55-1520-210-23-2
7-100. ARMAMENT COUPLINGS. (5) Remove preformed packing (4), ring (3) and nut
(2) from fitting (1).
7-101. Description - Armament Couplings. External
armament couplings (12 and 17, figure 7-27), located on left (6) Remove dust cap (19) from coupling half (17).
and right side of helicopter are provided for attaching exter-
nal hydraulically operated armament system supports. The (7) Remove four nuts (21), four washers (20) and four
armament couplings also allow for quick disconnect of screws (15) attaching flange (16) to cabin structure. Remove
armament systems supports. flange (16) and coupling (17).
7-102. Removal - Armament Couplings. b. Armament Coupling (Return). Remove armament

coupling (12, figure 7-27) from return side of hydraulic
NOTE system as follows:
Removal procedures are typical for left or right (1) Place rags or shop towels under fitting (5) to catch
armament couplings. fluid seepage and disconnect tube assembly (9) from fitting.
a. Armament Coupling (Pressure). Remove armament (2) Break torque on nut (6) and remove fitting (5)
coupling (17, figure 7-27) from pressure side of hydraulic from coupling half (12).
system as follows:
(3) Remove packing (8), ring (7) and nut (6) from
(1) Remove hydraulic access door (81, figure 2-18). fitting (5).
(2) Remove access door (47 or 58). (4) Remove dust cap (18) from coupling half (12).
(3) Place rags or shop towels under fitting (1, figure (5) Remove four nuts (10), four washers (11) and
7-27) to catch fluid seepage. Disconnect tube assembly (22) four screws (14) attaching flange (13) to cabin structure and
from fitting (1). remove flange (13) and coupling half (12).
(4) Break torque on nut (2) and remove fitting (1)

from coupling half (17).
7-78 Change 5
TM 55-1520-210-23-2
1. Fitting 12. Coupling half

2. Nut 13. Flange
3. Ring 14. Screw
4. Preformed packing 15. Screw
5. Fitting 16. Flange
6. Nut 17. Coupling half
7. Ring 18. Dust cap
8. Preformed packing 19. Dust cap
9. Tube assembly 20. Washer
10. Nut 21. Nut
11. Washer 22. Tube assembly
Figure 7-27. Armament Couplings, Hydraulic —

Removal and Installation
7-79
TM 55-1520-210-23-2
7-103. Inspection — Armament Couplings. a. Armament Coupling (Pressure). Install arma-

ment coupling half (17, figure 7-27) to pressure side of
a. Inspect coupling halves (12 and 17, figure 7-27)
hydraulic system as follows:
for corrosion. Minor corrosion is allowed only to external
surface, provided damage area is polished (by sanding) (1) Install coupling half (17). Position flange
and treated (paragraph 11-72.6, step b). No corrosion (16) over coupling half (17) (with hinge down) and install
damage is allowed to fluted, or internal areas, of coupling screws (15), washers (20) and nuts (21).
halves.
(2) Install nut (2), ring (3) and packing (4) on
b. Inspect dust caps (18 and 19) for deterioration
fitting (1) and install fitting on coupling half (17) (with
and tears.
fitting end pointing down).
c. Inspect flanges (13 and 16) for corrosion. Minor
corrosion is allowed provided corroded area is removed (3) Install tube assembly (22) on fitting (1).
by polishing (sanding). Torque tube assembly connector, refer to table 7-3.
d. Inspect coupling halves (12 and 17) and attach- b. Armament Coupling (Return). Install armament
ing components for security. coupling half (12) to return side of hydraulic system as
follows:
e. Inspect coupling halves (12 and 17) for leaks.
f. Inspect all parts for thread damage. (1) Install coupling half (12) to cabin structure.
Position flange (13) over coupling half (12) (with hinge
g. Inspect coupling halves (12 and 17) for cracks. down) and install screws (14), washers (11) and nuts
No cracks are allowed. (10).
h. Inspect tube assemblies (9 and 22) in accor- (2) Install nut (6), ring (7) and packing (8) on
dance with paragraph 7-108. fitting (5) and install fitting on coupling half (17) (with
7-104. Repair — Armament Couplings. fitting end pointing down).
a. Internal corrosion damage to coupling halves (12 (3) Install tube assembly (9). Torque tube as-
and 17) requires replacement of part. sembly connector, refer to table 1-5.
b. Any damaged part that does not warrant time c. Bleed hydraulic system (paragraph 7-6).
expended for repairs, requires replacement of part.
d. Perform operational check of hydraulic system
c. Replace all packings and (backup) rings when and check for leakage (paragraphs 7-3 and 7-4, and
removed. table 7-1).
d. Replace all parts that have thread damage or
e. Install left or right access doors (47 or 58 and 81,
cracks.
figure 2-18).
e. Tighten any component that is loose.
f. Replace packing or damaged component when 7-106. HOSES, TUBING, AND ATTACHING HARD-
leaking fluid. WARE.
g. Replace dust caps (18 and 19) when torn or dete-
7-107. Description — Hoses, Tubing and Attaching
riorated.
Hardware. Throughout the hydraulic system are hoses,
7-105. Installation — Armament Couplings. tubing and attaching hardware that interconnects check
valves, relief valves, solenoid valves, irreversible valves,
NOTE pump, reservoir and cyclic, collective, tail rotor cylinder
Installation procedures are typical for left assemblies. The tube assemblies are secured to cabin
or right armament couplings. structure with clamps, spacers, washers and nuts.
7-80 Change 14
TM 55-1520-210-23-2
7-108. Removal — Hoses, Tubing, and Attaching g. Ensure that all hose and tube assemblies do not
Hardware. foul, to prevent wear from chafing. Spiral wrap all hoses
that are chafing with tape (C282).
a. Remove hose assemblies, attaching clamps,
and hardware from cabin structure as necessary to per- h. Any damage to hoses, tubes and hardware that
form maintenance functions of hydraulic system. does not warrant time expended for repairs, necessitates
b. Remove tube assemblies, attaching clamps, and replacement of part.
hardware from cabin structure as necessary to perform
maintenance functions to the hydraulic system. 7-111. Installation — Hoses, Tubing and Attaching
Hardware.
7-109. Inspection — Hoses, Tubing and Attaching
Hardware.
CAUTION
NOTE
For further inspection criteria and/or test- No clamps will be installed on flexible
ing of hydraulic hose or tube assemblies, braided lines which move with the actua-
refer to TM 1-1500-204-23 series. tor, except where specified. Inspect the
lines for chafing through full travel and
a. Inspect hose and tube assemblies for leaks, se- reposition lines as necessary for clear-
curity, corrosion, cracks. ance.
b. Inspect hose assemblies for deterioration or fray- NOTE
ing.
Threads of tube and hose connectors and
c. Inspect hose and tube assemblies for deforma- fittings will have hydraulic fluid (C130 or
tion. C131) applied to them prior to torquing. Do
d. Inspect hose and tube assemblies for wear or not exceed limits outlined in table 1-5 or
binding. torque threads when dry.
a. Install hose assemblies and attaching clamps
7-110. Repair — Hoses, Tubing and Attaching Hard-
and hardware to cabin structure as necessary to perform
ware.
maintenance functions to the hydraulic system. refer-
a. For repairs to hose or tube assemblies, refer to ence: when component has been removed for repairs or
TM 1-1500-204-23 series. damaged part is being replaced.
b. Replace hose or tube assemblies when cracked b. Install tube assemblies and attaching clamps and
or deteriorated. hardware to cabin structure as necessary to perform
c. Replace clamps or hardware when damaged. maintenance functions to the hydraulic system, refer-
ence: when component has been removed for repairs, or
d. Tighten hose or tube assembly when leaking. damaged part is being replaced.
e. Tighten hardware attaching hose or tube assem-
bly when loose.
SECTION II. PNEUMATIC SYSTEM
f. Replace hose or tube assembly when component
is deformed. Not Applicable
Change 14 7-81/(7-82 blank)

TM 55-1520-210-23-2
CHAPTER 8
INSTRUMENT SYSTEMS
SECTION I. INSTRUMENT MAINTENANCE
8-1. INSTRUMENT MAINTENANCE. 8-6. Repair or Replacement—Instrument Main-

tenance. a. Replace missing or illegible range mark-
8-2. Description-Instrument Maintenance. In- ings on cover glasses of instruments.
strument maintenance refers to general maintenance
procedures which are applicable to all instruments
NOTE
mounted in the instrument panel.
When replacing instrument range markings
8-3. Cleaning—Instrument Maintenance. Clean
(see TM 55-1520-210-10 for ranges except
panel and instrument cover glasses with a suitable
for Torque Pressure Indicator, see paragraph
soft, lint-free cloth.
8-6.d below) use a suitable lacquer, tape
(C274), or prepared decals. Protect markings
8-4. Inspection-Instrument Maintenance. a. In-
by applying a light coat of clear adhesive var-
spect for loose, cracked, or broken cover glasses or
nish or lacquer. Apply range markings accu-
slippage.
rately on cover glass.
b. Inspect for proper and secure mounting.
b. Replace any required decals which are not clearly
legible.
c. Inspect range markings and decals for complete-
ness and legibility.
c. Replace any instrument if cover glass is loose,
cracked or broken, or when found to be unserviceable.
d. Inspect for proper operation.
d. Marking—Torque Pressure Indicator.
e. Inspect for loose, missing or improperly installed
hardware.
(1) Obtain torque figure from engine data plate.
8-5. Removal-Instrument Maintenance. a. En-
(2) Use this figure to determine instrument mark-
sure all electrical power is OFF.
ing as follows:
b. Disconnect electrical leads or instrument piping
ENGINE DATA PLATE INSTRUMENT
from back of panel. Necessary access maybe through
TORQUE FIGURE MARKING POINT
pedestal, through back of cabin mounting holes in panel
58 47
after instrument is detached.
59 48
60 49
c. Protect ends of electrical leads, and cap open
61 50
piping and openings on instrument.
62 51
63 51.5
NOTE 64 52
On helicopters, Serial No. 66-746 and subse- (3) Place red line on indicator at this point. This
quent; the MS28042 clamp will be used to is maximum indicated torque for this aircraft.
mount certain round instruments. In order to
remove this clamp it will be necessary to hold 8-7. Installation—Instrument Maintenance.
the clamp from the aft side while removing the
screw from the front of the panel.
d. Remove mounting screws or loosen mounting

On helicopters, Serial No. 66-746 and subse-
clamp screw. Remove instrument.
quent; the MS28042 clamp will be used to
Change 4 8-1
TM 55-1520-210-23-2
mount certain round instruments. The installa- b. Remove protective caps or covers as necessary.
tion technique required to ensure instrument Connect electrical leads and instrument piping.
security is that the clamp must be held in place
from the aft side while tightened by a screw
visible on the front side of the panel. A gap
between the head of the screw and the face
of the instrument panel may exist. Do not at- Failure to perform required instrument/indica-
tempt to overtorque the screw to eliminate the tor functional tests specified in this chapter
clearance since the scissors mechanism of the can result in operation limits being exceeded
clamp will be damaged. with a false indication of operating within al-
lowable limits.
NOTE
c. Check instrument operation and perform func-
tional test if specified in this chapter for the instrument
When installing AIMS altimeter ensure that the
installed.
space is installed with thickest section at the
bottom to prevent chafing.
8-8. INSTRUMENT PREMAINTENANCE
a. Position instrument in panel. Install mounting REQUIREMENTS.
screws or tighten screw of mounting clamp.
8-9. Description—Instrument Premaintenance

Requirements. Throughout this chapter, unless oth-
erwise specified, instrument maintenance, testing, and
When connecting electrical plugs to dual ta- troubleshooting procedures will utilize only tools and
chometer indicator, ensure that plugs are con- equipment contained in Electronic Equipment Tool Kit,
nected to correct receptacle. TK100/G and multimeter (AN/PSM-6A, or equivalent.)
NOTE
Rotate engine, transmission pressure and tem-

perature gages so that 9 o’clock is normal
operating range.
SECTION Il. ENGINE INSTRUMENTS
8-10. ENGINE INSTRUMENTS. producer tachometer and gas producer tachometer

generator as the other system.
8-11. Description-Engine Instruments. Engine
instruments include the tachometer, engine oil pres- 8-14. DUAL TACHOMETER.
sure, engine oil temperature, exhaust gas tempera-
ture, fuel pressure, and torque pressure indicating sys- 8-15. Description—Dual Tachometer. The dual
tems. tachometer indicates both main rotor rpm and engine
output shaft rpm. Each tachometer has a synchro-
8-12. TACHOMETER INDICATING nous motor connected electrically to separate tachom-
SYSTEMS. eter generator. The system operates independently of
helicopter electrical power systems. The rotor rpm
8-13. Description-Tachometer Indicating Sys- pointer indicates on the inner scale of instrument, and
tems. The tachometer indicating systems are self-gen- the engine rpm pointer indicates on the outer scale.
erating rotary type systems consisting of the dual ta- The pointers will be aligned when engine and rotor
chometer, rotor tachometer generator, and power speeds are synchronized in normal operation.
turbine tachometer generator as one system; and gas
8-2 Change 4
TM 55-1520-210-23-2
8-16. Cleaning – Dual Tachometer. Refer to TEST POINTS INDICATOR TOLERANCE

paragraph 8-3 for cleaning procedure. (RPM) (RPM)
8-17. Inspection — Dual Tachometer. Refer to o o ±3

paragraph 8-4 for inspection procedures. 531 40 ±4
1063 80 ±4
1992 150 ±4
8-18. Functional Test – Dual Tachometer 2532 190 ±4
(AVIM) a. Disconnect plug (P35) from rotor 3055 230 ±4
tachometer generator .Connect plug to the MASTER 3320 250 ±4
GENERATOR output plug on tachometer tester (T- 3580 270 ±3
90). Energize test stand and set controls according to 3851 290 ±2
the instructions on the cover of the tester. 3984 300 ±2
4117 310 ±2
b. Check that the rotor tachometer portion of the 4250 320 ±2
indicator indicates within tolerance of the various 4383 330 ±3
check points in the following: 4649 350 ±3
8-3
TM 55-1520-210-23-2
c. Disconnect plug (P35) from the tachometer TEST POINTS INDICATOR TOLERANCE
tester (T90) and reconnect it to the rotor tachometer (RPM) (RPM)
generator. Check that connector is properly mated
and secure. 3832 6000 ± 30
3954 6200 ± 30
d. Disconnect plug (P86) from the power turbine 4023 6300 ± 20
tachometer generator. Connect plug to the MASTER 4151 6500 ± 30
4342 6800 ± 40
GENERATOR output plug on tachometer tester (T90).
4534 7100 ±60
Energize test stand and set controls according to the
tester instructions on the cover of the tester.
e. Check that the power turbine portion of the f. Disconnect plug (P86) from the test stand and
indicator indicates within tolerance of the various reconnect it to the power turbine tachometer
check points in the following:
and secure.
TEST POINTS INDICATOR TOLERANCE 8-19. Troubleshooting — Dual Tachometer. Use

(RPM) (RPM) table 8-1 and perform necessary checks to isolate
trouble. Broken or shorted wiring is always a probable
0 0 ± 50 cause of malfunction or failure and has not been
511 800 ± 70 included. (figure F-11.)
956 1500 ± 70
1980 3100 ± 70 NOTE
2491 3900 ±70
2938 4600 ± 70 Before using this table, be sure all normal
3257 5100 ±50 operational checks have been
3576 5600 ± 50 performed.
Table 8-1. Troubleshooting Dual Tachometer
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. Tachometer has excessive scale error.
STEP 1. Determine if indicator has weak magnet assembly.
Replace indicator if defective (paragraph 8-1).
2. Tachometer indication only half of actual speed.
STEP 1. Determine if electrical connectors are connected to correct receptacle on indicator.
Reconnect electrical connectors if reversed at indicator.
3. No reading on tachometer indicator.
STEP 1. Check for poor connection at indicator or generator.
Clean or tighten connections (paragraph 8-24).
8-4
TM 55-1520-210-23-2
Table 8-1. Troubleshooting Dual Tachometer (Cont)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
STEP 2. Determine if internal circuit is defective in indicator or generator.
Replace defective indicator and/or generator (paragraphs 8-1, 8-22, and 8-31).
STEP 3. Check system wiring.
Repair defective wiring.
4. High or low reading on indicator either constant or intermittent.
STEP 1. Determine if indicator resistance is out of adjustment.
8-20. Removal/Installation—Dual Tachometer. Re- 8-25. Inspection—Power Turbine Tachometer Gen-

fer to paragraphs 8-5 and 8-7 for removal and installation erator.
procedures.
a. Inspect tachometer generator case for cracks,
excessive wear, or any visible damage.
8-21. Repair or Replacement—Dual Tachome-
ter. Refer to paragraph 8-6 for repair or replacement b. Check connector for damaged or bent pins and
criteria. cracked inserts.
c. Check that rotor turns freely and there is no vis-
8-22. POWER TURBINE TACHOMETER GENERA- ible indication of excessive wear to bearings.
TOR.
8-26. Troubleshooting—Power Turbine Tachometer
8-23. Description—Power Turbine Tachometer Gen- Generator.
erator. The power turbine tachometer generator is
mounted on the governor and tachometer drive gearbox a. Remove cowling from left side of engine.
on the left upper side of the engine, and is connected to b. Disconnect electrical receptacle, remove mount-
the dual tachometer indicators on the instrument panels. ing nuts and washers and lift tachometer generator from
engine.
8-24. Cleaning—Power Turbine Tachometer Gener-
ator. 8-27. Removal—Power Turbine Tachometer Genera-
tor.
a. Remove moisture and loose dirt with a clean, soft
cloth. a. Open cowling on left side of engine.
b. Disconnect electrical receptable, remove mount-
ing nuts and washers and lift tachometer generator from
WARNING engine.
Dry cleaning solvent is flammable and its 8-28. Repair or Replacement—Power Turbine
fumes are toxic. Provide adequate ventila- Tachometer Generator.
tion. Do not use near a flame.
a. Replace tachometer generator if case is cracked
b. Remove grease, fungus, and dirt with a clean, or damaged.
lint-free cloth dampened with solvent (C261).
b. Replace tachometer generator if rotor does not
c. Remove dirt from electrical connectors with a turn freely or for visible indication of excessive wear to
bristle brush (C52). bearings or drive mechanism.
Change 14 8-5
TM 55-1520-210-23-2
NOTE right side of the transmission. The generator is mounted

on the hydraulic pump and tachometer drive quill as-
Replacement of power turbine tachometer gen- sembly and is connected to the dual tachometer indi-
erator will require testing the rpm limit warning cators on the instrument panels.
system (paragraph 9-183).
c. Repair damaged connectors. 8-33. Cleaning—Rotor Tachometer Generator.

Refer to paragraph 8-24 cleaning procedures are the
8-29. Testing-Power Turbine Tachometer Gen- same.
erator. a. Remove tachometer generator from heli-
copter and mount on tachometer tester (T-91). Con-
nect generator to the TEST GENERATOR INPUT 8-34. Inspection-Rotor Tachometer Generator.
Operate tester according to instructions on cover and Refer to paragraph 8-25, inspection procedures are
check voltage outputs of the tachometer generator. the same.
With a 40 ohm “Y” connected resistance and a shaft
speed of 4200 rpm, check voltage output across each
phase of the generator (A-B, A-C, and B-C). The 8-35. Troubleshooting—Rotor Tachometer Gen-
three voltage outputs should be 21 ± 0.5 Vac. erator. Refer to paragraph 8-19 for troubleshooting
procedures.
b. Decrease generator speed to 1,000 rpm with a
20 ohm “Y” connected resistance.
8-36. Removal-Rotor Tachometer Generator. a.
c. Check the voltage output of the three phases. Remove cowling from right side of transmission.
Voltage should not go below 3.5 Vac.
b. Disconnect electrical receptacle, remove mount-
d. Disconnect tachometer generator and remove ing nuts and washers, and lift rotor tachometer gen-
from the tachometer tester (T90). erator from helicopter.
e. Measure the resistance of each phase (A–B, A–

C, and B–C). At 25° Celsius (77°F), the resistance 8-37. Repair or Replacement—Rotor Tachom-
should be between 15 and 50 ohms. Each phase eter Generator. a. Replace tachometer generator if
should be within two (2) ohm of each other. case is cracked or damaged.
f. At completion of testing, install tachometer gen- b. Replace tachometer generator if rotor does not
erator and connect electrical plug and check for proper turn freely or if visible indication of excessive wear to
mating and security. bearings.
NOTE
8-30. Installation—Power Turbine Tachometer
Generator.
Replacement of rotor tachometer generator will
require testing the rpm limits warning system
NOTE (paragraph 9-183).
Coat tachometer generator shaft and pack mat-

ing square drives of shaft in accessory drive 8-38. Testing—Rotor Tachometer Generator.
gearbox 2/3 full with lubricant (C161 ). Refer to paragraph 8-29, procedures are the same.
a. Position tachometer generator and gasket on

studs and install nuts. 8-39. Installation-Rotor Tachometer Generator.
a. Apply a thin film of antiseize compound (C47) to
b. Connect electrical receptacle and install cowling. tachometer generator square drives and to mating
square drives in transmission.
8-31. ROTOR TACHOMETER
GENERATOR b. Position tachometer generator and gasket on
mounting studs and install washers and nuts.
8-32. Description-Rotor Tachometer Generator.
The rotor tachometer generator is located on the lower c. Connect electrical receptacle and install cowling.
8-6 Change 4
TM 55-1520-210-23-2
8-40. GAS PRODUCER TACHOMETER c. Disconnect plug (P87) from tachometer tester
INDICATOR. (T90) and reconnect it to gas producer tachometer
and secure.
8-41. Description — Gas Producer Tachometer
Indicator. The gas producer tachometer, located on 8-48. Installation — Gas Producer Tachometer
the instrument panel, provides indication in percent Indicator. a. Refer to paragraph 8-7 for installation
rpm of the engine gas producer (first stage on N1 procedures.
turbine and compressor) by connection to a
synchronous generator, mounted on engine b. Perform N1 System accuracy check in ac-
accessory drive section. The indicator and generator cordance with TM 55-4920-401-13 & P.
circuit are independent of helicopter electrical power
system. 8-49. GAS PRODUCER TACHOMETER
GENERATOR.
8-42. Cleaning — Gas Producer Tachometer
Indicator. Refer to paragraph 8-3 for cleaning
procedure. 8-50. Description — Gas Producer Tachometer
Generator. The gas producer tachometer generator,
8-43. Inspection — Gas Producer Tachometer located on the right side of the engine on the
Indicator. Refer to paragraph 8-4 for inspection accessory drive gearbox, monitors the rpm of the gas
procedure. producer turbine and transmits voltage signals to
drive the gas producer tachometer indicator.
8-44. Troubleshooting — Gas Producer
Tachometer Indicator. Refer to paragraph 8-19; 8-51. Cleaning — Gas Producer Tachometer
procedures are the same. Generator. Refer to paragraph 8-24; procedures are
the same.
8-45. Removal — Gas Producer Tachometer
Indicator. Refer to paragraph 8-5 for removal 8-52. Inspection — Gas Producer Tachometer
procedure. Generator. Refer to paragraph 8-25; procedures are
the same.
8-46. Repair or Replacement — Gas Producer
Tachometer Indicator. Refer to paragraph 8-6 for 8-53. Troubleshooting — G a s P r o d u c e r
repair or replacement criteria. Tachometer Generator. Refer to paragraph 8-19
for troubleshooting.
8-47. Bench Test — Gas Producer Tachometer
Indicator (AVIM). a. Disconnect plug (P87) from gas 8-54. Removal – Gas Producer Tachometer
producer tachometer generator. Connect plug to the Generator. Refer to paragraph 8-27; procedures
MASTER GENERATOR output plug on the are the same.
tachometer tester (T90). Energize the test stand and
set controls according to the instructions on the cover 8-55. Repair or Replacement — Gas Producer
of the tester. Tachometer Generator. Refer to paragraph
8-28; procedures are the same.
b. Check that the gas producer tachometer
indicator indicates within tolerance of the various 8-56. Testing – Gas Producer Tachometer
check points in the following: Generator. Refer to paragraph 8-29; procedures
are the same.
TEST POINTS INDICATOR TOLERANCE 8-57. Installation – Gas Producer Tachometer

(RPM) (RPM) Generator. a. Refer to paragraph 8-30; procedures
are the same.
5% 5% ±1.00
20% 20% ± 1.25 b. Perform N1 System accuracy check in ac-
70% 70% ± 1.25 cordance with TM 55-4920-401-13 & P.
100% 100% ±1.00
8-7
TM 55-1520-210-23-2
8-58. ENGINE OIL PRESSURE IN- b. Connect variable pressure (0 -150 psi) tester
DICATING SYSTEM. (T10.1) to input line on engine oil pressure
transmitter.
8-59. Description — Engine Oil Pressure In-
dicating System. The engine oil pressure indicat- c. Energize main or standby inverter. Close 28V
ing system includes the engine oil pressure XFMR circuit breaker and ENG OIL PRESS circuit
indicator and the engine oil pressure transmitter. breaker.
The system is powered from the 28 vac bus, and is
protected by a 1 ampere engine oil pressure in- d. Apply pressure to the transmitter input
dicating circuit breaker. port while monitoring the engine oil pressure
indicator. Helicopters using T53-L-13 series en-
8-60. ENGINE OIL PRESSURE gines indicated pressure shall be 100 psi when
INDICATOR. applied pressure is 100 ± 5 psi.
8-61. Description — Engine Oil Pressure 8-65. Troubleshooting – Engine Oil Pressure
Indicator. The engine oil pressure indicator, located Indicator. Use table 8-2 and perform checks as
on the instrument panel, indicates engine oil necessary to isolate trouble. (See figure F-12.)
pressure in psi by means of the engine oil pressure
transmitter.
NOTE
8-62. Cleaning – Engine Oil Pressure Indicator.
Refer to paragraph 8-3 for cleaning procedures. Before using this table, be sure all normal
operational checks have b e e n
8-63. Inspection — Engine Oil Pressure Indicator. performed.
Refer to paragraph 8-4 for inspection procedure.
8-64. Functional Test – engine Oil Pressure

Indicator. a. Disconnect pressure line from the
engine oil pressure transmitter.
Table 8-2. Troubleshooting Engine Oil Pressure Indicator
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. Pressure indicator is reading low.
STEP 1. Check for kinked or obstructed pressure line.
Replace or clean obstructed Iine (paragraph 8-1).
2. Pressure indicator is inaccurate or sticking.
STEP 1. Determine if indicator is defective.
3. Pressure indicator has sluggish action.
STEP 1. Check for sludge in pressure line.
Bleed pressure line.
4. Pressure indicator is inoperative.
8-8 Change 2
TM 55-1520-210-23-2
Table 8-2. Troubleshooting Engine Oil Pressure Indicator (Cont)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
STEP 1. Determine if pressure indicator is defective.
STEP 2. Perform continuity check of circuit between transmitter and indicator.
Repair or replace electrical leads or wiring (paragraph 9-5).
5. Pressure indicator shows fluctuating pressure.
STEP 1. Check for loose electrical connections and determine if instrument is clamped too tight.
Tighten electrical connections or readjust clamp.
STEP 2. Ensure that correct restrictor (0.025 to 0.027 inch orifice) is installed in system.
Install correct restrictor (paragraph 8-77).
STEP 3. Restrictor orifice blocked or clogged.
Clean restrictor orifice.
8 - 6 6 . Removal — Engine Oil Pressure 8 - 7 1 . C l e a n i n g – Engine Oil Pressure

Indicator. Refer to paragraph 8-5 for removal Transmitter. a. Remove moisture and loose dirt with
procedure. a clean, soft cloth.
8-67. Repair or Replacement — Engine Oil

pressure Indicator. Refer to paragraph 8-6 for
repair or replacement criteria.
Dry cleaning solvent is flammable and its
8-68. Installation — Engine Oil Pressure In- fumes are toxic. provide adequate
dicator. Align engine oil pressure indicator so ventilation. Do not use near flame.
that 90 psi is at 9 o’clock for T53-L-13 engine. b. Remove oil, grease, fungus, and dirt with
Refer to paragraph 8-7 for installation proce- a clean, lint-free cloth dampened with dry
dure. cleaning solvent (C261).
8-69. ENGINE OIL PRESSURE TRANSMIT-
TER. c. Remove dirt from electrical connectors
with a soft bristle brush (C52).
8-70. Description — Engine Oil Pressure
Transmitter. The engine oil pressure transmitter, 8-72. Inspection — Engine Oil Pressure
located on top of the engine inlet section, monitors Transmitter. a. Inspect pressure transmitter for
engine oil pressure and transmits voltage signals to cracks, secure and proper mounting, and proper
the engine oil pressure indicator. operation.
8-9
TM 55-1520-210-23-2
b. Inspect oil line and fitting connection for leaks 8-77. Installation — Engine Oil Pressure
and proper installation. Transmitter.
c. Inspect electrical connector for damaged or

bent pins and cracked inserts.
8-73. Functional Test – Engine Oil Pressure

Check that correct restrictor (0.025
Transmitter.
TO 0.027 inch orifice) is installed at
NOTE oil filter.
a. Position transmitter in support and install
The pressure transmitter is functionally mounting nut. Remove protective cover from
tested during testing of the pressure transmitter and install elbow, nut and new pack-
indicator using variable pressure tester,
ing with elbow pointing up. Insure vented plug is
paragraph 8-64. The following electrical
installed in transmitter.
resistance check may be conducted on
the pressure transmitter independently, b. Remove protective covers and attach oil
line and electrical connector to transmitter. In-
from the pressure indicator.
stall cowling.
a. Using multimeter (T3 or equivalent), check
resistance between contacts of electrical receptacle 8 - 7 0 . ENGINE OIL TEMPERATURE
on top of transmitter. INDICATING SYSTEM.
b. Resistance should be approximately 10 ohms 8-79. Description — Engine Oil Temperature
Indicating System. The engine oil temperature
across contacts A to C and B to C, and approximately
indicating system includes the engine oil
20 ohms across contacts A to B.
temperature indicator and the engine oil temperature
8-74. Troubleshooting — Engine Oil Pressure bulb. The system is powered from the 28 Vdc
Transmitter. Refer to. paragraph 8-65 for essential bus and is protected by a 5 ampere ENG &
XMSN TEMP IND circuit breaker.
troubleshooting.
8-80. ENGINE OIL TEMPERATURE
8 - 7 6 . R e m o v a l – Engine Oil Pressure INDICATOR.
Transmitter. a. Remove cowling from engine.
8-81. Description – Engine Oil Temperature
b. Disconnect electrical connector. Discon- Indicator. The engine oil temperature indicator,
nect oil line from elbow. Place protective covers located on the instrument panel, indicates engine oil
over connector and oil line. Remove elbow, nut temperature in degrees Calsius by means of an
and, packing from transmitter. electrical resistance type temperature bulb.
c. Remove transmitter mounting nut. With-
draw transmitter from support and install protec- 8-82. Cleaning - Engine Oil Temperature
tive cover. Indicator. Refer to paragraph 8-3 for cleaning
8-76. Repair or Replacement – Engine Oil procedures.
Pressure Transmitter. a. Repair damaged electrical
connectors. 8-83. Inspection — Engine OiI Temperature
Indicator. Refer to paragraph 8-4 for inspection
b. Tighten loose oil line or fitting connection. procedure.
c. Replace defective or damaged oil line or

fitting. 8-84. Functional Test - Engine Oil Temperature
Indicator. a. Place BAT switch to ON. Close ENG &
d. Replace pressure transmitter if cracked or XMSN TEMP IND circuit breaker.
damaged.
b. Check that temperature indcator indicate
e. Reinstall improperly mounted pressure approximately ambient temperature.
transmitter.
8-10
TM 55-1520-210-23-2
NOTE
8-85. Troubleshooting — Engine Oil Temperature
Indicator. Use table 8-3 and perform checks as Before using this table, be sure all normal
necessary to isolate trouble (figure F-13). operational checks have been
performed.
Table 8-3. Troubleshooting Engine Oil Temperature Indicator.
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION.
1. Oil temperature indication off scale at low end, or low reading — constant or intermittent.
STEP 2. Perform continuity check from temperature bulb to indicator.
Repair or replace electrical leads or wiring (paragraph 9-5).
2. Oil Temperature indication off scale at high end, or high reading — either constant or intermittent.
STEP 1. Check for short circuit in temperature bulb
Replace temperature bulb if defective (paragraph 8-95).
STEP 2. Check for open circuit in temperature bulb or between temperature bulb and indicator.
Replace temperature bulb or repair electrical wiring (paragraph 8-95).
STEP 3. Check for defective indicator.
3. No indication on temperature indicator.
STEP 1. Ensure voltage is present on 28 Vdc bus and check for defective ENG & XMSN TEMP IND circuit
breaker.
Replace circuit breaker if defective (paragraph 9-12).
STEP 2. Check for open electrical wire from circuit breaker to indicator.
Repair electrical wiring.
8-11
TM 55-1520-210-23-2
8 - 8 6 . R e m o v a l – Engine Oil Temperature 8-89. Installation — Engine Oil Temperature

Indicator. Refer to paragraph 8-5 for removal Indicator. Align engine oil temperature indicator
procedure. so that 70°C is at 9 o’clock position. Refer to
paragraph 8-7 for installation procedure.
8-87. Repair or Replacement — Engine Oil
Temperature Indicator. Refer to paragraph 8-6 for
repair or replacement criteria. 8-90. ENGINE OIL TEMPERATURE BULB.
8 - 8 8 . T e s t i n g – Engine Oil Temperature 8-91. Description — Engine Oil Temperature

Indicator. (AVIM) a. Disconnect electrical plug in Bulb. The engine oil temperature bulb, installed in
back of oil temperature indicator. Remove indicator the engine oil pump housing is a resistance type
from instrument panel. Connect indicator to electric temperature bulb which monitors the engine oil
thermometer tester, field type (T91) using the temperature and transmits varying voltage signals to
appropriate adapter cable provided with the tester. the engine oil temperature indicator.
8-92. Cleaning – Engine Oil Temperature Bulb.

cloth.
Always be certain that the indicator is

connected before turning switch “7” to
the “24” volt position.
b. Check zero setting of the voltmeter “1” and Dry cleaning solvent is flammable and its
adjust if necessary. Turn switch “7” to the “24” volt fumes are toxic. Provide adequate
position. ventilation. Do not use near a flame.
c. Adjust pointer of voltmeter “1” to coincide b. Remove oil, grease, fungus, and dirt with a
with the red line at 28.50 volts by operating rheostat clean, lint-free cloth dampened with dry clean-
“5.”. Position switch “8” to the left and single ing solvent (C261).
position.
c. Remove dirt from electrical connectors
d. Set temperature selector switch “2” to with a soft bristle brush (C62).
temperature points in the “left inner scale” (90.38
ohms at zero degrees temperature). 8-93. Inspection — Engine Oil Temperature Bulb.
a. Inspect temperature bulb for cracks, leaks, security
e. Rotate switch “2” to required test points. Tap and proper mounting.
the indicator before taking a reading. The test points
and tolerances are listed in the following: b. Inspect electrical connector for damaged or
bent pins and cracked inserts.
INDICATOR 8-94. Troubleshooting - Engine Oil Temperature

TEST POINTS READING TOLERANCE Bulb. Refer to paragraph 8-85 for troubleshooting.
-70 -70° Celsius ±4 8-95. Removal – Engine Oil Temperature Bulb.

-30 -30° Celsius ±4 a. Cut Iockwire and disconnect electrical connector.
0 0° Celsius ±2
+30 30° Celsius ±2 b. Remove Iockwire and unscrew temperature
+80 80° Celsius ±2 bulb from oil manifold.
+120 120° Celsius ±3
+150 150° Celsius ±4 c. Remove gasket.
f. Turn switch “7” to the “OFF’ position and 8-96. Repair or Replacement – Engine Oil
disconnect indicator from tester. Install indicator in Temperature Bulb. a. Repair damaged electrical
instrument panel and check for security. connectors.
8-12
TM 55-1520-210-23-2
b. Replace damaged or worn gasket. (2) With a Whetstone bridge, measure the
resistance of the temperature bulb between pin A and
c. Replace temperature bulb if cracked or B. Ambient temperature test points and tolerances
damaged. are listed in the following :
8-97. Bench Test — Engine Oil Temperature

Bulb (AVIM). a. Resistance Check.
(1) Remove oil temperature bulb to be checked

and allow sufficient time to adjust to ambient
temperature.
AMBlENT TEMPERATURE RESISTANCE TOLERANCE

TEST POINT DEGREES (OHMS) (OHMS)
-20° Celsius (-4°F) 83.77 ± 0.4

-10° Celsius (14°F) 87.04 ± 0.4
0° Celsius (32°F) 90.38 ± 0.4
10° Celsius (50°F) 93.80 ± 0.4
20° Celsius (68°F) 97.31 ± 0.4
30° Celsius (86°F) 100.91 ± 0.4
40° Celsius (104°F) 104.60 ± 0.4
b. I n s u l a t i o n L e a k a g e T e s t . W i t h t h e 8-101. EXHAUST GAS TEMPERATURE

temperature bulb subjected to a 100 volt potential INDICATOR.
between any electrical pin and the bulb housing, the
minimum resistance shall be 5 megohms. Reinstall 8-102. Description — Exhaust Gas Temperature
temperature bulb Indicator. The exhaust gas temperature indicator,
located on the instrument panel, indicates exhaust
gas temperature in degrees Celsius. The indicator
8-98. Installation — Engine Oil Temperature operates on electrical potential from the engine
Bulb. a. Coat threads and gasket with lubricating oil thermocouple harness, mounted in the aft section of
(C169) when installing gasket on temperature the engine exhaust diffuser.
bulb.
b. Install temperature bulb and gasket in 8-103. Cleaning – Exhaust Gas Temperature
manifold. Indicator. Refer to paragraph 8-3 for cleaning
procedure.
c. Lockwire to adjacent bolt head on manifold.
8-104. Inspection — Exhaust Gas Temperature
d. Connect and Iockwire electrical connector. Indicator. Refer to paragraph 8-4 for inspection
procedure.
8-99. EXHAUST GAS TEMPERATURE 8-105. Functional Test — Exhaust Gas

INDICATING SYSTEM. Temperature Indicator. a. Connect and operate the
engine exhaust gas temperature tester (T3.1 ) in
accordance with TM 55-4920-244-14.
8-100. Description — Exhaust Gas Temperature
Indicating System. The exhaust gas temperature (1) Determine EGT indicator accuracy and
indicating system includes the exhaust gas adjust or replace as required.
temperature indicator and the thermocouple lead
spool resistor. The system is self-generating, (2) Establish circuit insulation to ground, and
operating on electrical potential from the engine confirm that thermocouple probes are operative.
thermocouple harness assembly.
8-13
TM 55-1520-210-23-2
(3) Perform EGT circuit resistance check, and (2) Troubleshoot as necessary, using exhaust
adjust thermocouple lead spool resistor to obtain 8 ± gas temperature tester to isolate causes of error.
0.05 ohms (paragraph 8-117).
NOTE 8-106. Troubleshooting — Exhaust Gas

Temperature Indicator. Use table 8-4 and perform
Engine EGT tester and helicopter checks as necessary to isolate trouble (figure F-14.)
instrument must be at same ambient
temperature for accurate check.
NOTE
b. Perform functional check of EGT circuit.
Before using this table, be sure all normal
(1) EGT system error must not exceed ± operational checks have been
10° Celsius at test temperature (600° Celsius). performed.
Table 8-4. Troubleshooting Exhaust Gas Temperature Indicator
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. EGT indicator reads high or low.
STEP 1. Perform functional test of EGT indicator (paragraph 8-105).
Replace indicator if defective (paragraph 8-1). Adjust thermocouple lead spool resistor to obtain
correct resistance. Replace thermocouple lead spool resistor if circuit resistance is less than 7.95
ohms (paragraph 8-117).
2. EGT indicator fails to indicate.
STEP 1. Troubleshoot EGT wiring. (See figure F-14.)
Replace defective wiring (paragraph 9-5).
STEP 2. Perform functional test of EGT indicator (paragraph 8-105).
Replace indicator if defective (paragraph 8-1). Adjust thermocouple lead spool resistor to obtain
correct resistance (paragraph 8-117).
8-107. Removal — Exhaust Gas Temperature terminals and preclude violent needle
Indicator. Refer to paragraph 8-5 for removal movements and damage by static
procedure. electricity. Instrument internal
components are easily damaged,
rendering t h e i n s t r u m e n t o u t o f
calibration or inoperative. Do not replace
washers on instrument terminal posts, as
When removing exhaust gas temperature they are of special material. Replacing
gage, place a short piece of wire across them with standard washers will cause a
the terminal posts. This will ground the faulty EGT indication.
8-14
TM 55-1520-210-23-2
8-108. Repair or Replacement – Exhaust Gas a. Apply millivoltage to the indicator terminals
Temperature Indicator. Refer to paragraph 8-6 for for each test point as specified in table 8-5 for the
repair or replacement criteria. prevailing ambient temperature. The millivoltage
shall be applied to the indicator through a series
external circuit resistance of 8 ± 0.05 ohms. The
8-109. Bench Test – Exhaust Gas Temperature
millivoltage applied shall be measured with a
Indicator (AVIM).
potential measuring instrument having a minimum
accuracy of 0.2 percent and a minimum readability of
NOTE 0.2 percent.
Prior to bench test, the indicator shall be b. Tap the indicator slightly after each reading.
subjected to a constant room The difference in reading after tapping shall be
temperature for a period of not less than considered friction error. Refer to table 8-6 for scale
one hour. error and friction error tolerances.
Table 8-6. Millivolts vs Temperature
AMBlENT INDICATOR TEST POINT °Celsius

TEMPERATURE MILLIVOLTS
°Celsius 500 600 700 800 900 1,000
10 20.24 24.50 28.74 32.91 36.96 40.91
15 20.04 24.30 28.54 32.71 36.76 40.71
20 19.84 24.10 28.34 32.51 36.56 40.51
25 19.64 23.90 28.14 32.31 36.36 40.31
30 19.44 23.70 27.94 32.11 36.16 40.11
35 19.24 23.50 27.74 31.90 35.96 39.90
NOTE: For intermediate ambient temperatures, subtract

0.04 mv for each °Celsius above the next lower ambient
temperature.
Table 8-6. EGT Indicator Scale and Friction Error Tolerances Plus or Minus °Celsius
TEST POINTS °CELSIUS SCALE ERROR FRICTION
500 20 30
600 10 30
700 5 30
800 10 30
900 20 30
1,000 30 30
8-15
TM 55-1520-210-23-2
8-110. Installation - Exhaust Gas Temperature a. Check total circuit lead resistance by using
Indicator. Refer to paragraph 8-7 for installation an EGT analyzer (T3.1) connected to the indicator
procedure. leads (indicator disconnected and engine fur-
NOTE nished harness connected). Resistance should
read 8 ohms plus or minus 0.05 ohm. Replace
Replacement of exhaust gas tempera-
thermocouple spool resistor if reading is less than
ture indicator requires a function test
7.95 ohms.
in accordance with paragraph 8-105.
NOTE
8-111. THERMOCOUPLE LEAD
SPOOL RESISTOR. Visually inspect engine thermocouples
for damage, clean all circuit connec-
8-112. Description – Thermocouple Lead Spool tors and re-check circuit resistance
Resistor. The thermocouple lead spool resistor
prior to adjusting or replacing spool.
provides a means of adjusting the resistance within
the EGT circuitry to calibrate the EGT indicator.
8-113. Cleaning — Thermocouple Lead Spool b. Adjust resistance by removing short lengths of
Resistor. Remove moisture and dirt from cover with a wire from the resistance spool. (Reference paragraph
clean, lint-free cloth. 8-120.b).
8-114. Inspection — Thermocouple Lead Spool
8-118. Removal – Thermocouple Lead spool
Resistor. Inspect resistor for loose connections,
Resistor. a. Remove cover.
corrosion, broken wires, broken terminals, and
damage to cover or cover fasteners. b. Remove alumel lead to resistor.
8-116. Functional Test – Thermocouple Lead c. Unsolder resistor spool lead and remove
Spool Resistor. Refer to paragraph 8-105 for spool.
functional test procedure. 8-119. Repair or Replacement — Thermocouple
Lead Spool Resistor. a. Tighten loose connections.
8-116. Troubleshooting – Thermocouple Lead
Spool Resistor. Refer to paragraph 8-106 for b. Replace or repair damaged cover.
troubleshooting. c. Replace spool resistor if wires are broken or
8-117. Adjustment - Thermocouple Lead Spool corroded.
Resistor. d. Replace spool resistor if circuit resistance is
less than 7.95 ohms.
8-120. Installation – Thermocouple Lead Spool
Resistor.
NOTE
New spool resistors have only one end of
the winding soldered to a terminal. The
To maintain proper accuracy, use only an
other end is free to permit adjustment.
EGT analyzer when making resistance
adjustment. a. Position resistor spool in place, solder lead to
spool terminal and attach alumel lead to resistor lug.
b. Scrape off insulation at free end of wire.
Touch bare wire to other terminal and check circuit
NOTE
resistance.
(1) If circuit resistance is 7.95 to 8.05 ohms,
The EGT indicator is calibrated to give
solder bare wire to terminal.
accurate temperature readings when the
circuit resistance is 8 ohms. Adjustment (2) If circuit resistance exceeds 8.05 ohms,
of spool resistor may be required when unsolder end of resistor winding. Unwind a turn or
engine or thermocouple harness is two of wire at a time and scrape off insulation. Touch
replaced. A d j u s t m e n t c a n a l s o bare wire to the terminal and check circuit resistance.
compensate for change in thermocouple When resistance of 7.95 to 8.05 ohms is indicated,
harness resistance (resistance increases cut the wire and solder to terminal.
with time in service). See paragraph 8- (3) If circuit resistance is less than 7.95 ohms,
105 for resistance check. replace spool resistor and repeat preceding steps a
and b.
c. Install cover.
8-16 Change 2
TM 55-1520-210-23-2
8-121. FUEL PRESSURE INDICATING 8-126. Inspection — Fuel Pressure Indicator.

SYSTEM. Refer to paragraph 8-4 for inspection procedure.
8-127. Functional Test — Fuel Pressure

Indicator. a. Energize main inverter by placing INV
8-122. Description — Fuel Pressure Indicating
switch to MAIN.
System. The fuel pressure indicating system
includes the fuel pressure indicator and the fuel
b. Close FUEL PRESSURE IND circuit breaker.
pressure transmitter. The system is powered by the
28 Vac bus, and is protected by a one ampere FUEL
c. Disconnect the fuel pressure line from fuel
PRESSURE lND circuit breaker.
pressure transmitter. Using variable pressure tester
(T10.1), apply pressure while monitoring pilots fuel
pressure indicator. Indicated pressure shall be 50 ± 7
8-123. FUEL PRESSURE INDICATOR. psi when applied pressure is 50 psi.
d. Open FUEL PRESSURE IND circuit breaker

and reconnect the fuel pressure lines.
8-124. Description — Fuel Pressure Indicator.
The fuel pressure indicator, located on the instrument 8-128. Troubleshooting — Fuel Pressure
panel, provides indication in psi of pressure in the Indicator. Use Table 8-7 and perform checks as
main fuel supply line by means of an electrical fuel necessary to isolate trouble. (figure F-12.)
pressure transmitter.
NOTE
8-125. Cleaning — Fuel Pressure Indicator. Refer operational checks have been
to paragraph 8-3 for cleaning procedures. performed.
Table 8-7. Troubleshooting Fuel Pressure Indicator
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. Pressure indicator is reading low.
Replace or clean obstructed line.
3. Pressure indicator is inoperative.
8-17
TM 55-1520-210-23-2
Table 8-7. Troubleshooting Fuel Pressure Indicator (Cont)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
Repair or Replace electrical leads.
STEP 3. Perform functional test (paragraph 8-127) to determine if pressure transmitter is defective.
Replace defective pressure transmitter (paragraph 8-132).
4. Pressure indicator shows fluctuating pressure indication.
Tighten electrical connections or readjust clamp.
Replace defective pressure transmittal (paragraph 8-1).
8-129. Removal — Fuel Pressure Indicator. Refer b. Remove oil, grease, fungus, and dirt with a
to paragraph 8-5 for removal procedures. clean, lint-free cloth dampened with dry cleaning
solvent (C261).
8-130. Repair or Replacement — Fuel Pressure
Indicator. Refer to paragraph 8-6 for repair or c. Remove dirt from electrical connectors with a
replacement criteria. bristle brush (C52).
8-131. Installation — Fuel Pressure Indicator. 8-136. Inspection — Fuel Pressure Transmitter.
Refer to paragraph 8-7 for installation procedure. a. Inspect pressure transmitter for cracks, secure and
proper mounting, and proper operation.
8-132. FUEL PRESSURE TRANSMITTER. b. Inspect fuel line and fitting connection for
leaks and proper installation.
8-133. Description – Fuel Pressure Transmitter. c. Inspect electrical connector for damaged or
The fuel pressure transmitter, mounted on right bent pins and cracked inserts.
engine deck level just ahead of forward firewall,
monitors pressure in the main fuel supply line and 8-136. Functional Test – Fuel Pressure
transmits voltage signals to the fuel pressure Transmitter. Refer to paragraph 8-127 for functional
indicator (paragraph 8-123). test.
8-134. Cleaning — Fuel Pressure Transmitter. a. 8-137. Troubleshooting — Fuel Pressure
Remove moisture and loose dirt with clean, soft cloth. Transmitter. Refer to paragraph 8-128 for
troubleshooting.
8-138. Removal - Fuel Pressure Transmitter. a.
Open right aft pylon access door to gain access to
pressure transmitter.
fumes are toxic. Provide adequate b. Cut Iockwire and disconnect electrical
ventilation. Do not use near a flame. connector from transmitter.
8-18
TM 55-1520-210-23-2
c. Disconnect pressure hose from transmitter 8-147. Functional Test—Torque Pressure Indica-
mount. tor.
d. Remove four screws and washers from transmit- a. Disconnect pressure line from the torque pres-
ter mount. sure transmitter.
e. Remove transmitter. b. Connect variable pressure (0-150 psi) tester

(T10.1) to input line on torque pressure transmitter.
8-139. Repair or Replacement—Fuel Pressure c. Energize main or standby inverter. Close 28V
Transmitter. XFMR circuit breaker and TORQUE PRESSURE IND
circuit breaker.
a. Repair damaged electrical connectors.
d. Apply pressure to the transmitter input port moni-
b. Tighten loose fuel line or fitting connection. toring the torque pressure indicator. Vary torque pres-
sure from 0 to 60 psi in increments of 10 psi. The toler-
c. Replace defective or damaged fuel line or fitting.
ance for each pressure is shown in the table below. The
d. Replace pressure transmitter if cracked or dam- indicated pressure should not exceed the applied pres-
aged. sure +/- the tolerance at room temperature.
e. Reinstall improperly mounted pressure transmit- Test Pressure (PSI) Tolerance (+/- PSI)
ter. 0 1.0
10 1.0
8-140. Installation—Fuel Pressure Transmitter.
20 1.0
a. Install transmitter in mount using four screws and 30 1.0
four washers.
40 1.0
b. Connect fuel pressure hose to union and connect 50 1.0
electrical connector and lockwire. 60 1.0
c. Close access door.
NOTE
8-141. TORQUE PRESSURE INDICATING SYSTEM. The following Torque Pressure Indicator/
Torque Pressure Transmitter combina-
8-142. Description—Torque Pressure Indicating tions are required for Torque System ap-
System. The torque pressure indicating system in- plications: Calibrated gage must be used
cludes the torque pressure indicator (paragraph 8-143) to check the system at intervals listed
and torque pressure transmitter (paragraph 8-152). The above.
system is powered from the 28 Vac bus, and is protected (1) Edison Transmitter with Edison Indicator.
by a 1 ampere TORQUE PRESSURE IND circuit break-
er. (2) Edison Transmitter with Courter Indicator.
(3) Edison Transmitter with General Aero Prod-
8-143. TORQUE PRESSURE INDICATOR. ucts Indicator.
(4) Bendix Transmitter with Edison Indicator.
8-144. Description—Torque Pressure Indica-
tor. The torque pressure indicator, mounted in the in- (5) Bendix Transmitter with Courter Indicator.
strument panel, indicates engine output shaft torque
pressure in psi by means of the torque pressure transmit- 8-148. Troubleshooting—Torque Pressure Indica-
ter (paragraph 8-152). tor. Use table 8-8 and perform checks as necessary to
isolate trouble (figure F-12).
8-145. Cleaning—Torque Pressure Indicator. Refer NOTE
to paragraph 8-3 for cleaning procedure. Before using this table, be sure all normal
operational checks have been performed.
8-146. Inspection—Torque Pressure Indicator. Re- Calibrated gage must be used to check the
fer to paragraph 8-4 for inspection procedure. system at intervals listed above.
Change 14 8-19
TM 55-1520-210-23-2
Table 8-8. Troubleshooting Torque Pressure lndicator
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
STEP1. Determine if indicator is defective.
Replace indicator if defective (paragraph 8-1 and 8-147).
2. Pressure indicator has sluggish action.
STEP 1. Check for sludge in pressure line.
Bleed pressure line.
3. Pressure indicator is inoperative or reading low.
Replace indicator if defective (paragraph 8-1 and 8-147).
Repair or replace electrical Ieads.

Replace or clean obstructed Iine.
STEP 4. Perform functional check (paragraph 8-147) to determine if pressure transmitter is defective.
STEP 6. Determine if pressure metering valve is defective.

Refer to TM 55-2840-229-23.
STEP 6. Determine if inverter voltage output is correct. Check voltage output to indicator.
4. Pressure indicator shows fluctuating pressure indication.
Tighten eIectrical connections or readjust clamp.
STEP 2. Ensure that correct restrictor (0.025 to 0.027 orifice) is installed in system.
Install correct restrictor (paragraph 8-160).
STEP 3. Restrictor orifice blocked or clogged.
Clean restrictor orifice.
8-20
TM 55-1520-210-23-2
Table 8-8. Troubleshooting Torque Press lndicator (Cont)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
8-149. Removal — Torque Pressure Indicator, 8-155. Inspection — Torque Pressure

Refer to paragraph 8-5 for removal procedure. Transmitter. a. Inspect pressure transmitter for
cracks, secure and proper mounting, and proper
8 - 1 5 0 . Repair or Replacement — Torque operation.
Pressure Indicator. Refer to paragraph 8-6 for repair
or replacement criteria. b. Inspect oil line and fitting connection for
leaks and proper installation.
8-151. Installation — Torque Pressure Indicator.
Refer to paragraph 8-7 for installation p r o c e - c. Inspect electrical connector for damaged or
dure. Perform functional test, paragraph 8-147. bent pins and cracked inserts.
8-152. TORQUE PRESSURE 8-156. Functional Test — Torque Pressure

TRANSMITTER. Transmitter. Refer to paragraph 8-147 for functional
test.
8 - 1 5 3 . Description — Torque pressure
Transmitter. The torque pressure transmitter, 8-157. Troubleshooting — Torque pressure
mounted on a bracket on the right side of the engine, Transmitter. Refer to paragraph 8-148 for
monitors engine output shaft torque and transmits troubleshooting.
varying voltage signals to the torque pressure
indicator (paragraph 8-143). ..
8-158. Removal — Torque Pressure Transmitter.
8-154. Cleaning — Torque Pressure Transmitter. a. Open upper right engine cowling.
cloth. b. Disconnect electrical connector and oil line
from pressure transmitter.
c. Cap opening of oil line. Protect electrical

connector with electrical tap (C142).

fumes are toxic. Provide adequate d. Cut Iockwire, remove jam nut and remove
ventilation. Do not use near a flame. pressure transmitter from mounting bracket.
b. Remove oil, grease, fungus, and dirt with a

clean lint-free cloth dampened with dry cleaning 8 - 1 5 9 . Repair or Replacement — Torque
solvent (C261). Pressure Transmitter. a. Repair damaged electrical
connectors.
c. Remove dirt from electrical connectors with a
soft bristle brush (C52). b. Tighten loose oil line or fitting connection.
8-21
TM 55-1520-210-23-2
c. Replace defective or damaged oil line or NOTE

fitting.
Refer to paragraph 4-147 for
d. Replaced pressure transmitter if cracked or proper placement of u n i o n .
damaged. a. Position pressure transmitter onto
mounting bracket, install jamnut. Install lock-
e. Reinstall pressure transmitter. wire.
b. Remove protective covers and con-
8-160. Installation - Torque Pressure nect oil line and electrical connector to
Transmitter. pressure transmitter. Install cowling.
Check that correct restrictor (0.025 TO

0.027 Inch orfice) is installed in torque
pressure port of engine (right side)
prior to connecting oil pressure line to
the forward end of transmitter.
SECTION Ill. FLIGHT INSTRUMENTS
8-161. FLIGHT INSTRUMENTS. 8-165. Cleaning — Pitot-Static System, a. Pitot-

8-162. Description — Flight Instruments. Static Lines, Tubing, and Fittings.
Flight instruments include the pitot-static
system, airspeed indicator, barometric altim- (1) Disconnect pitot and static lines from
eter, attitude indicating system, turn and slip airspeed indicators. Disconnect static lines from
indicator, clock and radar altimeter, and ver- altimeters and vertical velocity indicator. Cap
tical velocity indicator. openings to prevent entrance of foreign
material.
8-163. PITOT-STATIC SYSTEM.
NOTE
E x c e p t f o r t h e u s e o f s y s t em (2) Remove drain cap(s) and blow all lines
clean with filtered, compressed air.
drain, a functional check of the
pitot static system and pitot stat- (3) U n c a p o p e n i n g s i n i n s t r u m e n t s .
ic instruments will be performed Apply silicone compound (C260) to threads
following any opening and clos- of nuts and fittings and reconnect all lines.
ing of the pitot static system.
8-164. Description — Pitot Static. System. The (4) Install drain cap(s).
pitot-static system consists of the electrically heated
pitot tube, two static ports, pitot and static drains, and (5) P e r f o r m functional tests (para-
pitot and static lines and tubing necessary to connect graph 8-218.2).
to airspeed indicators, altimeters, and vertical
velocity indicator. The pitot tube, which has a heating b. Pitot Tube.
element for icing conditions, is located on forward left
side of cabin nose, or top right hand side of cabin roof.
Static air pressure vents are located just forward of
each crew door, with piping to altimeters, vertical
velocity indicators, and airspeed indicators. Dry cleaning solvent is flammable and its
Helicopters having pitot tube installed in roof have fumes are toxic. Provide adequate
static port incorporated into pitot head (figure 8-1) ventilation. Do not use near flame.
NOTE (1) Clean pitot tube head with a clean,
lint-free cloth dampened with dry cleaning
Pitot tube is mounted on cabin roof on solvent (C261).
helicopters Serial No. 66-746 and
subsequent, and on nose on helicopters
prior to Serial No. 66-746.
8-22
TM 55-1520-210-23-2
(2) Clean mount with a clean, lint-free cloth b. Pitot Tube.

dampened with dry cleaning solvent (C205).
(1) Inspect pitot tube for clogged or obstructed
inlet opening, and clogged drain hole on bottom of
8-166. Inspection — Pitot-Static System. tube.
a. Pitot-Static Lines, Tubing, and Fittings.
(2) Inspect pitot tube for cracks or damage.
(1) Inspect lines, tubing, and fittings for leaks, (3) If pitot tube head is removed, inspect
chafing, crimping, or other visible damage. electrical receptacle, pins, and sockets for damage.
c. Operational Check.
(2) Inspect system for improperly installed
fittings and clamps. (1) Close PITOT TUBE HEATER circuit breaker.
(3) Inspect static pressure vents to ensure that (2) Position pitot heater switch (S9) to ON and
they are clean and free of foreign matter that may check that pitot tube heating element is energized.
obstruct airflow. Return switch (S9) to OFF.
Figure 8-1. Instrument Piping (Roof-Mounted Pitot Tube) (Sheet 1 of 2)
8-23
TM 55-1520-210-23-2
Figure 8-1. Instrument Piping (Nose-Mounted Pitot Tube) (Sheet 2 of 2)
8-167. Functional Test — Pitot-Static System. (3) Remove pitot and static lines.
Perform functional test. Refer to paragraph
8-218.2. b. Pitot Tube.
8-168. Troubleshooting — Pitot-Static System. (1) Check that system electrical power is OFF.
Refer to applicable portions of tables 8-9, 8-10, 8-13
and perform checks as necessary to isolate trouble. (2) Gain access to pitot tube. Access is
obtained through overhead console if pitot tube is roof
mounted and through nose compartment if pitot tube
8-169. Removal — Pitot-Static System. a. Pitot- is nose mounted.
Static Lines, Tubing, and Fittings.
(3) From inside the helicopter, remove the
(1) Disconnect pitot and static lines from clamps securing the pitot line and pitot heater
indicators. Cap openings in indicators to prevent electrical wires.
entrance of foreign material.
(2) Disconnect applicable fittings and clamps. (4) Disconnect tube assembly(s) and install
protective caps on open ends of fittings.
8-24
TM 55-1520-210-23-2
(5) From outside the helicopter, remove the (2) Apply silicone compound (C250) to threads of
screws and Iockwashers attaching pitot tube head to coupling.
support.
(3) Connect pitot line coupling to adapter.
(6) Carefully pull pitot tube from support to expose
electrical connector and pitot line coupling. Discon- (4) Connect electrical connector to pitot tube con-
nect electrical connector. Disconnect coupling from nector.
adapter. Cap open adapter and tape electrical con-
nector to prevent entrance of foreign material. (5) On roof mounted pitot tubes only, apply seal-
ant (C244). Carefully position pitot tube into support
8-170. Repair or Replacement-Pitot-Static Sys- and install mounting screws and Iockwashers.
tem. a. Pitot-Static Lines, Tubing, and Fittings.
(6) From inside helicopters, remove protective
(1) Replace defective or damaged pitot and static caps from fittings. Apply silicone compound (C250) to
lines or tubing threads of nuts and fittings, and connect.
(2) Tighten or properly install fittings and clamps (7) Install pitot line clamp and electrical clamp
(3) Replace defective or damaged fittings or

clamps. 8-172. AIRSPEED INDICATOR.
b. Pitot Tube. 8-173. Description—Airspeed Indicator. The air-

speed indicator, located on the instrument panel, is a
(1) Replace pitot tube if inlet opening is closed or standard pitot-static instrument. The single-scale indi-
obstructed, drain hole is clogged, or electrical connec- cator provides airspeed indication in knots by measur-
tor is damaged. ing differences between impact air pressure from the
pitot tube and atmospheric pressure from the static
(2) Replace pitot tube it cracked or damaged to pressure port(s).
the extent it would restrict impact air pressure.
(3) Replace defective or damaged pitot electrical 8-174. Cleaning—Airspeed Indicator. Refer to
connector. paragraph 8-3 for cleaning procedure.
(4) Tighten or properly install fittings.

8-175. Inspection—Airspeed Indicator. Refer to
6-171. Installation—Pitot-Static System. a. Pi- paragraph 8-4 for inspection procedure.
tot-Static Lines, Tubing, and Fittings.
8-176. Functional Test—Airspeed Indicator. Re-
(1) Route pitot and static lines in place through
clamps. Apply silicone compound (C195) to threads of speed indicator.
nuts and fittings and connect all lines.
(2) Apply silicone compound (C250) to threads of 8-177. Troubleshooting—Airspeed Indicator.

tubing nuts and fittings. Position tubing in place and Use table 8-9 and perform checks as necessary to
connect. Install clamps. isolate trouble (figure 8-1).
(3) Conduct functional test of system. (Refer to

NOTE
paragraph 8-218.2.
Before using this table, be sure all normal op-
b. Pitot Tube.
erational checks have been performed.
(i) At pitot tube support, remove protective cap
from adapter and remove tape from electrical connec-
tor.
Change 4 8-25
TM 55-1520-210-23-2
Table 8-9. Troubleshooting - Airspeed Indicator.
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. Pointer fails to respond.
Determine if pitot or static lines are improperly connected or disconnected (paragraph 8-166).
Connect line(s).
2. Pointer indicates incorrectly.
STEP 1. Determine if lines are clogged.
Open drain(s), disconnect and blow lines clear (paragraph 8-165).
STEP 2. Perform functional test (TM 1-1500-204-23-4).
Replace defective indicator or lines (paragraph 8-1).
8-178. Removal - Airspeed Indicator. Refer to has electronic circuitry to provide digital information to
paragraph 8-5 for removal procedure. the IFF equipment. Refer to TM 11-1520-210-20 for
additional information.
8-179. Repair or Replacement-Airspeed Indica-
tor. Refer to paragraph 8-6 for repair or replacement 8-183. Cleaning - Barometric Altimeter. Refer to
criteria. paragraph 8-3 for cleaning procedure.
8-180. Installation - Airspeed Indicator. Refer to 8-184. Inspection - Barometric Altimeter. Refer
paragraph 8-7 for installation procedure. to paragraph 8-4 for inspection procedure.
8-181. BAROMETRIC ALTIMETER. 8-185. Functional Test - Barometric Altimeter.

Refer to paragraph 8-218.2 for functional test of
8-182. Description - Barometric altimeter. The altimeter. AIMS altimeters, if installed, require a mini-
barometric altimeter, located on the instrument panel, mum of one minute warm up before testing and setting.
furnishes direct readings of helicopter height in feet
above sea level. The altimeter is connected through 8-186. Troubleshooting - Barometric Altimeter.
piping to static pressure port(s) to sense atmospheric Use table 8-10 and perform checks as necessary to
pressure. An external adjustment knob is provided to isolate trouble (figure 8-1).
make compensation for variations of prevailing baro-
metric pressure. NOTE
Some helicopters have a type AAU-31 or a type Before using this table, be sure all nor-
AAU-32 barometric altimeter installed instead of the mal operational checks have been per-
standard type AAU-8/A installation. The type AAU-32 formed.
8-26 Change 7
TM 55-1520-210-23-2
Table 8-10. Troubleshooting – Barometric Altimeter
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. Pointer fails to respond.
Determine if static lines are improperly connected or disconnected (paragraph 8-166).
Connect Iine(s).
2. Pointer indicates incorrectly.
STEP 1. Determine if lines are clogged.
Open drain(s), disconnect and blow lines clear (paragraph 8-165).
STEP 2. Perform functional test (TM 55-1500-204-25/1) .
Replace defective indicator or lines (paragraph 8-1).
8 - 1 8 7 . Removal – Altimeter. Refer to Refer to TM 11-1520-210 series maintenance

paragraph 8-5 for removal procedure. manuals for information and procedures per-
8 - 1 8 8 . Repair or Replacement — taining to the roll and pitch gyro.
Altimeter. Refer to paragraph 8-6 for repair or
replacement criteria.
8-189. Installation — Altimeter. Refer to C A U T I O N
paragraph 8-7 for installation procedure. To avoid possible damage to the MD-1
displacement gyroscope, do not move
8-190. ATTITUDE INDICATING the helicoptor for twenty-five minutes
SYSTEM. after removing power from the
NOTE gyrocompass system. If the helicopter
must be moved within twenty-five
The source of data to drive the pi- minutes after shutdown, reapply power
lot’s attitude indicator is selected to the MD-1 displacement gyroscope for
by the. Attitude Indicator Switch. 5 minutes prior to moving.
The sources are the ASN-86 (INS)
and the MD-1 Attitude Gyro. 8-192. ATTITUDE INDICATORS.
8-191. Description — Attitude Indicating 8-193. Description – Attitude Indicators. The
System. The attitude indicating system in- pilots and copilots attitude indicators, mounted in the
cludes the pilots and copilots attitude indica- instrument panel, display flight attitude of the
helicopter relative to the earth. Pitch attitude is
tors and roll and pitch gyro. On helicopters
indicated by motion of the sphere with respect to the
prior to Serial No. 65-9565, the indicator
miniature airplane. Roll attitude is indicated by
amplifier is separate from the pilots attitude motion of the roll pointer with respect to the fixed roll
indicator and is located in the nose compart- scale located at the top of the display. The indicator
ment. The system is powered from the 115V ac sphere can be adjusted to zero indication by the pitch
bus and pilots and copilots indicators are each trim knob and roll trim knob. The copilots attitude
protected by two 1 ampere circuit breakers. indicator contains a PULL TO CAGE knob to cage and
8-27
TM 55-1520-210-23-2
release the self-contained gyro. The power OFF flag axes remain stable. Open PILOT ATTD circuit break-
is energized (out of view) by a tap on the power supply. ers and turn spare inverter off.
Any interruption of indicator power will indicate a failure
b. Copilots Attitude Indicator.
and the flag will be exposed.
8-194. Cleaning - Attitude Indicators. Refer to
paragraph 8-3 for cleaning procedure.
C A U T I O N
8-195. Inspection - Attitude Indicators Refer to
paragraph 8-4 for inspection procedure. The co-pilot attitude indicator should be
8-196. Functional Check - Attitude Indicators. caged and held momentarily as inverter
power is appiled.
a. Pilots Attitude Indicator (Type IND-A5-UH1).
(1) Prior to main inverter turn on, pull out PULL
(1) Energize main inverter and close both
TO CAGE knob on co-pilot attitude indicator. Turn
PILOT ATTD circuit breakers. Check that OFF flag
main inverter on and dose both co-pilot attitude circuit
(power warning) disappears within two minutes, and
breakers. Check that OFF flag (power warning) disap-
that the display erects properly and remains stable in
pears. Release PULL TO CAGE knob. The gyro
both pitch and roll.
should cage and release, settling to a proper display in
both pitch and roll.
(2) Rotate roll trim knob (on upper right side of
indicator) to its clockwise limit. Check that bank index
(2) Rotate pitch trim knob to its clockwise limit.
pointer moves left, indicating 8 to 20 degrees.
Check that deflection of the miniature airplane is
approximately 15 degrees downward.
(3) Rotate roll trim knob to its counterclockwise
limit. Check that bank index pointer moves right, indi-
(3) Rotate pitch trim knob to its countercloc-
cating 8 to 20 degrees. Return roll trim knob to zero kwise limit. Check that deflection of the miniature air-
trim. plane is approximately 10 degrees upward. Return
pitch trim knob to zero trim.
(4) Rotate pitch trim knob (on lower right side of
indicator) to its clockwise limit. Check that indicator (4) Turn main inverter off and open COPILOT
(miniature airplane) shall indicate 5 to 20 degrees drive ATTD circuit breakers.
(down).
8-197. Troubleshooting - Attitude Indicators
(5) Rotate pitch trim knob to its counterclock- Use table 8-11 and perform checks as necessary to
wise limit. Check that indicator (miniature airplane) isolate trouble (figure F-16).
shall indicate 5 to 20 degrees climb (up). Return pitch
trim knob to zero trim. NOTE
(6) Turn main inverter off, and, after a few Before using this table, be sure all
seconds delay, turn spare inverter on. Check that dis- normal operational checks have been
play remains properly erected, and that pitch and bank performed.
Table 8-11. Troubleshooting - Attitude Indicators
CONDITION
TEST OR INSPECTION
Corrective ACTION
1. Indicator does not operate.
STEP 1. Conduct continuity test of circuit to determine if wiring is defective.
Repair or replace defective wiring.

Replace defective indicator (paragraph 8-1 and 8-196).
8-28 Change 7
TM 55-1520-210-23-2
8-198. Removal — Attitude Indicators. Refer to para- 8-203. Cleaning — Turn and Slip Indicator. Refer to
graph 8-5 for removal procedure. paragraph 8-3 for cleaning procedure.
8-199. Repair or Replacement — Attitude Indica- 8-204. Inspection — Turn and Slip Indicator. Refer to
tors. Refer to paragraph 8-6 for repair or replacement paragraph 8-4 for inspection procedure.
criteria.
a. Inspect for obvious defects.
8-200. Installation — Attitude Indicators. Refer to b. Repair minor defects.
paragraph 8-7 for installation procedure.
c. Replace if defect is major or cannot be repaired.
8-201. TURN AND SLIP INDICATOR.
d. Replace if pilot reports major defect.
8-202. Description — Turn and Slip Indicator. The
turn and slip indicator, located on the instrument panel, 8-205. Functional Test — Turn and Slip Indicator.
is controlled by an electrically actuated gyro. This instru- a. Close TURN & SLIP IND circuit breaker.
ment has a needle (turn indicator) and a ball (slip indica-
tor). Although the needle and ball are combined in one b. Check that indicator gyro is running.
instrument and are normally read and interpreted togeth-
er, each has its own specific function, and operates inde- 8-206. Troubleshooting — Turn and Slip Indica-
pendently of the other. The ball indicates when the heli- tor. Use table 8-12 and perform checks as necessary to
copter is in directional balance, either in a turn or in isolate trouble. (See figure F-13).
straight and level flight. If the helicopter is yawing or
slipping, the ball will be off center. The needle indicates NOTE
in which direction and at what rate the helicopter is turn- Before using this table, be sure all normal
ing. operational checks have been performed.
Table 8-12. Troubleshooting — Turn and Slip Indicator
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. Pointer remains centered, either constantly or intermittently.
STEP 1. Determine if gyro is sticking.
Replace defective indicator (paragraph 8-1).
STEP 2. Conduct continuity test of circuit to determine if wiring defective.
Replace defective wiring or connectors (paragraph 9-5).
2. Ball too sensitive.
Determine is damping fluid has leaked out of indicator.
8-207. Removal — Turn and Slip Indicator. Refer to a. Inspect for obvious defects.
paragraph 8-5 for removal procedure.
b. Repair minor defects.
8-208. Repair or Replacement — Turn and Slip Indi-
cator. Refer to paragraph 8-6 for repair or replacement c. Replace if defect is major or cannot be repaired.
criteria. Check the turn part of the instrument is calibrated
d. Replace if pilot reports major defect.
to a four minute turn, this checked by the pilot if judged
to be inaccurate or inoperative by said pilot replace and
send for recalibration/repair. The basic maintenance for 8-209. Installation — Turn and Slip Indicator. Refer
this device is: to paragraph 8-7 for installation procedure.
Change 14 8-29
TM 55-1520-210-23-2
8-210. VERTICAL VELOCITY 8-214. Functional Test – Vertical Velocity

INDICATOR. Indicator. Refer to paragraph 8-218.2 for func-
tional testing of vertical velocity indicator.
8-211. Description — Vertical Velocity Indicator.
8-216. Troubleshooting — Vertical Velocity
The vertical velocity indicator is connected to the
Indicator. Use table 8-13 and perform checks as
static air system to sense the rate of atmospheric
pressure change. The indicator registers ascent or necessary to isolate trouble (see figure 8-1).
descent in feet.
NOTE
8-212. Clesning — Vertical Velocity Indicator.
Refer to paragraph 8-3 for cleaning procedure.
Before using this table be sure all normal
operational checks have been
8-213. Inspection — Vertical Velocity Indicator.
performed.
Table 8-13. Troubleshooting Vertical Velocity Indicator.
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. Inaccurate readings.
STEP 1. Check for loose connections in static line (paragraph 8-166).
Tighten connections.
STEP 2. Determine if indicator case leaks.
Replace indicator if case leaks (paragraph 8-1).
Replace defective indicator (paragraph 8-1 ).
2. Indicator pointer off zero.
Determine if mechanism has shifted.
Tap face of indicator Iightly while adjusting and return pointer to zero by turning adjustment knob.
3. Excessive indicator pointer oscillation.
STEP 1. Determine if there is a leak in the static lines (paragraph 8-166).
Tighten connections red/or replace lines.
8-30
TM 55-1520-210-23-2
8-216. Removal —Vertical VeIocity Indicator. Refer to (1.1) An alternate method is to connect to pitot line.
paragraph 8-5 for removal procedure. For aircraft with a roof-mounted pitot static tube, drop the
overhead panel and disconnect the pitot and static lines. (For
8-217. Repair or Replacement — Vertical Velocity aircraft with nose-mounted pitot tubes, the pitot and static
Indicator. Refer to paragraph 8-6 for repair or replacement lines will be disconnected in chin bubble area.) Blow air
criteria. backwards through pitot and static tube/pitot tube and static
ports as necessary to clear obstruction.
8-218. Installation —Vertical Velocity Indicator. Refer
to paragraph 8-7 for installation procedure. (2) Connect hose assembly to pitot static test adapter
as shown on figure 8-1.1 to pitot head adapter on the separate
8-218.1 Radar Altimeter. When radar altimeter set AN/ pitot tube or to aircraft pitot line.
APN-209 is installed (MWO 55-1520-210-30-48) the pilot
and copilot are each provided with an instrument panel (3) Connect hose assembly to pitot head and
mounted indicator of absolute clearance above the ground. AIRSPEED outlet (rear of tester). Make sure both VACUUM
Refer to TM 11-1520-210-20 for description, installation and UP and DOWN valves are open and PRESSURE UP and
maintenance of the system components. DOWN valves are closed. Slowly open PRESSURE UP
valve until airspeed indicators read approximately 120 knots.
8-218.2 Functional Test — Pitot Static System. Then close PRESSURE UP valve.
WARNING (4) Gently tap airspeed indicators to remove friction

effects. If indicator drops more than 8.7 knots in one minute,
Do not turn selector valves or disconnect hoses a leak is present. Open PRESSURE DOWN valve until tester
unless instruments read zero. airspeed indicator reads zero.
Do not operate rate of climb indicator over 3000 (5) Troubleshoot to determine source of leak and
feet per minute ascending or descending. repair as necessary. Repeat above steps until airspeed drop is
8.7 knots or less.
CAUTION
b. Airspeed indicator Functional Test.
Do not apply suction to pitot lines. Do not apply
pressure to static lines. The only exception is (1) Make sure VACUUMUP and DOWN valves are
when specifically required in a procedure. opened and PRESSURE UP and DOWN valves are closed.
Slowly open PRESSURE UP valve until tester airspeed
indicator reads 40 knots. Then close PRESSURE UP valve.
When operating pressure side (airspeed indica-
tor) make sure vacuum UP and DOWN valves
are open. When operating vacuum side (altimeter, (2) Gently tap aircraft indicators to remove friction
rate of climb indicator) make sure PRESSURE effects. Continue opening PRESSURE UP valve in incre-
ments so that indicators read airspeeds shown in table 8-13.1.
UP and, DOWN valves are open.
NOTE (3) Slowly open PRESSUREDOWN valve until test

unit indicator reads zero. If readings are not within tolerances
Before starting any checks, make sure all con- shown in table 8-13.1, replace indicator with serviceable unit
nections are secure and system drain caps are and repeat above steps.
installed.
c. Static Line Leak Check (figure 8-1.2).
a. Pitot Line Leak Check (figure 8-1.1).
(1) Install flush static port adapter, P/N SK-ED-
(1) Install pitot static test adapter on roof-mounted 0017, an accessory for the pitot static systems tester, on
pitot static tube and place pitot drain seal pad behind aircraft equipped with separate static ports.
fin to seal drain holes. On nose-mouned pitot tubes,
seal pitot head drain holes (on bottom of head) with
pressure sensitive tape (C275). Attach pitot head ada-
pter P/N SK-ED-0018, provided as an accessory for the
pitot static system tester, to the pitot tube.
Change 5 8-31
TM 55-1520-210-23-2
(4) Slowly open VACUUM DOWN valve until

desired rate of descent is reached. After rate stabilizes,
gently tape the instrument body to remove any mechanical
Connecting pitot head to RATE OF CLIMB/AL- friction and compare the readings to the test unit calibra-
TIMETER outlet is done during static line leak tion data. Record the readings and close VACUUM
check to prevent damage to the airspeed in- DOWN valve.
dicator diaphragm or remove static line from
aircraft airspeed indicator and cap before (5) Replace vertical velocity indicator(s) that ex-
proceeding with static system checks. ceed tolerances listed in table 8-13.2.
(2) Connect a hose assembly from RATE OF e. Altimeter functional check.

CLIMB ALTIMETER outlet to both ports of pitot static test
adapter as shown on figure 8-1.2 or to both the pitot and (1) Apply 28 volt power to aircraft electrical system
static lines. On aircraft with separate pitot probes, the hose to provide electrical power for counter drum altimeter
assembly is connected from both pitot head adapter and vibrations.
flush static port adapter to the RATE OF CLIMB/AL-
TIMETER outlet. (2) Slowly apply vacuum to aircraft system at a
rate not to exceed tester and aircraft rate of climb ratings.
(3) Tape a piece of rubber over other static port. Continue to apply vacuum until altimeter readings reach
the next higher reading on table 8-13.3 above altimeter al-
(4) Adjust test unit and aircraft altimeter titude indicated when barometric scale is set at 29.92.
barometric scales to read 29.92. Gently tap altimeter Close vacuum valve and keep altimeter at this setting for
bodies and compare aircraft altimeter reading with test unit at least one minute, but not more than five minutes, then
altimeter reading corrected using calibration data (top of gently tap three pointer type altimeters before reading.
tester. Check to insure that vibrators are operative on counter
drum altimeters before readings are compared to
(5) If aircraft altimeter reading(s) differ from cor- tolerance in table 8-13.3. Compare the readings of the in-
rected tester altimeter reading by more than the altimeter stalled instrument against reading on the tester and
scale error tolerance requirements of table 8-13.3 replace calibration data card at the check points shown in table 8-
aircraft altimeter(s) with serviceable unit(s) and repeat 13.3.
step (4).
(3) Altimeters that do not pass the performance
(6) Make sure PRESSURE UP and DOWN valves requirements of table 8-13.3 shall be removed from
are open. Make sure VACUUM UP and DOWN valves are aircraft and turned in for overhaul. Install a serviceable al-
closed. Slowly open VACUUM UP valve until the aircraft timeter and repeat step c.(1), (2), (3), (4), (5), and e.(2)
altimeters read 1000 feet above reading established in above.
step (4).
(4) Remove all pitot static test adapters and
(7) Close VACUUM UP valve and gently tap both hoses. Reconnect all lines and remove all tape from static
aircraft altimeters until rate of climb indicator stabilizes at ports and pitot tubes.
zero. After stabilization, the altimeters should not drop
more than 100 feet in one minute. Slowly open VACUUM f. Replacement of AIMS Altimeter Encoder
DOWN valve until rate of climb stabilizes at zero. Repair
any faults (if necessary) and repeat this step until altitude (1) Disconnect pneumatic line to altimeter.
drop is less than 100 feet.
(2) Remove altimeter.
d. Vertical Velocity Indicator Functional Test.
(3) Connect hose assembly directly to altimeter
(1) Deleted from test set rate of climb/altimeter outlet.
(2) Deleted (4) Connect transponder/vibrator power connector

to altimeter.
(3) Make sure both PRESSURE UP and DOWN
valves are open. Close VACUUM UP and DOWN valves. (5) Connect transponder test set AN/APM-123 or
equivalent. Refer to TM 11-5895-1199-12 (Mode C opera-
Slowly open VACUUM UP valve until vertical velocity in-
dicator starts to move. As altimeter starts to read altitudes tion).
listed in table 8-13.2, check to see if rate of ascent is within (6) Perform non-radiation test. Reference TM 11-
tolerance. After rate stabilizes, gently tap the indicator
5895-490-20, Mode C.
body to remove any mechanical friction, and compare the
readings to the test unit calibration data (on top of test (7) If criteria is met, install altimeter/leak test to
unit). Record the readings and close VACUUM UP valve. right static drain line.
8-32 Change 5
TM 55-1520-210-23-2
SECTION IV. NAVIGATION INSTRUMENTS
8-219. NAVIGATION INSTRUMENTS. (AN/ASN-43). Pointer number one of each indicator displays
radio magnetic bearing information received from the direc-
tion finder set AN/ARN-83. Pointer number tow is used for VOR
8-220. Description - Navigation Instruments. presentation when VOR is installed. The ID-998 Indicator has
Navigation instruments include the course indicator, bear- benn relocated to the copilots instrument panel. The ID-250 RMI
ing heading indicator, and standby compass. has been replaced by the ID-663 BDHI and relocated to the pilot's
instrument panel. The compass dial on each indicator rotates
8-221. COURSE INDICATOR (ID1347( )/ARN). under the index references mark to indicate magnetic heading data
from either the Gyromagnetic Compass (ASN-43) or INS (ASN-
86. Pointer number one of each indicator displays magnetic
8-222. Description - Course Indicator (ID1347( )/ARN. bearing omformation from either the radio direction finder (ARN-83)
The course indicator provides visual indication of the posi- or the VOR (ARN-123). Pointer number two displays maqnetic
tion of the helicopter in relation to the station being bearing from either the TACAN (ARN-103) or INS (ASN-86).
received. The vertical pointer provides fly right, fly left, and Refer to TM 11-1520-210-20 for description, operatiomnal check,
on course indications. The horizontal pointer indicates troubleshooting, and maintenance of system componets. Refer
passage over the station and signal strength. Two power to paragraphs 8-3 through 8-7 for instrument maintenance.
OFF flags (vertical and horizontal) come into view when
power is interrupted or signals are unreliably weak. The
power OFF flags disappear from view under normal 8-225. STANDBY COMPASS.
operating conditions. Refer to TM 11-1520-210-20 for
description, operational check, troubleshooting, and main- 8-226. Description - Standby Compass The
tenance of system components. Refer to paragraphs 8-3 standby compass, of standard magnetic type, is provided
through 8-7 for instrument maintenance. for navigational use. This instrument is to be used with the
compass correction card which is located adjacent to the
8-223. RADIO MAGNETIC INDICATORS compass. Refer to paragraphs 8-3 through 8-7 for main-
tenance procedures.
(ID-998( )/ASN AND ID250( )/ARN).
8-227. Troubleshooting - Standby Compass Use
8-224. Description - Radio Magnetic Indicators lD- table 8-14 and perform checks as necessary to isolate
998( )/ASN and ID-250( )/ARN. The pilots ID-998( trouble.
)/ASN and copilots ID250( )/ARN RMI indicators are dual
pointer, moving dial type indicators. The ID250( )/ARN is NOTE
a repeater type indicator driven by the ID-998( )/ASN in-
dicator. The compass dial on each indicator rotates under Before using this table, be sure all normal opera-
the fixed index reference mark to indicate compass head- tional checks have been performed.
ing information from the gyromagnetic compass system
Change 5 8-33
TM 55-1520-210-23-2
Figure 8-1.1. Connection for Pitot Leak Check (Typical)
8-34 Change 5
TM 55-1520-210-23-2
STATIC
Figure 8-1.2. Connections for Static Leak Check (Typical)
Change 5 8-35
TM 55-1520-210-23-2
Table 8-13.1 Indicator Tolerance (±Knots)
Airspeed Check MS28045 MS28021 MS28046

Points (Knots) 10 to 150 20 to 250 40 to 400
Knots Knots Knots
40 3 5 4
60 3 3 3
80 3 3 3
100 3 4 3
120 3 4 3
140 3 5 4
160 5 4
Table 8-13.2 Vertical Velocity Tolerance/Scale Accuracy
Standard Altitude Check Rate Tolerance

Check Interval Ascent or Descent Scale Error
(Feet) (fpm) (fpm)
2000 to 2500 500 ±1OO

2000 to 2500 1000 ±200
2000 to 4000 2000 ±300
2000 to 5000 3000 ±300
15,000 to 17,000 2000 ±300
Table 8-13.3 Altimeter Scale Error
Altitude Tolerance
(feet) (±feet)
0 45
500 50
1000 50
2000 50
3000 60
5000 70
10000 95
15000 120
8-36 Change 5
TM 55-1520-210-23-2
Table 8-14. Troubleshooting Standby Compass
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. Excessive card error.
STEP 1. Check for external magnetic interference.
Locate magnetic interference and eliminate if possible.
STEP 2. Check for air or insufficient liquid in bowl.
Replace standby compass (paragraph 8-1).
STEP 3. Determine if compass is improperly compensated.
Accomplish compass compensation procedure (paragraph 8-228).
2. Card element not level.
Check for leaking float chamber.
3. Card has sluggish rotation.
Determine if pivots or jewels are dirty and restricting rotation or card magnet is weak.
8-228. Compensation - Standby Compass. The Refer to TM 11-1520-210 series maintenance

standby magnetic compass may be calibrated manuals. Refer to TM 55-1500-204-25/1 for
concurrently with the ASN-43 compass system. standard compass compensation procedure.
SECTION V. MISCELLANEOUS INSTRUMENTS
8-229. MISCELLANEOUS lN - transmission oil pressure indicating system,

STRUMENTS. transmission oil temperature indicating system, ac
voltmeter, dc voltmeter, dc Ioadmeter, free air
temperature gage, and radar warning indicating
8-230. Description — Miscellaneous system.
Instruments. The miscellaneous instruments
include the clock, fuel quantity indicating system,
8-37
TM 55-1520-210-23-2
8-231. CLOCK. 8-235. Functional Test — Clock. Check that

control knob on the case starts the pointers when
8-232. Description — Clock. The clock, located on pressed, stops both pointers when pressed a second
the instrument panel, is an 8-day clock with added time, and returns both pointers when pressed a third
stopwatch feature for elapsed time. The clock has a time.
sweep-second pointer and a minute totalizer hand to
indicate elapsed time. A control knob on the case 8-236. Troubleshooting — Clock. Use table 8-15
starts the pointers when pressed, stops both pointers and perform checks as necessary to isolate trouble.
when pressed a second time, and returns pointers to
12 o’clock when pressed a third time. A separate NOTE
control knob winds and sets the clock.
8-233. Cleaning – Clock. Refer to paragraph 8-3 operational checks have been
for cleaning procedure. performed.
8-234. Inspection — Clock. Refer to paragraph 8-

4 for inspection procedure.
Table 8-15. Troubleshooting Clock
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
Do not overwind clock.

1. Clock does not run.
STEP 1. Determine if clock needs winding.
Wind clock if needed.
STEP 2. Determine if clock is defective.
Replace clock if defective (paragraph 8-1).
2. Clock does not keep accurate time.
STEP 1. Determine if clock is out of adjustment.
Adjust clock to run faster or slower as needed (paragraph 8-237).
STEP 2. Determine if clock is defective.
3. Pointers do not start, stop, or return when control knob is pressed through three time cycles.
Determine if control knob, pointer(s), or instrument is defective.
8-38
TM 55-1520-210-23-2
8-237. Adjustment — Clock. Remove clock from The system is powered from the 115 Vac bus, and is
instrument panel. Adjustment is on back of clock protected by a one ampere FUEL QTY circuit breaker.
which adjusts clock to run faster or slower. Pressing the FUEL QUANTITY TEST SWITCH, located
on the pilots instrument panel, checks the fuel
8-238. Removal — Clock. Refer to paragraph 8-5 quantity indicator for zero return.
for removal procedure. 8-243. FUEL QUANTITY INDICATOR.
8-239. Repair or Replacement – Clock. Refer to

8-244. Description — Fuel Quantity Indicator.
paragraph 8-6 for repair or replacement criteria.
The fuel quantity indicator provides readings of fuel
supply in tank system. The indicator is connected to
8-240. Installation – Clock. Refer to paragraph 8-
capacitor-type probes and requires 115 Vac power
7 for installation procedure.
source.
FUEL QUANTITY INDICATING 8-245. Cleaning — Fuel Quantity Indicator. Refer

8-241.
to paragraph 8-3 for cleaning procedures.
SYSTEM.
8-246. Inspection — Fuel Quantity Indicator.
8-242. Description — Fuel Quantity Indicating 8-247. Troubleshooting — Fuel Quantity

system. The fuel quantity indicating system is a Indicator. Use table 8-16 and perform checks as
bridge capacitance, balance type system which necessary to isolate trouble. (See figure F-17.)
includes a fuel quantity indicator, located on the
● Before Using this table, be sure all normal
instrument panel, and three fuel quantity
transmitters; two located in the right side forward fuel o p e r a t i o n a l c h e c k s h a v e been
cell, and the other located in the aft center fuel cell. performed.
Table 8-16. Troubleshooting Fuel Quantity Indicator
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. Fuel quantity indicator reads low
STEP 1. Determine if fuel quantity system is out of adjustment.
Perform adjustment procedure (paragraph 8-249).
STEP 2. Determine if compensator capacitance is too high.
Replace tank unit (paragraph 8-252).
STEP 3. Determine if tank unit capacitance is low.
218-260 0 - 88 - 5 8-39
TM 55-1520-210-23-2
Table 8-16. Troubleshooting Fuel Quantity Indicator (Cont)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
2. Fuel quantity indicator reads high.
STEP 1. Determine if fuel quantity system is out of adjustment.
Perform adjustment procedure (paragraph 8-249).
STEP 2. Determine if tank unit capacitance is too high.
STEP 3. Check for open lead on compensator circuit.
Repair wiring as necessary.
STEP 4. Check for open circuit in compensator section of tank unit.
3. Fuel quantity indicator remains at one point on scale.
STEP 1. Ensure that 115 Vac, 400 Hz power is available and determine if indicator is defective.
STEP 2. Check for grounded coaxial lead.
Repair or replace wiring as necessary.
STEP 3. Determine if 400 Hz lead is grounded. (Prolonged existence of this condition will burn out fire
hazard resistor in indicator.)
Repair wiring and/or replace indicator (paragraph 8-1).
4. Fuel quantity indicator remains at zero or below.
Check for open wiring.
Repair wiring.
5. Indicator operation is sluggish.
Check wiring and tank unit for low insulation resistance of the circuit.
Replace or repair wiring or replace tank unit (paragraph 8-252).
8-40
TM 55-1520-210-23-2
Table 8-16. Trouble Fuel Quantity Indicator (Cont)
6. Fuel quantity indicator fluctuates.

STEP 1. Check electrical connections for proper installation.
Tighten or replace loose or faulty connections.
STEP 2. Check for loose or improperly mounted probes.
Tighten or correct probe installation.
STEP 3. Check for dogged or restricted fuel or vent lines.
Clear restriction or replace faulty line.
STEP 4. Check flapper valve for proper operation.
Adjust flapper valve (paragraph 10-56).
STEP 5. Check for leaking or sticking manifold check valve.
Check and replace manifold if faulty (paragraph 10-56).
STEP 6. Check for damaged fuel cell baffles.
Replace fuel cell (paragraph 10-3).
7. Fuel quantity indicator rotates clockwise.
STEP 1. Check for an open in wire E27A20 for Pin D(P4).
Repair or replace defective wire.
STEP 2. Check for open in coax cable.
Repair or replace defective cable.
8. Fuel quantity indicator rotates counterclockwise.
STEP 1. Check for short in wire E26A20 for Pin H(P4).
Repair or replace defective wire.
8-248. Removal-Fuel Quantity Indicator. (4) The tank unit capacitance should be as
to paragraph 8-5 for removal procedure. shown below: (See fig. 8-5).
8-249. Teat-Fuel Quantity system (AVIM). Tank
Consolidated or Simmonds Capacitance
Airborne (UUF)
NOTE
Refer to paragraph 8-249.1 when using PAA933 or 391019-001 25.7 ± 0.4
Tester T-68.1 .
PAA424 or 381057-06008 67.9 ± 0.4
a. Capacitance test. PAB934 or 381020-001 15.9 ± 0.3
(1) Using Tester (T68) measure the capaci- (compensator) 25.0 ± 1.9
tance between the coaxial end compensator Lo Z ter-
minals. Also between the coaxial and 400 Hz termi-
nals. NOTE
(2) When measuring the capacitance between Tolerance of measuring equipment must be
the coaxial and 400 Hertz terminal, ground the com- taken into consideration in making all
pensator to Lo Z terminal. capacitance measurements.
(3) Also, when measuring the capacitance b. Insulation resistance test. Using the three wire
between coaxial and compensator Lo Z terminals, insulation resistance tester, measure the insulation
ground the 400 Hertz terminal. resistance between the points lied below:
Change 8 8-41
TM 55-1520-210-23-2
Figure 8-5. Schematic Diagram - Fuel Quantity Installation (Crashworthy)
8-42
TM 55-1520-210-23-2
(1) Center of coaxial connector to ground — (3) Set tank unit section of tester to 239.7
not less than three megohms. UUF and leave compensator section set at 51.9
UUF. Adjust full control until pointer reads 1575
(2) C e n t e r o f 4 0 0 H e r t z c o n n e c t o r t o pounds.
ground — not less than three megohms. (4) With compensator section set at 51.9
UUF, vary tank unit section of tester so that
(3) Center of compensator connector to pointer reads at graduations shown. Capacitance
ground — not less than one megohm. must be as shown opposite indicator reading.
Adjust “EMPTY” and “FULL” adjustment at back
(4) Center of coaxial connector to center of of indicator as required.
400 Hertz connector — Refer to limits in step (7).
(5) Center of coaxial connector to center of Indicator Reading Capacitance (UUF)

compensator connector — not less than 800 (LBS)
megohms.
o 109.5
c. Test indicator amplifier bridge assembly. 400 142.6 ± 1.0
800 175.6 ± 1.0
(1) Set up test circuit (See figure 8-6.) 1200 208.7 ± 1.0
1575 239.7
NOTE
The adjustment controls require 40
complete turns to travel from end to end. NOTE
Also no stops are incorporated so that
when control runs off end of winding. Some indicators may need adjusting
indicator pointer will jump; continuous from non-crashworthy fuel system.
rotation in same direction will result in
pointer returning to its correct position. (5) Cause indicator to travel from 0 to 1575
pounds and from 1575 to 0 pounds. The travel
(2) Set capacitance of 109.5 UUF on tank
time must not be more than 30 seconds.
unit section of tester and 51.9 UUF on compensa-
tor section. Adjust empty control so that pointer (6) Adjust tester so that indicator is
reads zero. upscale. Close test switch. Indicator should go to
zero. Release test. Pointer should go back to its
original position.:
d. Insulation test. After all tank units and wir-
ing have been installed in the aircraft, it is recom-
mended that insulation resistance of the circuits
be tested. Using a three-wire insulation resistance
tester, make the following insulation resistance
tests at the amphenol connector disconnected
from the indicator:
(1) B e t w e e n compensator (Pin D) and

ground (Pin J) — not less than one megohm.
(2) Between coaxial and ground — not less

than one megohm.
(3) Between 400 Hertz (Pin H) and ground

— not less than one megohm.
Figure 8-6. Indicator Bench (4) Between coaxial and 400 Hertz (Pin H)
Test Circuit (Crashworthy) — not less than 700 megohms.
8-43
TM 55-1520-210-23-2
(5) Between coaxial and compensator (Pin f. Adjustment procedure (alternate method)
D) — not Iess than 800 megohms. partial fuel in tanks.
(6) Between 400 Hertz (Pin H) and compen- (1) Disconnect the amphenol connector at
sator (Pin D) — not less than 10 megohms. the indicator and insert the adapter cable. (See
figure 8-7.) Connect tester (T68) and leave aircraft
e. Adjustment procedure (preferred method) wiring disconnected.
empty tanks.
(2) Set the compensator section of the
(1) See that all connecting cables and units Tester to 51.9 UUF and the tank unit section to
have been installed properly, connections are 109.5 UUF. Adjust the “EMPTY” control on the
tight and the requirements of step 3 are met. indicator to cause pointer to read zero.
(2) Make sure all tanks are empty and turn (3) Leave compensator section set at 51.9
on power. UUF and set tank unit section to 239.7 UUF.
Adjust “FULL” control so that indicator pointer
(3) T u r n “EMPTY” control unit indicator reads at last dial division.
reads exactly zero.
(4) Connect Tester (T68) in parallel with g. Test values.

ships wiring. (See figure 8-7.)
(1) Tank unit empty capacities values.
(5) Set compensator section of Tester to
26.9 UUF and the tank unit section to 130.2 UUF.
(6) A d j u s t “FULL” control on indicator to Circuit Capacitance

cause pointer to read at last dial division (1575
pounds). Tank Unit (Dry) 109.5 ±1.1 UUF
Compensator Section
(7) Disconnect adapter cable and recon- (Dry) 25.0 UUF
nect ships wiring to indicator.
Figure 8-7. Circuit Arrangement and Adapter Cable for Adjustment Procedures
(Crashworthy)
8-44
TM 55-1520-210-23-2
(2) Added and full capacitance values. 8-249.1. Test/Adjust-Fuel Quantity system
(AVIM).
Capacitance (UFF) Indicator Readings
Added Full
130.2 239.7
(3) Tank unit resistance check values. Using Do not use any fuel quantity tester
the three wire insulation tester, or equivalent, mea- other than the PSD60-1AF with this
sure from center of coaxial connector to center of
400 Hertz connector. Values should be as given procedure.
below
Tank Unit
Part No. Resistance
391019-001 Not less than 3000 megohms Never connect a fuel gauge or signal
381057-06008 Not less than 1000 megohms conditioner unit (SCU) to an electri-
or 391046-145 cally live connector.
391020-001 Not less than 4500 megohms
h. Adjustment Procedure (Any UH-1H Fuel
System). If conditions permit, adjust fuel quantity
indicator system as follows:
If a circuit breaker pops during cal-
(1) Ensure tanks are empty, at Ieast to a level ibration or troubleshooting, a short
below bottom of tank units. circuit is indicated. Correct fault be-
fore reapplying power.
(2) Adjust “Empty" adjustment on indicator to
make indication read “EMPTY” or "O" fuel.
(3) Ensure ship is level and temperature is

reasonably near 60° F (at least between 32° F and
90°). Fill ship with JP-4 to bottom of refueling port. Use only authorized test equipment
If possible, note and record amount of fuel required to test troubleshoot, and calibrate
to fill ships tank the fuel quantity system. Shop tes-
ters, including multimeters and meg/
(4) Adjust “FULL” adjustment on indicator to ohmmeters, are not certified safe for
make indicator read proper full level for esteem. use on any wiring to the fuel tank.
(a) Deleted.
NOTE
(b) 206.5 gal. or 1342 Ibs for crashwort- The fuel quantity system operational
hy fuel system. check can be used in either of two
ways. The preferred method shall be
(c) Cross check that above amounts used when the fuel tanks can be
agree with amounts of fuel added to fill ship’s tank drained. The alternate method will be
used when conditions do not allow
fuel tanks to be drained i.e. combat/
mobilization. Though the alternate
NOTE method Is Considered adequate it is
possible for residue to be trapped In
Ship’s fuel volumes (gallon) capacity re- the probe area which could Indicate a
mains constant during ships life, but va- false quantity.
ries a Iittle from ship to ship. Fuel density
(pounds) varies with temperature (and
fuel type) when volume remains constant. a. Capacitance Test Using Tester (T68.1) and
The above method is accurate enough to "T" cable (T68.2) Preferred Method Empty Tanks.
be suitable for normal use and do account
for variables in ship’s indicator system. (5) Ground aircraft to earth ground.
Change 8 8-44.1
TM 55-1520-210-23-2
(2) Completely drain sump and fuel tank(s) to (13) Loosen clamp holding fuel quantity gauge in
be calibrated. instrument panel and remove gauge from panel.
(3) Verify that inverter which powers fuel quanti- CAUTION

ty indicator is turned off.
When disconnecting aircraft wiring
cable from indicator hold cable to
prevent retraction behind instrument
WARNING panel.
Always ground the tester to a good, (14) Disconnect aircraft wiring cable from fuel
clean aircraft ground. Do not con- quantity gauge.
nect ground wire behind circuit
breaker panels or near any exposed (15) Connect (J-1) of “T” cable to aircraft wiring
power termination. connector removed from gauge. Do not connect to
gauge.
(4) Connect tester chassis jack (J-7, figure NOTE
8-7.1) to airframe ground using ground lead supplied with Rotate select switch (S3, figure 8-7.1)
tester. to “TU” position.
(16) Read capacitance of empty tank plus caable

(5) Lift to unlock tester ON-OFF switch and turn
and record on worksheet line 3.
to “ON” position. If words “LO BATT” appear in upper
left-hand corner of LCD display (D-3) replace batteries in
tester. (17) Subtract capacitance of cable measured in
step 11. Capacitance must be between 107.5 pf and
111.5 pf.
(6) Allow tester to warm up for at least 3 minutes NOTE
before using.
If tank capacitance is out of tolerance,
check for trapped fuel at fuel drain.
(7) Connect “T” cable (figure 8-7.1) “LOZ”,
“HIZ”, and “Comp” leads to TANK UNITS terminals (J-4, (18) The tank unit capacitance should be as
J-5, and J-6 figure 8-7.1) respectively on tester. shown below:
(8) Rotate tester FUNCT switch (S-2) to “MEA-

SURE EXT” position. Consolidated or Simmonds Capacitance
Airborne
(9) Rotate tester SELECT switch (S-3) to “TU” PAA933 -391046-145 67.9 ±.7 pf
POSITION.
PAA424 -391019-001 25.7 ±.5 pf
PAB934 -391020-001 15.9 ±.5 pf
(10) Switch TANK IN/OUT switch on “T” cable to
the “IN” position. (Compensator) 25.0 ±.5 pf
NOTE
Worksheet figure 8-7.3 is to be locally (19) Rotate SELECT switch (S-3) on tester to
reproduced. “COMP” position. Read capacitance of compensator
plus cable capacitance on tester LCD. Record on work-
sheet line 4.
(11) Read capacitance of “TU” test leads. If read-
ing is over .5 pf, repair or replace cable. Record capaci-
tance on worksheet, line 1. (20) Subtract cable capacitance measured in
step (12) above from reading in step 19. Compensator
capacitance must be between 24.3 pf and 25.7 pf. Re-
(12) Rotate SELECT switch (S-3, figure 8-7.1) to cord COMP capacitance on worksheet line 5.
“COMP” position. Read capacitance of COMP leads. If
reading is over .5 pf, repair or replace cable. Record (21) Rotate SELECT switch (S-3) on tester to
capacitance on worksheet, line 2. “LOZ-HIZ” position.
8-44.2 Change 15
TM 55-1520-210-23-2
NOTE
The PSD60-1AF tester reads “over-
range” above 10,000 megohms by If a circuit breaker pops during cal-
flashing three colons and displaying ibration or troubleshooting, a short
four zeros circuit is indicated. Correct fault be-
fore reapplying power.
(22) Verify that the tester LCD reads over 20
megohms in “LOZ-HIZ” position. Record reading (36) Press and release indicator test switch
on line 7 of worksheet. on instrument panel.
(37) Adjust “E” trimmer at lower left (viewed
(23) Rotate SELECT switch (S-3) to the fol- from front of gauge) until pointer reads 0 lb.
Iowing positions and verify that the tester LCD reads
over 1 megohm in each position: (36) Repeat steps 36 and 37 above until
pointer returns to O lb.
“LOZ-SHLD” “LOZ-GND” (39) Rotate FUNCT switch (S-2) on tester to
"HIZ-SHLD" “HIZ-GND” “SIM TU & COMP” position.
Record readings on line 8 of worksheet. (40) Adjust “F" trimmer at lower right (viewed
from front of gauge) until pointer reads 1575 lb.
(24) Rotate SELECT switch (S-3) to “SHLD- (41) Press and release indicator test switch
GND” position. Verify that LCD read-out indicates on instrument panel.
O megohms.
(42) Repeat steps 40 end 41 until pointer re-
(25) Disconnect "T" cable leads from tester turns 1575 lb.
TANK UNITS terminals and connect to INDICATOR (43) Repeat steps 32 through 36 above.
“LOZ”, “HIZ” and “COMP” terminals respectively.
(44) Turn inverter off.
(26) Rotate tester FUNCT switch (S-2) to (45) Disconnect "T" cable from gauge and
"MEASURE INT" position. from aircraft wiring.
(27) Rotate SELECT switch (S-3) to the (46) Reconnect indicator to aircraft wiring
“COMP” position. and reinstall in panel.
b. Capacitance Test Using Tester (T68.1) and
(28) Set COMP simulator decade (D-2) to “T” cable (T68.2) Alternate Method Fuel In Tanks.
read W.
(1) Ground aircraft to earth ground.
(29) Adjust COMP vernier (V-2) to read 26.9 (2) Verify that inverter which powers fuel
pf on tester LCD display. quantity indicator is turned off.
(30) Rotate SELECT switch (S-3) to "TU"

position.
(31) Set TU simulator decade (D-1) to read

Always ground the tester to a good,
“011“.
clean aircraft ground. Do not conned
ground wire behind circuit breaker
(32) Adjust TU vernier (V-1) to read 130.2 pf panels or near any exposed power
on tester LCD display. termination.
(33) Rotate FUNCT switch (S-2) to “AIR- (3) Connect tester chassis jack (J-7, figure
CRAFT ONLY" position. 8-7.1) to airframe ground using ground lead sup-
plied with tester.
(34) Connect "T" cable (P-1) to fuel quantity (4) Lift to unlock tester ON-OFF switch and
indicator. turn to “ON” position. If words "LO BATT" appear in
upper left-hand comer of LCD display (D-3) re-
(36) Turn on inverter to power indicator. place batteries in tester.
Change 8-44.3
TM 55-1520-210-23-2
(5) Allow tester to warmup for at least 3 min- NOTE

utes before using. The PSD60-1AF tester reads “over-
range” shove 10,000 megohms by
(6) Connect “T” cable (figure 8-7.2) "LOZ",
flashing three colons and displaying
"HIZ", and “Comp" leads to TANK UNITS terninals
four zeros.
(J-4, J-5, and J-6, figure 8-7.1) respectively on
tester. (16) Verify that the tester LCD reads over 20
megohms in "LOZ-HIZ" position. Record readings
(7) Rotate tester FUNCT switch (S-2) to on tine 3 of worksheet.
“MEASURE EXT" position.
(17) Rotate SELECT switch (S-3) to the fol-
(8) Rotate tester SELECT switch (S-3) to lowing positions and verify that the tester LCD reads
"TU" POSITION. over 1 megohm in each position:
(9) Switch TANK IN/OUT switch on "T" cable “LOZ-SHLD” “LOZ-GND"
to the “IN” position. “HIZ-SHLD” "HIZ-GND"
Record readings on line 4 of worksheet.
NOTE (18) Rotate SELECT switch (S-3) to "SHLD-
Worl sheet figure 8-7.3 is to be locally GND” position. Verify that LCD read-out indicates
reproduced. 0 megohms.
(10) Read capacitance of "TU" test leads. If (19) Disconnect "T" cable leads from tester
reading is over .5 pf, repairer replace cable. Record TANK UNITS terminals and connect to INDICATOR
capacitance on worksheet line 1. "LOZ”, ‘HIZ” and “COMP" terminals respectively.
(11) Rotate SELECT switch (S-3, figure (20) Rotate tester FUNCT switch (S-2) to
8-7.1) to “COMP” position. Read capacitance of "MEASURE INT" position.
COMP leads. If reading is over .5 pf, repair or re- (21) Rotate SELECT switch (S-3) to the
place cable. Record capacitance on worksheet, line “COMP position.
2.
(22) Set COMP simulator decade (D-2) to
(12) Loosen clamp holding fuel quantity read "03".
gauge in instrument panel and remove gauge from
panel. (23) Adjust COMP vernier (V-2) to read 51.9
pf on tester LCD display.
(24) Rotate SELECT switch (S-3) to "TU"
position.
(25) Set TU simulator decade (D-1) to read
When disconnecting aircraft wiring “008”.
cable from indicator hold cable to
prevent retraction behind instrument (26) Adjust TU vernier (V-1) to read 109.5 pf
panel. on tester LCD display.
(27) Rotate FUNCT switch (S-2) to “SIM TU
(13) Disconnect aircraft wiring cable from
& COMP” position.
fuel quantity gauge.
(28) Connect "T" cable (P-1) to fuel quantity
(14) Connect (J-1) of "T" cable to aircraft wir- indicator.
ing connector removed from gauge. Do not conned
to gauge. (29) Switch the TANK IN/OUT switch on the
interface cable to the "OUT" position.
(15) Rotate SELECT switch (S-3) on tester
to “LOZ-HIZ” position. (30) Turn on inverter to power indicator.
8-44.4 Change 8
TM 55-1520-210-23-2
Figure 8-7.1 Fuel Quantity Test Set P/N PSD60-1 AF

Change 8 8-44.5
TM 55-1520-210-23-2
Figure 6-7.2 Fuel Quantity "T" Cable P/N PSDAF-537
8-44.6 Change 8
TM 55-1520-210-23-2
FIGURE 8-7.3 FUEL QUANTITY CALIBRATION WORKSHEET
Change 8 8-44.7/(8-44.8 blank)

TM 55-1520-210-23-2
8-251. Installation-Fuel Quantity Indicator.

Refer to paragraph 8-7 for installation procedure.
If a circuit breaker pops during cal- NOTE

ibration or troubleshooting, a short
circuit is indicated. Connect fault be- New fuel quantity indicators must be ad-
fore reapplying power. justed, refer to paragraph 8-249.c. when
using Tester (T68) and paragraph
(31) Press and release indicator test switch 8-249.1 when using Tester (T68.1)
on instrument panel.
8-252. FUEL QUANTITY TRANSMIT-
(32) Adjust “E” trimmer at lower left (viewed TERS.
from front of gauge) until pointer reads 0 lb.
8-253. Description-FueI QuantityTransmitters.
(33) Repeat steps 31 and 32 above until Three fuel quantity transmitter probes (tanks units)
pointer returns to 0 lb. are installed, two in the forward right aide fuel cell
and one in the aft center fuel cell. The probes act
(34) Rotate FUNCT switch (S-2) on tester to as sensors for the fuel quantity indicator (paragraph
“MEASURE INT” position. 8-243).
(35) Set TU simulator decade (D-1) to read 8-254. Removal-Fuel Quantity Transmitters
“022”.
a. Defuel helicopter (Refer to Chapter 1.)
(38) AdjustTU vernier (V-1) to read 239.7 pf b. Remove section of cabin ftoor over right hand
on tester LCD display. fuel cell.
(37) Rotate FUNCT switch (S-2) to "SIM TU c. Remove circular cover plate on top of forward
& COMP" position. right side fuel cell.
d. Remove fuel cell sump.
(38) Adjust "F" trimmer at lower right (viewed e. Detach upper and lower support clamps of
from front of gauge) until pointer reads 1575 lb. each probe from threaded inserts of cell wall by
(39) Press and release indicator test switch removing bolt, washer and spacer from each damp.
on instrument panel. f. Remove probes, with attached damps and
electrical leads, from cell. Remove damps from
(49) Repeat steps 38 and 39 until pointer re- probes.
turns to 1575 lb. g. Disconnect electrical Ieads and vent line from
(41) Rotate FUNCT switch (S-2) on teeter to connectors on aft center fuel cell access door.
"MEASURE INT" position. h. Detach access door by removing four retain-
ers, eight bolts, washers, sixteen screws and wash-
(42) Repeat steps 25 through 32 above. ers.
i. Remove access door, tilting and turning as
(43) Turn inverter off.
necessary to allow attached quantity probe and float
(44) Disconnect "T" cable from gauge and switches to pass through access port. Cover ex-
from aircraft wiring. posed open port.
j. Disconnect probe electrical leads from con-
(48) Reconnect indicator to aircraft wiring nectors on door. Cut tie straps and remove probe
and reinstall in panel. from support dips.
8-250. Repair or Replacement-Fuel Quantity 8-255. Inspection-Fuel Quantity Transmitter.

Indicator. Refer to paragraph 8-6 for repair or re- a. inspect transmitter for security, corrosion,
placement criteria. and cracks.
Change 8 8-45
TM 55-1520-210-23-2
NOTE 8-256. TRANSMISSION OIL PRESSURE

INDICATING SYSTEM.
Inspect transmitter for dents, scratches, gauges
or indications of being dropped during han- 8-259. Description-Transmission Oil Pressure
dling. Replace if droppage is suspected. Indicating System. The transmission oil pressure in-
dicating system consists of the transmission oil pres-
b. Electrical leads are susceptible to chafing sup- sure transmitter (paragraph 8-269) and indicator (para-
port bracket assemblies. Ensure that wires are in ser- graph 8-260)
viceable condition and are routed correctly to preclude
a chafing condition.
8-260. TRANSMISSION OIL
8-256. Repair or Replacement-Fuel Quantity PRESSURE INDICATOR.
Transmitter. a. Reinstall improperly mounted trans-
mitter. 8-261. Description-Transmission Oil Pressure
Indicator. The transmission oil pressure indicator pro-
b. Replace transmitter if cracked or damaged. vides continuous readings in psi by means of an elec-
trical transmitter (paragraph 8-269) mounted directly
8-257. Installation-Fuel Quantity Transmitter. into an oil manifold at right aft on transmission top
a. Assemble two clamps on each forward fuel cell case electrical circuit is operated by 28 Vac power
transmitter probe.
b. Position each probe in forward right-hand well 8-262. Cleaning Transmission Oil Pressure ln-
aligning upper and lower clamps to threaded inserts dicator. Refer to paragraph 8-3 for cleaning proce-
of cell wall. Secure each clamp with bolt, washer and dure.
spacer. On forward probe, also attach support clamp
of ejector pump outlet hose on upper clamp bolt of
probe. 8-263. inspection-Transmission Oil Pressure
Indicator. Refer to paragraph 8-4 for inspection pro-
c. Connect electrical leads of probes to connectors cedure.
on sump plate while installing sump assembly.
8-264. Functional Test—Transmission Oil Pres-
d. Install cover plate on fuel cell using a new pack- sure Indicator. Refer to paragraph 8-64. except, close
ing and screws. XMSN OIL PRESS circuit breaker.
e. Install cabin floor panel. 8-265. Troubleshooting-Transmission Oil Pres-

sure Indicator. Refer to paragraph 8-65 for trouble-
f. Install aft center fuel cell transmitter probe with shooting; procedure is the same.
large end up in clips on access door brackets. Secure
with teflon locking tie straps. 8-266. Removal—Transmission Oil Pressure ln-
dicator. Refer to paragraph 8-5 for removal proce-
g. Connect electrical leads to connectors on ac- dure.
cess door.
8-267. Repair or Replacement—Transmission
h. Place new packing in groove around access port. Oil Pressure Indicator. Refer to paragraph 8-6 for
Tilt and turn access door as necessary to pass quan- repair or replacement criteria.
tity probe and float switches through port into cell.
Align door and secure with sixteen screws and wash- 8-268. Installation-Transmission Oil Pressure
ers, and four retainers with eight bolts and washers. Indicator. Align transmission oil pressure indicator so
Torque bolts and screws 40 TO 60 inch-pounds. that 50 psi is at 9 o’clock position. Refer to paragraph
8-7 for installation procedures.
i. Connect fuel control vent line to check valve on
floor. Connect electrical leads to terminal block and
quantity gage connectors.
8-46 Change 4
TM 55-1520-210-23-2
8-269. TRANSMISSION OIL 8-280. TRANSMISSION OIL

PRESSURE TRANSMITTER. TEMPERATURE INDICATOR.
8-270. Description— Transmission Oil Pressure 8 - 2 8 1 . Description — Transmission Oil

Transmitter. The transmission oil pressure Temperature Indicator. The transmission oil
transmitter, located on the right side of the temperature indicator, located on the instrument
transmission, monitors transmission oil pressure and panel, indicates transmission oil temperature in
transmits voltage signals to the transmission oil degrees Celsius by means of an electrical resistance
pressure indicator. type temperature bulb.
8 - 2 8 2 . C l e a n i n g – Transmission Oil
8-271. Cleaning — Transmission Oil Pressure
Transmitter. Refer to paragraph 8-71 for cleaning;
cleaning procedure.
procedure is the same.
8 - 2 8 3 . Inspection — Transmission Oil
8-272. Inspection — Transmission Oil Pressure Temperature Indicator. Refer to paragraph 8-4 for
Transmitter. Refer to paragraph 8-72 for inspection; inspection procedure.
8 - 2 8 4 . Functional and Bench Test —
Transmission Oil Temperature Indicator. Refer to
8-273. Functional Test — Transmission Oil
paragraphs 8-84 and 8-88 for functional and bench
Pressure Transmitter. Refer to paragraph 8-73 for
test; procedure is the same.
functional test; procedure is the same.
8-285. Troubleshooting — Transmission Oil
8-274. Troubleshooting — Transmission Oil Temperature Indicator. Refer to paragraph 8-85 for
Pressure Transmitter. Refer to paragraph 8-65 for troubleshooting.
troubleshooting.
8 - 2 8 6 . R e m o v a l — Transmission Oil
8-275. Removal — Transmission Oil Pressure
Transmitter. Refer to paragraph 8-75 for removal; removal procedure.
8-287. Repair and Replacement — Transmission
8-276. Repair and Replacement — Trans- Oil Temperature Indicator. Refer to paragraph 8-6
mission Oil Pressure Transmitter. Refer to for repair and replacement criteria.
paragraph 8-76 for repair and replacement;
8-288. Installation — Transmission Oil Tem-
criteria is the same.
perature Indicator. A!ign transmission oil tem-
8-277. Installation — Transmission Oil Pressure perature indicator so that 75° C is at 9 o’clock
Transmitter. Refer to paragraph 8-77 for installation; position. Refer to paragraph 8-7 for installation
procedure is the same. procedure.
TEMPERATURE BULB.
TEMPERATURE INDICATING SYSTEM. 8 - 2 9 0 . Description — Transmission Oil
Temperature Bulb. The transmission oil temperature
8 - 2 7 9 . Description — Transmission Oil bulb, installed in the transmission oil manifold,
Temperature Indicating System. The transmission monitors transmission oil temperature and transmits
oil temperature indicating system consists of the voltage signals to the transmission oil temperature
transmission oil temperature indicator and an indicator.
electrical resistance type thermobulb. The system is
powered from the 28 Vdc essential bus, and is 8 - 2 9 1 . Cleaning –- Transmission Oil
protected by a 5 ampere ENG & XMSN TEMP IND Temperature Bulb. Refer to paragraph 8-92 for
circuit breaker. cleaning; procedure is the same.
8-47
TM 55-1520-210-23-2
8-292. Inspection - Transmission Oil Temper- 8-299.1. DELETED.

ature Bulb. Refer to paragraph 8-93 for inspec-
tion; procedure is the same. 8-300. DC VOLTMETER.
8-293. Troubleshooting - Transmission Oil

Temperature Bulb. Refer to paragraph 8-85 for 8-301. Description - DC Voltmeter. A dc volt-
troubleshooting. meter is provided to indicate the voltage of the main
generator, standby generator, essential bus, non-
8-294. Removal - Transmission Oil Tempera- essential bus, or battery. These sources are
ture Bulb. Refer to paragraph 8-95 for removal; selected by the VM selector on the dc power panel
procedure is the same. in the overhead console. The dc voltmeter is func-
tionally tested as part of the Direct Current Power
Distribution System (paragraphs 9-58 and 9-59).
8-295. Repair and Replacement - Transmis-
Refer to paragraphs 8-3 through 8-7 for mainte-
sion Oil Temperature Bulb. Refer to paragraph
nance procedures.
8-96 for repair and replacement; criteria is the
same.
8-301.1 DELETED.
8-296. Bench Test - Transmission Oil Temper-
ature Bulb. Refer to paragraph 8-97 for bench 8-302. Troubleshooting - DC Voltmeter. Use
test; procedure is the same. table 8-17 and perform checks as necessary to
isolate trouble. (See figure F-18).
8-297. Installation - Transmission Oil Temper-
ature Bulb. Refer to paragraph 8-98 for installa-
NOTE
tion; procedure is the same.
8-298. DELETED. Before using this table, be sure all

normal operational checks have
8-299. DELETED. been performed.
Table 8-17. Troubleshooting DC Voltmeter
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. No reading or erratic reading on dc voltmeter.
STEP 1. Check for open or short circuit in voltmeter.
Replace voltmeter if defective (paragraph 8-1).
STEP 2. Determine if mechanism in instrument is worn or dirty.
Replace voltmeter if defective (paragraph 8-1).
8-48 Change 7
TM 55-1520-210-23-2
8-303. LOADMETER. 8-308. Inspection - Free Air Temperature

Gage.
8-304. Description - Loadmeter. Two dc load-
meters are provided for main and standby dc gener- a. Inspect assembly for corrosion.
ators to indicate output or load of each generator as
a percent of total capacity. The dc Ioadmeter is func-
tionally tested as a part of Direct Current Distribu- b. Inspect for discoloration.
tion System (paragraphs 9-58 and 9-59). Refer to
paragraphs 8-3 through 8-7 for maintenance proce- c. Inspect for leaking seal.
dures.
d. Check for proper temperature indication.
8-304.1. DELETED
8-305. FREE AIR TEMPERATURE GAGE. 8-309. Functional Test - Free Air Temperature
Gage. Refer to TM 1-1500-204-23-4.
8-306. Description - Free Air Temperature
Gage. The free air temperature gage is a bimetal- 8-310. Troubleshooting - Free Air Tempera-
lic, probe type thermometer mounted on the upper ture Gage. Use table 8-18 and perform neces-
left side of the pilots windshields. The probe portion sary checks to isolate trouble.
is exposed to outside temperature through a rubber
grommet mounted on the skin of the helicopter. The
indicator is calibrated in degrees Celsius. NOTE
8-307. Cleaning - Free Air Temperature Before using this table, be sure all
Gage. Refer to paragraph 8-3 for cleaning proce- normal operational checks have
dure. been performed.
Table 8-18. Troubleshooting Free Air Temperature Gage
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. Gage indicating upscale of range.
STEP 1. Check for missing or improperly installed sunshie!d
Install missing or reinstall improperly mounted sunshield.
STEP 2. Determine if gage is defective.
Replace gage if defective (paragraph 8-1).
2. Gage indicating downscale of range.
STEP 1. Determine if gage is defective.
Replace gage if defective (paragraph 8-1).
Change 7 8-49
TM 55-1520-210-23-2
8-311. Removal - Free Air Temperature Gage. 8-313. Installation - Free Air Temperature
Gage.
a. Unscrew and remove sunshield dished
a. Test new gage. (Refer to TM 1-1500-204-
washer, and one case washer from outer end of
23-4).
thermometer.
b. Hold washers and thermometer case in posi-
b. Remove thermometer and other case tion at mounting flange.
washer from inside of pilots compartment.
c. Insert probe through grommet and mounting
8-312. Repair or Replacement - Free Air Tem- flange.
perature Gage. Replace gage if any of the
inspection requirements are not met (paragraph d. Place sunshield over thermometer probe and
8-308). tighten.
8-50 Change 7
-
8-314. RADAR WARNING INDICATING SYS- 8-314.1. DELETED.
TEM (AN/APR-39) (WHEN INSTALLED).
The radar warning system provides the pilot 8-314.2. Countermeasures System, An/
with both visual and audible warning when a high ra- ALQ-144. (Provisions Only — When Installed).
dar threat environment is encountered. The system This jamming system (figure 8-10) provides a coun-
(see figure 8-8) is effectively operated by use of a termeasures function for certain threat environ-
control panel located on the pilots right console and ments. The system is effectively operated by use of
an indcator on the instrument panel. Refer to TM a control panel located on the pilots console and an
11-1520-210-20 for description, operational indicator on the master caution panel. Refer to TM
check, troubleshooting, and maintenance of sys- 11-1520-210-20 for description, operational
tem components. Refer to paragraph 8-1 for instru- check, troubleshooting and maintenance of system
ment maintenance. components.
SECTION VI. INSTRUMENT PANELS
8-315. INSTRUMENT PANELS AND GLARE- b. Remove grease, fungus, and dirt with a
SHIELD. clean, lint-free cloth dampened with dry cleaning
solvent (C261 ).
8-316. Description - Instrument Panel, Glare-
shield and Glareshield Extension (NVG) (Night 8-318. Inspection - Instrument Panel, Glare-
Fix - Phase 1). The instrument panel is mounted shield and Glareshield Extension (NVG) (Night
on the top forward section of the pedestal and con- Fix - Phase 1).
tains all instruments for the pilot and copilot. Instru-
ment panel vibration may be eliminated or mini- a. Visually inspect panels for surface scratches,
mized by adjusting the tube and brace assemblies war-page, cracks, and loose mounting screws.
provided for this purpose. The tube assemblies are
attached to the helicopter structure by means of a b. Inspect compass correction cards, placards,
pin, washers, and cotter pin. They are equipped and decals for legibility.
with a clevis and check nut for adjustment. The
brace assemblies are attached to the pedestal and c. Inspect brace assemblies for sagging,
may be adjusted by turnbuckles incorporated in the cracks, and permanent set.
brace assemblies. A glareshield is attached to the
top edge of the instrument panel to reduce glare and d. Inspect rheostats and switches for missing
improve instrument readability. On UH-1 helicop- and loose knobs.
ters modified for Night Vision Goggles (NVG) (Night
Fix - Phase 1), a glareshield extension has been e. Inspect glareshield and glareshield extension
installed on the existing glareshield to accept NVG (if installed) for cracks or loose mounting.
lighting.
8-319. Removal - Instrument Panel and Glare-
8-317. Cleaning - Instrument Panel, Glare- s h i e l d .
shield and Glareshield Extension (NYG) (Night
Fix - Phase 1). a. Ensure all electrical power is off.
a. Remove moisture and loose dirt with a clean, b. Disconnect all electrical receptacles and
soft cloth. hoses from instruments and glareshield.
c. Cover all receptacles and hoses to prevent

entrance of foreign particles.
d. Cover openings on instruments.
d.1. Remove attaching hardware from glare-

shield and remove glareshield.
Dry cleaning solvent is flammable and
its fumes are toxic. Provide adequate e. Remove pin, washers, and cotter pin secur-
ventilation. Do not use near a flame. ing each tube assembly.
Change 7 8-51
TM 55-1520-210-23-2
f. Remove instrument panel from helicopter. c. If rubber channel on NVG extension is loose
or missing, rebound with adhesive (C22) or replace.
8-319.1. Removal - Glareshield (NVG) (Night
Fix - Phase 1). 8-321. Installation - Instrument PaneI, Glare-
shield and Glareshield Extension (NVG) (Night
a. Remove attaching hardware from cockpit Fix - Phase 1).
l i g h t s .
a. Ensure all electrical power is off.
b. Remove attaching hardware from glareshield
extension and remove extension from glareshield.
b. Install brace assemblies if removed.
8-320. Repair or Replacement - Instrument
Panel. e. Position panel in place on console and install
mounting hardware.
a. Repair cracks (Refer to TM 1-1500-204-23
series). d. Connect electrical receptacles to instru-
ments.
b. Replace brace assemblies if warped.
e. Apply silicone compound (C250) to threads
c. Replace loose or worn mounting screws. of pitot-static fittings.
8-320.1. Repair or Replacement - Glareshield f. Connect nylon fittings. Torque coupling nuts
and Glareshield Extension (NVG) (Night Fix - fingertight.
Phase 1).
g. If NVG extension was removed, reinstall on
a. Cracks less than two inches in length maybe
giareshield. Install cockpit lights on extension.
repaired with epoxy (C29). Cracks in excess of two
inches shall be cause for replacement.
h. Reinstall glareshield on instrument panel.
b. If necessary, reprint repaired area with paint
(C145). i. Reconnect all electrical wires.
Page 8-54, including Figure 8-9 have been deleted.
8-52 Change 7
TM 55-1520-210-23-2
Figure 8-8. Radar Warning System AN/APR-39
TM 55-1520-210-23-2
Figure 8-10. Radar Countermeasures System AN/ALQ-144

TM 55-1520-210-23-2
CHAPTER 9
ELECTRICAL SYSTEMS
SECTION I. DIRECT CURRENT POWER DISTRIBUTION SYSTEM
NOTE
Power loading charts and detail system wiring

diagrams are contained in Appendix F. Aviation
Unit Maintenance activities shall request AVIM
for electrical system repairs in accordance with
the Maintenance Allocation Chart, Appendix B.
9-1. DIRECT CURRENT POWER DISTRIBU- failure. A bus-reset feature is provided to permit
TION SYSTEM. reactivation of these loads at the pilots discretion.
9-2. Description - Direct Current Power 9-2.1. DELETED.

Distribution System. The direct current power
distribution system provides all basic power for 9-3. COMMON ELECTRICAL COMPONENTS
operation of electrical components installed in the (DC).
helicopter and consists of the main and standby
generators, battery, external power, and dc bus 9-4. Description - Common Electrical Compo-
systems. nents (DC). Common electrical components
include the miscellaneous electrical components
The primary electrical power is supplied by the (paragraph 9-5), circuit breakers (paragraph 9-12),
transmission driven 30 volt, 300 ampere main gen- and control panels (paragraph 9-19).
erator (G2). In the event of main generator failure,
emergency dc power is supplied by the engine 9-5. MISCELLANEOUS ELECTRICAL COM-
driven, 30 volt, 300 ampere standby starter-genera- PONENTS.
tor (G6). If both generators fail, power is supplied by
the 24 volt, 34 ampere/hour battery which also 9-6. Description - Miscellaneous Electrical
furnishes starting power. Components. Capacitors, diodes, leads and wir-
ing, panel lights, connectors, relays, rheostats,
Primary power is distributed by a dual-bus arrange- shock mounts, shunts and bus bars, switches, ter-
ment, so that nonessential dc loads are automati- minal boards, 5-volt instrument lighting circuitry,
cally de-energized in the event of main generator and transistors are included in this category.
C h a n g e 7 9-1
TM 55-1520-210-23-2
9-7. Cleaning - Miscellaneous Electrical Compo- i. Inspect terminal boards for cracks, corrosion, se-
nents (General). curity, and damaged threads.
a. Remove moisture, dust, and loose dirt with a j. Inspect panel lights for faulty bulbs, security, and
clean, soft cloth. corrosion.
k. Visually check capacitors for loose connections,
security of mounting, leaking dielectric, and apparent
WARNING
damage.
Dry cleaning solvent is flammable and its l. Visually check diodes for loose connection and
fumes are toxic. Provide adequate ventila- broken leads. Check suspected faulty diode front to back
tion. Do not use near a flame. conductivity ratio with standard ohmmeter.
b. Remove grease, fungus, and dirt from the equip- m. Visually check transistor mount for security.
ment cases and mountings; use a cloth dampened (not Check suspected faulty transistor by voltmeter.
wet) with solvent (C261). n. Inspect 5-volt power supplies for damage to case
and evidence of corrosion, pits or discoloration. Inspect
9-8. Inspection - Miscellaneous Electrical Compo- mounting hardware for retention and security. Inspect
nents. terminal board for loose terminals and security.
a. Inspect rheostats for security, corrosion, burned
element, damaged wiper, cracks, and correct resistance. 9-9. Removal - Miscellaneous Electrical Compo-
nents.
b. Inspect switches for weak detents, security, cor-
rosion, faulty operation and continuity in ON and infinity
in OFF position. WARNING
c. Inspect plugs, connectors and receptacles for se- Before removing any electrical compo-
curity, contact corrosion, damaged contacts, broken nent, ensure all electrical power is off.
wires, faulty contacts, insert cracks, and faulty insulation. a. Remove attaching hardware, clamps, connec-
d. Inspect leads and wiring for loose terminals, tors or conductors; identify connectors and/or conduc-
chafing, corrosion or deteriorated condition, faulty or tors.
damaged insulation, excessive mechanical stress, bro- b. Remove component.
ken strands, damaged shielding, shorted shielding, rout-
ing and mounting conditions. 9-10. Repair or Replacement - Miscellaneous Elec-
trical Components.
e. Inspect conduits for security, surface damage,
cracks, dents, corrosion, and deterioration. a. Tighten loose terminal connectors, mounting and
attachments of electrical components.
f. Inspect shunts and bus bars for corrosion, securi-
ty, deep scratches, physical damage, deformity; and dis- b. Replace miscellaneous electrical components
coloration (indicating excessive overloading). that fail to meet inspection requirements.
g. Inspect shockmounts for binding, compression, c. Clean corrosion from connectors and recep-
retention, security, cracks, distortion, and corroded tacles with cleaner (C42).
bonding.
9-11. Installation - Miscellaneous Electrical Compo-
h. Inspect relays for loose connections, damaged nents.
or broken contact pins or terminals, damage to case or
a. Install component and secure with attaching
insulation between contact pins, and evidence of corro-
hardware or damps.
sion, pits, or discoloration (indicating arcing due to loose
connections, internal shorting, or excessive overload). b. Attach identified terminals and/or connectors.
9-2 Change 14
TM 55-1520-210-23-2
9-12. DC CIRCUIT BREAKERS. c. Remove mounting hardware and lift circuit

breaker from panel assembly.
9-13. Description - DC Circuit Breakers. The
dc circuit breakers are mounted on the overhead
console. Dc circuits can be opened or dosed by 9-17. Repair and Replacement - DC Circuit
these circuit breakers. Breakers.
9-14. Cleaning - DC Circuit Breakers (Gen- a. Repair is limited to tightening or porperly

eral). Refer to paragraph 9-7. Procedure is the installing any loose or improperly installed mounting
same. hardware and connectors.
9-15. Inspection - DC Circuit Break-

ers. Inspect circuit breakers for reset retention, b. Replace circuit breaker if any other inspec-
activation for circuit ON and power OFF, faulty tion requirements are not met.
operation, corrosion, and security.
9-16. Removal -DC Circuit Breakers. 9-18. Installation -DC Circuit Breakers.
a. Ensure all electrical power is OFF, Discon- a. Position circuit breaker in panel assembly
nect battery. and install mounting hardware.
b. Disconnect wiring to appropriate circuit

breaker and cover wire ends with electrical tape b. Remove cover from wire ends and connect to
(C270). circuit breaker.
Change 7 9-3
TM 55-1520-210-23-2
9-19. CONTROL PANELS. c. Apply power and check components for

proper operation.
9-20. Description - Control Panels. The con-
trol panels on the overhead console areas follows: 9-26. BATTERY SYSTEM.
DOME LT-PITOT, EXT LTS, CABIN HEATING,
MlSC, DC POWER, INST LTG, and AC POWER. 9-27. Description - Battery System.
The control panels on the pedestal are as follows:
ENGINE, FORCE TRIM-HYD CONTROL, and a. The battery system is comprised of the bat-
CAUTION. tery (BT2), battery relays (K9 and K65), battery
feeder relay (K66), and BAT switch (S40). The bat-
9-21. Cleaning - Control Panels. Refer to tery system is associated with the forward and aft
paragraph 9-7. Procedure is the same. BATT VM circuit breakers (CB6), forward and aft
battery voltmeter terminal boards (TB60 and TB61),
9-22. Inspection - Control Panels. Visually DC VM switch (S2), dc voltmeter (M2), nonessential
inspect for scratches, chipped edges, faulty edge bus relay (K2) and NON-ESS BUS switch (S62).
light panels and bulbs, broken edge light panels, The battery also furnishes power for the XMSN OIL
damaged or faulty switches, loose or damaged LEVEL LT (125). See figure 9-1 for compartment
wiring and connectors, and broken or missing location and figure 9-2 for equipment location.
mounting fasteners.
b. On helicopters prior to S/N 65-9565, the bat-
9-23. Removal - Control Panels. tery circuit is activated by placing BATT SW (S40)
to the ON position. Battery relay (K9) is energized
NOTE and battery power is transferred through the con-
tacts of battery relay (K9) to the main and essential
The removal procedures for all elec- dc buses.
trical control panels are relatively the
same. A single removal procedure c. On helicopters S/N 65-9565 and subsequent,
may be used for any electrical control an alternate battery location is provided in the aft
panel. fuselage compartment and the specific battery
location depends on loading of mission equipment
a. Ensure all electrical power is OFF. for proper weight and balance of the helicopter. If
battery is installed in the nose compartment, placing
b Disengage fasteners holding panel moun- BATT SW (S40) to ON position energizes battery
ting. relay (K9). Battery power is transferred through the
contacts of battery relay (K9) to battery feeder relay
c. Carefully lift panel from mount. (K66) and through contacts of battery feeder relay
to the main and essential dc buses. If battery is
d. Disconnect electrical connector(s). installed in the aft fuselage compartment, placing
BATT SW (S40) to ON position energizes battery
9-24. Repair and Replacement - Control Pan- relay (K65) and battery power is transferred through
els. the contacts of battery relay (K65) to the main and
essential dc buses.
a. Repair any scratches or chipped edge light
panels. d. The nonessential bus relay (K2) is energized
when battery power is applied to the essential bus
b. Replace any burned out or defective bulbs on by placing the NON-ESS BUS switch (S62) to the
edge light panels. MANUAL position. Battery power is then applied
through the contacts of the nonessential bus relay
C. Replace control panel if any other inspection
to the nonessential bus.
requirements are not met.
e. The dc voltmeter (M2) monitors battery volt-
9-25. Installation - Control Panels. age when DC VM switch (S2) on dc power control
panel (A1) is positioned to BAT and BAT VM circuit
a. Connect electrical connector(s). breaker (CB6) is closed. The battery voltage
applied to the essential or nonessential bus may be
b. Position panel in mount, being careful not to monitored by placing the DC VM switch (S2) to ESS
damage wiring. Engage fasteners. BUS or NON-ESS BUS position.
9-4 Change 7
TM 55-1520-210-23-2
Figure 9-1. Compartment Location - Electrical
9-27.1. DELETED. NOTE
9-28. Functional Test - Battery System. Unless otherwise specified, the volt-
meter circuit breakers are to remain
a. Before connecting the battery, check for cor- closed throughout the test.
rect polarity and tightness of the battery leads and
terminations. d. Position DC VM switch (S2) to BAT and
check that voltmeter indicates battery voltage.
b. Open all circuit breakers and place all e. Position DC VM switch (S2) to each remain-
switches in the off position. Place NON-ESS bus ing position. Voltmeter should indicate zero voltage.
switch to normal. Ensure that battery switch is OFF.
Connect battery. f. Position DC VM switch (S2) to ESS BUS.
Position BAT switch (S40) to ON. Check that volt-
c. Close standby Ioadmeter circuit breaker, meter indicates battery voltage. Other positions,
main generator voltmeter circuit breaker, battery except BAT, should indicate zero.
relay circuit breaker, nonessential bus voltmeter
circuit breaker, and the GEN and BUS reset circuit g. Position nonessential bus switch (S62) to
breaker, (these circuit breakers are located in elec- MANUAL ON and check that voltmeter indicates
trical compartment and on the overhead console.) battery voltage for the NON ESS BUS, ESS BUS
and BAT positions of the selector switch. Return
switches to normal.

TM 55-1520-210-23-2
Figure 9-2. Electrical Equipment Location (Sheet 1 of 3)
Change 7 9-7
TM 55-1520-210-23-2
9-8 Change 7
TM 55-1520-210-23-2
CODE CODE
ITEM DESCRIPTION ITEM DESCRIPTION
L4 Solonold, Hydraulic Bypass TB16 Terminal Board, Cockpit Lights - Right-Hand

L8 Magnetic Brake, Anti-Torque Force Trim TB25 Terminal Board, Thermocouple-Indicator
L9 Magnetic Brake, Fore & Aft Force Trim
TB29 Terminal Board, Instrument Ground
L10 Magnetic Brake, Lateral Force Trim
TB35 Terminal Board, Right-Hand Fuel Cell
P66 Plug, Fuel Pressure Mixture TB36 Terminal Board, External Power Diode
P71 Plug, Fuel Valve Shut-Off TB39 Terminal Board, Electrical Compartment-Aft
P95 Plug, Fire Detector Element - Left-Hand TB60 Terminal board, Battery Voltage- Forward
P97 Plug, Fire Detector Element - Left-Hand TB100 Terminal board, 5-Volt Power Supply-Pilot and
PSI 5-Volt Power Supply-Pilot (PS-274B) Copilot
PS2 5-Volt Power Supply-Copilot (PS-274B)
VR1 Voltage Regulator-Main Generator
R1 Shunt-Ammeter - Standby Generator VR2 Voltage Regulator-Standby Generator
R2 Shunt-Ammeter - Main Generator
R3 Resistor, Windshield Wiper Z3 Flasher Unit, Navigation Lights
R7 Resister, Navigation Lights - Dim
1. Power Factor Correction Circuit Breakers
R12 Resistor, Spool Thermocouple
R27 Resister, AC Load Balancing 2. Battery Voltmeter Circuit Breaker
3. AM-3209( )/ASN Amplifier, Electronic Control
S195 Engine Chip Detector 4. Vertical Gyro - Type MD-1
S4 Switch, Transmission Sump Inspection Light 5. Junction Box - Upper, BJ-4-F
S27 Switch, Hydraulic Pressure
6. Junction Box - Lower, BJ-4-A
S31 Switch, Limit-External Power Door
7. Circuit Breakers
S101 Switch, Differential Pressure
a. Main Generator Voltmeter
T1 Transformer, 115/28 Volt b. Standby Generator Loadmeter
TB1 Terminal Board, Forward Instrument Panel Voltmeter
TB9 Terminal Board, Top and Dome Lights c. Standby Generator Loadmeter
TB12 Terminal Board, Pedestal Panel Edge Lights d. Main Generator Field
TB15 Terminal Board, Cockpit Lights - Left-Hand 8. ODDS Power Module
Pages 9-10 and 9-11, Including Figure 9-2.1, have been deleted.
Change 7 9-9
TM 55-1520-236-23-2
Figure 9-2.1 Deleted
Change 7 9-11
TM 55-1520-210-23-2
Figure 9-2.1, Has been deleted.
h. Repeat steps e., f., and g. with the battery or 24 usually easily detected and corrected. Broken wiring is
volt external power source connected to the power always a probable cause of circuit malfunction or fail-
cables at the quick-disconnect in the aft battery loca- ure and has not been included (Figure F-18).
tion.
NOTE
9-29. Troubleshooting - Battery System. U s e
Table 9-1 and perform checks as necessary to isolate Before you use this table, be sure you
trouble. In the following table, tripped circuit breakers have performed all normal operational
are omitted from indications of trouble. Such trouble is checks.
9-12 Change 7
TM 55-1520-210-23-2
Table 9-1. Troubleshooting Battery System
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. Dc voltmeter indicates zero volts with BAT VM circuit breaker closed and DC VM switch in BAT position.
STEP 1. Ensure that battery is installed and power is available. Check that battery voltage is present on both
sides of BAT VM circuit breaker with a multimeter.
If voltage is present on battery side but not present on dc voltmeter side of circuit breaker,
replace circuit breaker (paragraph 9-12).
STEP 2. Check for battery voltage at diode (CR30).
If voltage is present on battery side but no present on dc voltmeter side of diode, replace diode
(paragraph 9-5).
STEP 3. Ensure that battery voltage is present at terminal 17 of DC VM switch (S2) and check for voltage
on terminal 11.
If voltage is present on terminal 17 but not present on terminal 11, replace DC VM switch (para-
graph 9-5).
STEP 4. Check for battery voltage across dc voltmeter (M2).
If battery voltage is present, replace dc voltmeter (paragraph 8-1 ).
2. DC voltmeter indicates zero volts with BAT switch (S40) ON, DC VM switch (S2) in ESS BUS, and GEN &
BUS RESET circuit breaker closed. (Dc voltmeter indicates correct voltage with DC VM switch in BAT posi-
tion.)
STEP 1. Check that battery voltage is present on 28 Vdc essential bus with a multimeter. (If voltage is not
present on essential bus, continue with step 3.) Using a multimeter, determine if voltage is present across a
GEN & BUS RESET circuit breaker.
Replace the GEN & BUS RESET circuit breaker if defective (paragraph 9-12).
STEP 2. Ensure that essential bus voltage is present on terminal 14 of DC VM switch (S2) and check for
voltage at terminal 11.
Replace DC VM switch if voltage is not present at terminal 11 (paragraph 9-5).
STEP 3. CHECK that BAT switch (S40) completes ground circuit in ON position.
Replace BAT switch if defective (paragraph 9-9).
STEP 3.1. DELETED.
STEP 4. When battery is installed in aft battery compartment and battery voltage is present on terminal A1
of battery relay (K65), determine if battery relay (K65) is actuated by checking for battery voltage at terminal.
Change 7 9-13
TM 55-1520-210-23-2
Table 9-1. Troubleshooting Battery System (Cont)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
A2. If relay is not actuated, determine that ground potential is present at terminal X2 and check for relay
actuating voltage across terminals X1 and X2.
Replace relay if actuating voltage is present across terminals X1 and X2 and relay is not actuated
(paragraph 9-5).
STEP 5. When battery is installed in nose compartment and battery voltage is present on terminal A2 of
battery relay (K9), determine if battery relay (K9) is actuated by checking for battery voltage at terminal A1. If
relay is not actuated, determine that ground potential is present at terminal X2 and check for relay actuating
voltage across terminals X1 and X2.
(paragraph 9-5).
STEP 6. With battery relay (K9) actuated and battery voltage present at terminal A2 of battery feeder relay
(K66), determine if battery feeder relay is actuated by checking for battery voltage at terminal A1. If relay is
not actuated, determine that ground potential is present at terminal X2 and check for relay actuating voltage
across terminals X1 and X2.
(paragraph 9-5).
3. Dc voltmeter indicates zero volts with BAT switch (S40) ON, DC VM switch (S2) in NON ESS BUS, NON-ESS
BUS switch (S62) in MANUAL, and NON ESS BUS VM circuit breaker closed. (Dc voltmeter indicates correct
voltage in BAT and ESS BUS positions. )
STEP 1. Check for battery voltage at 28 Vdc nonessential bus and NON ESS BUS VM circuit breaker. (If
battery voltage is not present on 28 Vdc and nonessential bus, continue with step 3.)
Replace NON ESS BUS VM circuit breaker if defective (paragraph 9-5).
STEP 2. Ensure that nonessential bus voltage is present at terminal 13 of DC VM switch (S2) and check for
voltage at terminal 11.
Replace DC VM switch if voltage is not present on terminal 11 (paragraph 9-5).
STEP 3. With battery voltage from main bus present on terminal A2 of nonessential bus relay (K2),
determine if nonessential bus relay is actuated by checking for battery voltage at terminal A2. If relay is not
actuated, determine that ground potential is present at terminal X1 and check for actuating voltage across
terminals X1 and X2.
Replace relay if activating voltage is present across terminals X1 and X2 and relay is not actuated
(paragraph 9-5).
9-14
TM 55-1520-210-23-2
Table 9-1. Troubleshooting Battery System (Cont)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
STEP 4. Check for battery voltage on center contact of nonessential;: bus switch (S62).
Replace nonessential bus switch If defective paragraph 9-).
4. Battery (BT 2) will not hold charge.
STEP 1. Determine if battery usage is too great
Use external power source whenever possible.
STEP 2. Check for too low charging rate.
Adjust voltage regulator (paragraph 9-75).
STEP 3. Perform a visual inspection for broken cell partitions.
Replace battery If cell partition is broken (paragraph 9-36).
STEP 4. Determine if battery cells are unbalanced.
Refer to TM 114140-203-23 for servicing of battery.
5. Battery life is short
Determine if electrolyte level is below top of plate.
Refer to TM 11-140-203-23 for servicing of battery.
6. Excessive loss of electrolyte.
STEP 1. Determine if charging rate is too high. (If loss is in individual cells only, call is faulty.)
Reduce charging rate (paragraph 9-75); replace battery (paragraph 9-36).
STEP 2. Inspect for cracked battery case.
Replace battery if battery case is defective (paragraph 9-46).
7. Battery Terminals corroded.
Check for excessive charging or discharging rate.
Clean terminals (paragraph 9-32) and adjust charging rate or load (paragraph 9-75).
8. Polarity is reversed.
Determine if battery connections are reversed.
Reverse wiring connections if necessary.
Change 10 9-15
TM 55-1520-210-23-2
9-30. BATTERY. on the generator loadmeter. If the change indicated is

less than 5 amperes, the battery is considered
931. Description -Battery. The 24 Volt, 34 ampere- adequately charged.
hour, nickel cadmium type battery is located in the nose
compartment (See figure -1.) A battery shelf assembly is 9-35. Deleted.
provided as an at alternate battery location n the aft
fuselage compartment, accessible by a door on the right 9-36. Removal Battery.
side. The battery shelf assembly is comprised of aft
battery relay (K65), terminal board (TrB81), BATT VM
circuit breaker, associated wiring, vent tubs, tie-down
rods, etc. required, to install the battery in at fuselage
compartment. (Refer to Chapter 2 for sheet metal repair
of the battery shelf assembly.) Utilization of a specific DANGEROUS CHEMICALS ARE USED IN
battery location depends on loading of mission NICKEL-CADMIUM BATTERIES.
equipment for proper weight and balance of the
helicopter. Each battery location is equipped with vent The electrolyte used in nickel-cadmium
tubes, eyebolts for attaching tiedown rods, and a battery batteries contains potassium hydroxide
cable. The prime purpose for the battery is to start the (KOH), which Is a caustic chemical agent
engine at remote fields where external power is not Serious and deep bums of body tissue will
available. If the battery is used to power inverters, use result if the electrolyte comes in contact with
win be limited to a maximum of 5 minutes. After engine the eyes or any part of the body. Use rubber
is started, the battery switch should remain on until the gloves, rubber apron, and protective eye
battery is fully recharged by the main generator. Refer to covering when handling the battery. If
TM 1-6140-203-23 for maintenance instructions other accidental contact with the electrolyte is
than removal or installation.
made, use ONLY clean water and
Immediately (seconds count) flush
contaminated areas. Continue Flushing with
large quantities of clean water. Seek medical
Remove battery to heated area If helicopter is attention Immediately. Before removing or
to remain at outside tiedown for a prolonged installing the battery, insure that the battery
period at O’ F (-18’ C) or below. switch is off and the battery has cooled down
if overheated. Removal or Installation of the
9-32. Deleted. battery connector while the battery is under
load may result in explosion, electrical
9-33. Deleted. arcing, and possible severe bums to
personnel.
9-34. Condition Check Battery. On the helicopter a
charged battery can be determined only by moving the
battery switch from ON to OFF and observing the effect
9-16 Change 10
TM 55-1520-210-23-2
9-38. Installation – Battery.
C0 2 has an acceptable fire extinguishing

agent once a fire has developed. In no DANGEROUS CHEMICALS ARE USED
case should C0 2 be directed into a IN NICKEL-CADMIUM BATTERIES
battery compartment to effect cooling or
displace explosive gases. The static The electrolyte used in nickel-cadmium
electricity generated by the discharge of batteries contains potassium hydroxide
the extinguishers could explode (KOH), which is a caustic chemical
hydrogen/oxygen gases trapped in the agent. Serious and deep burns of body
battery compartment. tissue will result if the electrolyte comes
in contact with the 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
Take every possible step to keep the ONLY clean water and immediately
nickel-cadmium battery as far away as (seconds count) flush contaminated
possible from the lead-acid type of areas. Continue flushing with large
battery. Do not use the same tools and quantities of clean water. Seek medical
materials (screwdriver, wrenches, attention immediately. Before removing
gloves, apron, etc.) for both types of or installing the battery, insure that the
batteries. Anything associated with the battery switch is off and the battery has
lead-acid battery, even the air, must cooled down if overheated. Removal or
never come in contact with the nickel- installation of the battery connector
cadmium battery or its electrolyte. Even while the battery is under load may result
a trace of sulphuric acid fumes from a in explosion, electrical arcing, and
lead-acid battery may result in damage to possible severe burns to personnel.
the nickel-cadmium battery. If sulphuric
acid has been inadvertently mixed with the
electrolyte in the battery, the upper areas
of the cells will appear greenish in color.
In such cases, the battery must be
replaced. Take every possible step to keep the
a. Check that BAT switch is OFF, and external nickel-cadmium battery as far away as
power is not applied. Open compartment door. possible from the lead-acid type of
battery. Do not use the same tools and
b. Disconnect battery cable connector by turning
materials (screwdriver, wrenches,
knob counterclockwise.
gloves, apron, etc. ) for both types of
c. Disconnect two vent tubes from battery case.
batteries. Anything associated with the
d. Cut lockwire, open tie-down clamps lead-acid battery, even the air, must
and disengage rods from battery cover. never come in contact with the nickel-
Lift battery from compartment. cadmium battery or its electrolyte. Even
e, If battery is to be relocated, detach each tie- a trace of sulphuric acid fumes from a
down rod from eyebolt at lower end by removing lead-acid battery may result in damage to
attaching bolt with nut and washers, the nickel-cadmium battery. If sulphuric
acid has been inadvertently mixed with the
f. Stow battery cable connector in dummy electrolyte in the battery, the upper areas
receptacle Close compartment door. of the cells will appear greenish in color.
In such cases, the battery must be
9-37. Deleted replaced.
9-17
TM 55-1520-210-23-2
ment. Helicopters S/N 65-9565 and subsequent have

a battery relay for each battery location. Battery relay
(K65) is mounted in the aft battery compartment. The
relay is an electrically operated switch between the
battery and the main bus bar. It is controlled by a switch
Rigid connecting link (205-030-249-3) must which opens or closes the circuit to the actuating coil
be installed in aft battery compartment before of the relay. Refer to paragraphs 9-5 through 9-11 for
flight or ground run. maintenance procedures.
NOTE 9-41. BATTERY FEEDER RELAY.
Insure battery area is clean before 9-42. Description - Battery Feeder Relay. The
installation of battery. battery feeder relay (K66) located in the aft electrical
compartment, is connected between the main dc bus
a. Open compartment door. If battery is being and battery relay (K9). It serves to isolate the forward
relocated, install tie-down rods on eyebolts provided battery circuit from the main dc bus when the battery
on shelf, using bolts, nuts, and washers removed from is installed in the aft battery position. It is automatically
old location. Detach battery cable connector from actuated when the battery is installed in the nose
dummy receptacle. compartment and battery relay (K9) is actuated. Refer
to paragraphs 9-5 through 9-11 for maintenance pro-
cedures.
9-43. EXTERNAL POWER SYSTEM.
Incorrect installation of the battery cover does 9-44. Description - External Power
not allow the rubber retainer strip to cover two System. During ground operations, external power
center cell caps. Loosening of these caps and may be connected to the systems through an external
electrolyte-spillage may cause battery over- power receptacle (J109), located in lower left side of
heating and/or explosion. AFT fuselage, below electrical equipment compart-
ment access door. No special action or switching is
b. Place battery on shelf, aligned for connections. necessary to connect external power. If external power
Engage tie-down rods to strap on cover. Secure and connections are of the correct polarity, the external
Iockwire (Cl 55). power relay (K1), located in the aft electrical compart-
ment, doses automatically, and connects the ground
c. Connect two vent tubes to battery case and unit to the main power cables energizing the essential
tighten clamps. bus; if not, no action occurs. The nonessential bus is
d. Insert cable connector in battery receptacle energized with NON-ESS BUS switch (S62) in either
NORMAL or MANUAL position. All circuits in the
and secure by turning knob clockwise.
helicopter, with exception of the overvoltage protection
e. Check that battery voltmeter circuit breaker, circuit, function the same on external power as on
near left side of battery, is closed and that voltmeter will helicopter power. Helicopter circuits are not protected
show indication when BAT switch is ON. Return switch against overvoltage when operating on external
to OFF after test. Close compartment door. power.
NOTE
9-45. Functional Test - External Power System.
If the battery exhibits signs of over-
heating or overcharging, such as fumes NOTE
or vapor coming from the vent tube or
free electrolyte present inside case, Unless otherwise specified, the volt-
adjustment of voltage regulator should meter circuit breaker is to remain closed
be checked. throughout all operational checks.
Except where otherwise specified, all
9-39. BATTERY RELAY. operational checks shall utilize external
power. All circuit breakers shall be
9-40. Description - Battery Relay. Battery relay opened before external power is
(K9) is mounted in the left side of the nose compart- connected to the helicopter.
9-18 Change 7
TM 55-1520-210-23-2
a . Before connecting external power for the first circuit breaker. Dc voltmeter should indicate external
time, check for correct polarity, and terminations, and power on the essential bus.
accomplish following steps:
d. Place NON-ESS BUS switch (S62) in the
NORMAL position. Place DC VM switch (S2) in NON-
b. Apply 28 Vdc of reverse polarity between the
ESS BUS position. Voltmeter should indicate 28 Vdc
small pin on the external power receptacle and the
frame of the helicopter. Check that the external power on the nonessential bus. Repeat test with NON-ESS
relay does not close. Remove 28 Vdc reverse polarity. switch (S62) in MANUAL position. Voltmeter should
indicate 28 Vdc on the nonessential bus.
c. Connect a 28 Vdc external power source to 9-46. Troubleshooting – External Power
the helicopter external power receptacle (J109). System. Use table 9-2 and perform checks as
Energize power source. Close GEN & BUS RESET necessary to isolate trouble. In the following table,
tripped circuit breakers and burned-out indicator
Table 9-2. Troubleshooting External Power System
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. Power not available when external power plug is inserted into connector (J109).
STEP 1. Inspect for loose connection between external power plug and connector (J109)
Reconnect external power plug if loose.
STEP 2. Check for reversed polarity in external power plug.
Reconnect at attachment points on APU if reversed.
STEP 3. Check for low voltage from external power supply.

Increase output of external power.
9-19
TM 55-1520-210-23-2
Table 9-2. Troubleshooting External Power System
STEP 4. Determine if external power relay (KI) is activated. If relay is not actuated, check that ground
potential is present at terminal X1 of relay. Check that relay actuating voltage is present across terminals X1
and X2 of relay.
Replace external power relay if relay actuating voltage is present but relay is not activated
[paragraph 9-5).
lamps are omitted from indications of trouble. Such connection of an external power source to the
trouble is usually easily detected and corrected. helicopter.
Broken wiring is always a probable cause of circuit
malfunction or failure and has not been included. 9-49. Cleaning — External Power Receptacle.
(See figure F-19.) Refer to paragraph 9-7 for cleaning procedure.
NOTE
9-50. Inspection — External Power Receptacle.
Before you use this table, be sure you
have performed all normal operational
checks. 9-51. Removal — External Power Receptacle. a,
Ensure that all electrical power is OFF.
9-47. EXTERNAL POWER RECEP-
TACLE.
b. Remove nuts and washers from terminal
9-48. Description - External Power Receptacle. posts of receptacle and remove wires to recepta-
The external power receptacle (J109) is located in cle. Cover wire ends with tape (C275).
lower left side of AFT fuselage below the electrical
equipment compartment access door and is covered c. Remove mounting screws and lift receptacle
by a small access door. The receptacle provides for from bracket.
9-20
TM 55-1520-210-23-2
9-52. Repair or Replacement - External Power control of the reverse current relay. A warning light is
Receptacle. Refer to paragraph 9-10 for repair or provided on the caution panel to indicate when the
replacement criteria. main generator reverse current relay is not closed. The
warning light is provided with dc power from the battery
9-53. Installation - External Power Receptacle. or standby generator through the contacts of the bus
control relay (K4). The main generator supplies power
a. Position receptacle on bracket and install to the bus control relay coil through the IND terminal on
mounting screws. the reverse current relay when it closes and connects
the main generator to the main bus.
b. Remove tape from wire ends and install wire
ends on terminal posts of receptacle. c. The standby generator (G6) develops voltage
whenever it is being driven by the engine. The voltage
9-54. EXTERNAL POWER RELAY. regulator (VR2) in the standby system is adjusted so
the voltage output of the standby generator is
9-55. Description - External Power Relay. The approximately one volt below that of the main
external power relay (K1 ), installed in the aft electrical generator normal output. A reverse current relay (K23)
compartment, connects an external source of power is also provided for the standby system. Control of the
through the external power receptacle to the electrical reverse current relay is provided for by the standby
system of the helicopter. A diode (CR2), mounted on position of the starter-generator switch (S70) and the
terminal board (TB36), is located near the relay, and bus control relay (K4). During normal operation the
serves to complete ground return for the holding coil main generator reverse current relay energizes the
and prevents reverse polarity to the helicopter electri- bus control relay when the main generator is
cal system. Refer to paragraph 9-5 through 9-11 for connected to the bus. The bus control relay performs
maintenance procedures. three functions: (1) Opens the circuit between the
standby position of the starter-generator switch and
9-56. GENERATOR AND DC BUS SYSTEM. the standby reverse current relay preventing the relay
from automatically connecting the standby generator
9-57. Description - Generator and DC Bus Sys- to the main bus. (2) Opens the circuit to the DC
tem. generator light, turning the caution light off. (3)
Completes a circuit from the essential bus through the
a. The dc bus system supplies regulated power “normal on” position of the nonessential bus switch
for all dc electrical components of the helicopter. This (S62) to the nonessential bus relay (K2), energizing
system is fed by external power, battery (BT2), main the nonessential bus. If the main generator fails or is
dc generator (G2), and standby starter-generator disconnected from the main bus for any reason, the
(G6). following events occur. The bus control relay is
de-energized. The DC GENERATOR segment on the
b. The self-excited main generator (G2) normally
caution panel illuminates. The circuit to the
supplies electrical power to the main bus when its out- nonessential bus relay opens to de-energize the
put voltage is approximately 1/2 volt above that exist- nonessential bus. While the circuit between the
ing at the bus. Mechanical power is not supplied to the standby position of the starter-generator switch and
main generator until the engine starts driving the main the standby reverse current relay is completed to
rotor transmission. The voltage of the main generator connect the standby generator to the main bus.
at which it starts supplying power to bus system will Overvoltage protection is provided for the standby
vary according to the voltage applied to the main bus system by a built-in over-voltage circuit breaker on
from other sources (other sources may be: battery, solid state voltage regulators. A Ioadmeter (M1) is
standby generator, or external power supply.) If no provided for measuring the system amperage load on
other voltage source is connected to the bus, the main the standby generator. On helicopters S/N 66-746 and
generator will be connected to the main bus when its subsequent, a standby generator field relay (K15) is
output is 22 to 24 volts with main generator switch on. provided.
The main generator reverse current relay (K5)
automatically closes and opens the circuit between the d. The purpose of the standby generator field
generator and the main bus. The voltage regulator control relay is to open the standby generator shunt
(VR1) provides for proper generator voltage output field circuit whenever the coil is energized. Power is
during normal operating speeds and loads. A field applied to the coil whenever the starter relay is
control relay (K7) operating in conjunction with the energized by pressing the start switch. The shunt field
overvoltage relay (K6) protects the dc powered circuit is completed through the relay when the start
components on the helicopter from overvoltage from switch is released.
the main generator. A generator switch (S8) is pro-
vided on the dc power control panel to provide manual 9-57.1. Deleted
Change 7 9-21
TM 55-1520-210-23-2
9-58. Functional Test - Generator and DC Bus able 28 volt dc power source (26 to 33 Vdc). Observing
System. the proper polarity.
a. Perform functional test of main generator (2) Close both standby generator loadmeter
circuitry as follows: circuit breakers in the electrical compartment. Position
starter-generator switch (S70) to START. Energize
(1) Disconnect wires P13A4, P13B4, and external power source. There should be no voltage on
P13C4 from positive terminal B, and disconnect wires the main bus in the electrical compartment. Check that
P14A4, P14B4, and P14C4 from negative terminal E dc voltmeter indicates power source voltage in the
of main generator. Connect these wires to an adjust- STBY GEN position.
able 28 volt dc power source (26 to 33 Vdc), observing
the proper polarity. (3) Close STBY GEN FIELD circuit breaker.
Position starter-generator switch (S70) to STBY GEN
(2) Energize power source. and check that essential bus is energized.
(3) Close GEN & BUS RESET, MAIN GEN VM (4) Close GEN & BUS RESET circuit breaker.
and CAUTION LIGHTS circuit breakers. There should Position nonessential bus switch (S62) to MANUAL
be no voltage on the main bus in the electrical compart- ON. Both essential and nonessential buses should be
ment. Check that dc voltmeter indicates voltage in the energized. Check that dc voltmeter indicates voltage
MAIN GEN position. of the power source in the STBY GEN, ESS BUS and
(4) Close MAIN GEN FIELD circuit breaker. NON ESS BUS positions.
Position generator switch (S8) to ON. Reverse current (5) Momentarily engage a load, such as the
relay (K5) should close and both essential and
main inverter, and check that the standby generator
non-essential buses should be energized. Check that
Ioadmeter reads upscale. Return all switches and
DC GENERATOR caution light is off.
breakers to the open position and reconnect wires to
(5) Momentarily turn on a load, such as the their proper terminals.
main inverter, and check that main generator
9.58.1. Deleted.
loadmeter reads upscale.
NOTE 9-59. Troubleshooting - Generator and DC Bus
System.
Solid state voltage regulators have an
overvoltage circuit breaker set to trip at a. On helicopters prior to S/N 66-746, perform
approximately 30.5 volts to cut power checks as necessary to isolate trouble using the
following troubleshooting table 9-3. In the following
from generator field.
table, tripped circuit breakers and burned out indicator
(6) Ensure that BATT switch (S40) is OFF. lamps are omitted from indications of trouble. Such
Slowly increase voltage to the power source. At 31 to trouble is usually easily detected and corrected.
33 volts, overvoltage relay (K6) should actuate, Broken wiring is always a probable cause of circuit
causing field relay (K7) to trip and reverse current relay malfunction or failure and has not been included. (See
(K51) to open and thus remove voltage from all buses. figure F-20.)
Do not exceed 33 volts.
b. On helicopters S/N 66-746 and subsequent,
(7) Reduce voltage to 28 volts. Position battery perform checks as necessary to isolate trouble using
switch (S40) to ON. Reset main generator system by the following troubleshooting table 9-4. In the following
placing generator switch (S8) in the RESET position table, tripped circuit breakers and burned-out indicator
and then back to OFF. Return battery switch to OFF. lamps are omitted from indications of trouble. Such
Position generator switch to ON Field relay (K7) should trouble is usually easily detected and corrected.
reset and reverse current relay (K5) should reclose Broken wiring is always a probable cause of circuit
again energizing all buses. malfunction or failure and has not been included (See
figure F-20)
(8) Return generator switch to OFF, open GEN
& BUS RESET circuit breaker, and reconnect wires. NOTE
b. Perform functional test of standby starter-
generator circuit as follows:
(1) Ensure BATT SW is OFF. Disconnect wire checks.
P37A1 from positive terminal B and disconnect wires
K5A4 and K5C4 from negative terminal E on the Pages 9-23 and 9-24 Deleted
starter-generator. Connect these wires to an adjust-
9-22 Change 7
TM 55-1520-210-23-2
NOTE

checks.
Table 9-3. Troubleshooting Generator and DC Bus System (Helicopters Prior to S/N 66-746)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. DC GENERATOR light on caution panel not illuminated prior to engine start-up. Bus is energized by battery or
external power and caution light circuit breaker is closed.
STEP 1. Determine if bus control relay (K4) is defective by connecting a jumper between terminals B2 and
B3 on relay.
Replace relay if DC GENERATOR light comes on (paragraph 9-5).
STEP 2. Determine if master caution panel (A4) is defective by disconnecting plug P24 from caution panel
and checking for dc voltage between W (+) and Z (-). Negative voltage should be present. Replace lamps in
GENERATOR segment and reconnect plug P24.
Replace master caution panel if light still does not illuminate (paragraph 9-12).
2. DC GENERATOR light on caution panel does not go out after engine start-up.
STEP 1. Determine if main generator voltage is less than 1.0 volt above standby generator voltage.
Adjust or replace main generator voltage regulator (VR1 ) (paragraph 9-71).
STEP 2. Determine if bus control relay (K4) is defective by moving DC VOLTMETER switch alternately to
MAIN GEN, STBY GEN, and ESS BUS positions.
Replace bus control relay if rated voltage is indicated in all positions and main generator voltage is
on essential bus (paragraph 9-5). If rated voltage is indicated in all positions and standby
generator voltage is on essential bus, continue with step 2.
STEP 3. Check for dc voltage at SW terminal of reverse current relay (K5).
Replace reverse current relay if dc voltage is present at SW terminal (paragraph 9-5).
3. No output from main generator (standby generator operates normally).
If voltage begins to build up, return MAIN GEN switch quickly to OFF to prevent excessive
voltage build-up.
9-25
TM 55-1520-210-23-2
Table 9-3. Troubleshooting Generator and DC Bus System (Helicopters Prior to S/N 66-746) (Cont)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
STEP 1. Place MAIN GEN switch in OFF and dc voltmeter switch (S2) in MAIN GEN position. Remove
plug P60 from main generator field relay, and jumper-connect pins H and N. Place MAIN GEN switch in
ON position and observe dc voltmeter.
Replace main generator (G2) if voltage does not build up (paragraphs 9-64 and 9-65).
STEP 2. Check main generator field relay (K7). If relay is tripped, place dc voltmeter switch in MAIN GEN
position; then, while observing voltmeter, momentarily place MAIN GEN switch in RESET position.
Replace overvoltage relay (K6) if voltage builds up and generator cuts out at less than 31
volts on each reset attempt (paragraph 9-5).
STEP 3. Remove plug P60 from main generator field relay (K7). Check for continuity between relay
sockets N and P.
Replace main generator field relay if no continuity exits or if resistance is more than one ohm
(paragraph 9-5).
STEP 4. If main generator field relay (K7) will not reset, check for voltage between pin B and helicopter
structure when MAIN GEN switch is moved to RESET position.
Replace relay if voltage is present (paragraph 9-5).
STEP 5. Flash field generator, failure of the generator to produce output voltage or current may be caused
by loss of residual magnetism in the generator field poles. Restore generator residual magnetism by
flashing field as follows:
Remove carbon pile voltage regulater from the base or disconnect the wire from terminal
F+/A of the solid state voltage regulator. Place battery switch in off position. Attach one end
of the 16 gauge jumper wire to terminal “A” of the carbon pile voltage regulator base or to the
wire disconnected from terminal F+/A of the solid state voltage regulator and other end to
positive bus. Place battery switch momentarily on, then back off. Remove jumper wire. Rein-
stall carbon pile voltage regulator or reconnect the wire to terminal F+/A of the solid state
voltage regulator.
4. No output from standby generator (main generator operates normally).
STEP 1. Determine if built-in protective circuit breaker on solid state voltage regulator (VR2) has tripped.
Reset circuit breaker. Replace voltage regulator if circuit breaker continues to trip (paragraph
9-71).
CAUTION
If voltage begins to build up, remove jumper from across terminals.
STEP 2. Disconnect the wire from the standby voltage regulator terminal F+/A. Place dc voltmeter switch
in STBY GEN position. Momentarily place a 16 gauge jumper wire across main voltage regulator terminal
L+/B and the wire disconnected from F+/A of the standby voltage regulator.
Replace standby generator (G6) if voltage does not build up (paragraph 4-159). Replace
standby generator voltage regulator (VR2) if voltage does build up (paragraph 9-71).
STEP 3. Flash generator field, refer to Condition 3, Step 5, Instructions.
9-26 Change 14
TM 55-1520-210-23-2
Table 9-3. Troubleshooting Generator and DC Bus System (Helicopters Prior to S/N 66-746) (Cont)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
5. Standby generator output normal but does not switch onto main bus when main generator is cut out.
Check for dc voltage at terminal D2 on bus control relay (K4). If voltage is present (no voltage may
indicate STARTER-GEN switch is defective), jumper-connect terminals D2 and D3.
Replace bus control relay if standby generator switches onto main bus. Replace standby
generator reverse current relay (K23) if standby generator does not switch onto main bus
(paragraph 9-5).
Change 14 9-26.1/(9-26.2 blank)

TM 55-1520-210-23-2
Table 9-4. Troubleshooting Generator and DC Bus System

(Helicopters SIN 6746 and Subsequent)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. DC GENERATOR light on caution panel is not illuminated prior to engine start Bus is energized from battery or
external power and caution light circuit breaker is closed.
STEP 1. Temporarily connect jumper wire between terminals B2 and B3 on bus control relay (K4).
Replace bus control relay It light Illuminates (paragraph 9-5).
STEP 2. Disconnect plug P24 from master caution light panel (A4) and check for dc voltage between terminals W(+)
and Z (-) of the plug.
Replace master caution light panel i voltage Is present (paragraph 9-5).
2. DC GENERATOR light on caution panel does not extinguish after engine start and generator is placed in operation.
STEP 1. Check for main generator voltage on essential bus.
Replace bus control relay (K4) If generator voltage Is present on essential bus (paragraph 9-5).
STEP 2. Check for standby generator voltage on essential bus.
Replace main generator reverse current relay (KS) n standby generator voltage is present on essential
bus (paragraph 9-5).
STEP 3. Measure main generator output voltage.
Adjust or replace main generator voltage regulator (VRI) ir less than 1.0 volt above standby generator
voltage (paragraph 9-71).
3. No voltage output from main generator but starter-generator operates normally.
STEP 1. Determine if main generator voltage regulator (VR1) is improperly adjusted or defective.
Adjust or replace main generator voltage regulator I defective (paragraph 9-71).
STEP 2. Check for defective main generator (G2).
Replace main generator If defective (paragraph 9-40).
Change 10 9-27
TM 55-1520-210-23-2

(Helicopters S/N 66-746 and Subsequent) (Cont)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
STEP 3. Check for defective or improperly adjusted overvoltage relay.
Adjust or replace overvoltage relay if defective (paragraph 9-5).
STEP 4. Check main generator switch (S8) for proper operation.
Replace main generator switch if defective (paragraph 9-5).
STEP 5. Place main generator switch (S8) to RESET and then to ON. (Bus energized by battery).
Replace main generator field relay (K7) if voltage does not build up (paragraph 9-5).
STEP 6. Flash generator field, refer to table 9-3, condition 3, step 5, instructions.
4. No voltage output from starter-generator. Main generator operates normally.
STEP 1. Determine if built-in protective circuit breaker on solid state voltage regulator (VR2) has tripped.
Reset circuit breaker. Replace voltage regulator if circuit breaker continues to trip (paragraph 9-71).
STEP 2. Determine if standby generator voltage regulator (VR2) is improperly adjusted or defective.
Adjust or replace standby generator voltage regulator if defective (paragraph 9-71).
STEP 3. Check for defective standby generator (G6).
Replace standby generator if defective (paragraph 9-68.3.).
STEP 4. Check starter-generator switch (S70) for proper operation.
Replace starter-generator switch if defective (paragraph 9-5).
STEP 5. Check for defective standby generator field control relay (K15).
Replace standby generator field control relay if defective (paragraph 9-5).
STEP 6. Check for defective bus control relay (K4).
Replace bus control relay if defective (paragraph 9-5).
STEP 7. Flash generator field, refer to table 9-3, condition 3, step 5, instructions.
9-28 Change 14
TM 55-1520-210-23-2

(Helicopters S/N 66-746 and Subsequent) (Cont)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
5. Standby generator does not switch onto bus to provide power when main generator is inoperative.
STEP 1. Check for dc voltage on terminal D2 of bus control relay (K4).
Replace starter-generator switch (S70) if voltage is not present (paragraph 9-5).
STEP 2. Jumper terminals D2 AND D3 on bus control relay (K4).
Replace bus control relay if standby generator output switches on to bus. Replace reverse
current relay (K23) if standby generator does not switch onto bus (paragraph 9-5).
6. No voltage to nonessential bus when NON-ESS BUS switch is in NORMAL position. Main generator voltage
is present on essential bus. GEN & BUS RESET circuit breaker is closed.
STEP 1. Ensure that actuating voltage is present across terminals X1 and X2 of bus control relay (K4) and
that 28 Vdc essential bus voltage is present at terminal A1. Check for voltage at terminal A2.
Replace bus control relay if voltage is not present at terminal A2 (paragraph 9-5).
Check for actuating voltage at nonessential bus relay (K2).
Replace nonessential bus switch (S62) if voltage is not present. Replace relay if voltage is
present (paragraph 9-5).
7. No voltage on nonessential bus when NON-ESS BUS switch is in MANUAL position. Main generator voltage
present on essential bus. GEN & BUS RESET circuit breaker is closed.
Check for actuating voltage at nonessential bus relay (K2).
Replace nonessential bus switch (S62) and/or GEN & BUS RESET circuit breaker if actuating
voltage is not present at relay (paragraphs 9-5 and 9-12). Replace relay if actuating voltage is
present (paragraph 9-5).
Page 9-30, Including Table 9-4.1, has been deleted.
Change 7 9-29(9-30 blank)

TM 55-1520-210-23-2
9-60. MAIN DC GENERATOR. Tie the two ends of the wire together and hook a spring
scale in the loop formed.
9-61. Description — Main DC Generator. The main
DC generator (G2) is mounted on an accessory pad on (3) Raise the brush by means of the scale until
the forward side of the main rotor transmission. Its capac- the lower end of the brush is even with the bottom edge
ity is rated at 300 amperes and its voltage is controlled of the brush holder. When in this position, the brush
by a voltage regulator which is part of the main generator spring tension should be between 35 and 52 oz. for P/N
system. The main DC generator is driven at the same 30010-000. Take an average of several readings, if the
speed as the engine output shaft and has to be turned spring tension is out of this range, replace the spring.
within a specific range of speed to furnished rated current h. Check that brush leads are flexible and have a
at normal regulated voltage. bright appearance.
9-62. Cleaning — Main DC Generator. i. Check commutator for a smooth bright appear-
ance with a light filming.
a. Remove moisture with a clean, soft cloth.
j. Check that brushes are properly seated (100
percent in direction of rotation and minimum of 75 per-
WARNING cent axially).
Dry cleaning solvent is flammable and its k. Visually check driveshaft splines for wear.
fumes are toxic. Do not use near a flame. NOTE
Provide adequate ventilation. Spline is safe to a top land dimension of
b. Remove grease, fungus and dirt with a clean, zero, but if service records indicate top
lint-free cloth dampened with solvent (C261). land dimension may reach zero prior to
new service period, the driveshaft or ar-
c. Remove dirt from electrical terminals with a mature should be replaced.
bristle brush (C62).
9-63.1 Flashing The Field Of Generator. Failure of a
9-63. Inspection — Main DC Generator. generator to produce output voltage or current may be
a. Visually inspect generator for damage. caused by loss of residual magnetism in the generator
field poles. Restore Generator Residual Magnetism by
b. Check terminals for damage and terminal board flashing field as follows:
to ensure that it is not warped or cracked.
c. Check brush cover for dents and loose or bent a. Remove voltage regulator.
pins.
b. Place battery switch in OFF position.
d. Check diagonal groove in aft end of brush. If no
part of groove is visible, brush requires replacement. c. Attach one end of a jumper cable to terminal A
of voltage regulators base and other end to positive bus.
e. Check that wear indicator (diagonal groove in
brush) indicates that brush has more than one-fourth life d. Momentarily place battery switch in ON position.
remaining.
f. Check brushes for freedom of movement in e. Remove jumper cable.
holders.
9-64. Removal — Main DC Generator.
g. Check brush springs for proper tension on
brushes. a. Open forward transmission fairing.
(1) Using a new brush assembly (see figure b. Tag wires to identify for reinstallation and dis-
9-2.1.1), cut a groove down the center of each side and connect from generator.
across the bottom of both sections. When prepared in c. Loosen attaching nuts and position each wash-
this manner, each brush section will have a continuous er out of recess, rotate generator and pull generator free
groove around two sides and the bottom. of transmission drive.
9-65. Repair or Replacement — Main DC Generator.

CAUTION
a. Repair brush cover dents.
This operation renders this brush assem-
bly unfit for service. Use only for checking b. (AVIM) Replace brush when no part of diagonal
spring tension. groove is visible on aft end of brush. Refer to paragraph
9-65.1.
(2) Place a thin wire around the brush in the
groove; then insert the brush in one of the brush holders. c. No other repairs are authorized.
Change 15 9-31
TM 55-1520-210-23-2
TM 55-1520-210-23-2
9-65.1. (AVIM) Replacement - Generator Brush- 9-66. Installation-Main DC Generator.

es. New brushes must be sanded and run in to prop-
a . Apply light coat of grease (C161) on generator
erly seat them on the commutator before applying full
shaft. Install new gasket. Align generator with trans-
load to the generator. Failure to do so can result in
mission drive, and slide generator into drive splines.
excessive sparking, which will cause burning and pit-
ting of the commutator. b. Position generator on studs with terminals one
bolt left of helicopter centerline rotate generator and
a . Remove generator from aircraft. tighten retaining nuts to attach generator to drive pad.
c. Connect wires to generator terminals.
b . Remove generator brush cover.
d. Position rubber boot to cover generator con-
c . Remove worn brushes. nections and secure with Iacing cord.
d . Install new brushes. e. Perform a voltage regulator check if a new or
different generator is installed. Refer to paragraph
e . Preliminary Brush Seating. 9-75.
(1) Raise each brush spring with a stiff wire 9-67. STANDBY GENERATOR (STARTER-GEN-
hook and lift brush away from the commutator, until the ERATOR).
brush spring can hold the brush in position by resting 9-68. Description - Standby Generator. T h e
against the side of the brush. starter-generator (G6) is mounted on the aft side of
the engine accessory drive gearbox. It serves to drive
(2) Place strip of sandpaper (C233), slightly the engine compressor rotor during the start cycle and
wider than the combined width of the two brush halves, also serves as a 300 amp, engine driven standby gen-
around the commutator with the sand side out. Cut erator at normal engine speeds.
sandpaper strip to .125 inch less than the commutator
circumference. Secure one end of the strip to the com- 9-68.1. Cleaning - Standby Generator.
mutator surface with tape (C276) so that the taped end a. Remove moisture with a clean soft cloth.
will lead in the direction of normal rotation, and the
other end will remain loose.
(3) Lower one set of the brushes in place

against the sandpaper and carefully rotate the arma-
ture by hand in the normal direction of rotation until a
full seat is obtained on each brush. Do not sand exces-
sively. Remove excess carbon dust from sandpaper Dry cleaning solvent is flammable and
before sanding next set of brushes. Sand one set of its fumes are toxic. Do not use near a
brushes at a time. flame. Provide adequate ventilation.
b. Remove grease, fungus, and dirt with a clean,
(4) Remove the sandpaper; remove all carbon lint-free cloth dampened with solvent (C261 ).
dust with dry compressed air. c. Remove dirt from electrical terminals with a
f. Final Brush Seating.
d. When starter generator is oil soaked, return to
(1) Mount generator in Test Stand, Aircraft depot for internal cleaning.
Generator (Item T 16, Table 1-2) (TM 55-4920-2771 9-68.2. Inspection - Starter Generator.
15).
a. Visually inspect generator for damage.
(2) Operate the generator, with brush cover b. Check terminals for damage and terminal
installed, at approximately 5,000 rpm, with air inlet board to ensure that it is not warped or cracked.
temperature between 50°-104° F (10° -40° C), until
brushes are seated 100 percent minimum in the direc- c . Check brush cover for dents and loose or bent
tion of rotation and 90 percent minimum in the axial pins.
direction. NOTE
g. Remove generator from test stand. Starter generator must be removed to

adequately inspect brush wear and
h. Install generator on aircraft. condition.
9-32 Change 7
TM 55-1520-210-23-2
Figure 9-2.1.1 Checking Brush Spring Tension.
Change 2 9-32.1
TM 55-1520-210-23-2
d. Check diagonal groove in brush set. If no part of CAUTION

groove is visible, replace brush set. This operation renders this brush assembly
unfit for service. Use only for checking
a. Check that wear indicator (diagonal groove in brush spring tension.
brush) indicates that brush has more than one-fourth life
remaining. (2) Place a thin wire around the brush in the
groove, then insert the brush in one of the brush holders.
f. Check brushes for freedom of movement in Tie the two ends of the wire together and hook a spring
holders. scale in the loop formed.
g. Check brush springs for proper tension on (3) Raise the brush, by means of the scale
brushes. until the lower end of the brush is even with the bottom
edge of the brush holder. When in this position the
(1) Using a new brush assembly (see figure brush spring tension should be between 35 and 52 oz.
92.1.1), cut a groove down the center of each side and for P/N 30E2061-A Generator or 55 and 65 oz. for P/N
across the bottom of both sections. When prepared in 23064-001 Generator. Take an average of several
this manner, each brush section will have a continuous readings, if spring tension is out of this range, replace
groove around two sides and the bottom. the brush spring.
9-32.2 Change 10
TM 55-1520-210-23-2
h. Check that brush leads are flexible and have a

bright appearance.
i. Check commutator for a smooth bright appear-

ance with a light filming.
Caution must be used to avoid dropping
generator or setting generator onto tail rotor
j. Check that brushes are properly seated (100 drive shaft tunnel. Denting of tail rotor drive
percent in direction of rotation and a minimum of 75 shaft tunnel may cause it to come into con-
percent axially). tact and chafe the tail rotor drive shaft.
d. Loosen nuts on mounting studs. Carefully ro-

k. Check drive spline for excessive wear by rock- tate starter generator and pull straight aft until unit is
ing armature back and forth. If rocking occurs remove free of mounting studs and drive shaft engagement.
generator. Cover mounting pad to prevent entrance of foreign ma-
terial.
l. Check drive shaft assembly splines for wear by
measuring top land of each tooth. If top land dimension N O T E
is 0.015 inch or less, replace generator.
To facilitate easier removal of the starter/
generator, the tail rotor drive shaft tunnel
NOTE may be disconnected at the aft end, to allow
the tunnel to be lowered.
The spline is safe to a top land dimension
e. Remove inlet shroud (3) from starter generator.
of zero, but if service records indicate top
Loosen bolt on outlet shroud (5) and remove shroud.
land dimension may reach zero prior to the
next service period, the drive shaft or arma-
ture should be replaced. NOTE
If starter generator is equipped with end
9-68.3. Removal - Standby Generator. cover (7) and locating screws (6), these
items must be removed before removing
outlet shroud (5).
a. Disconnect battery. Disconnect electrical leads
from starter generator. 9-68.4. Repair or Replacement - All Starter Gen-
erators.
NOTE
a. Repair brush cover dents.
The Gas Producer Tachometer Generator b. (AVIM) Replace brushes when no part of
can be removed to facilitate replacement of diagonal groove is visible on aft end of brush. Refer to
starter generator. paragraph 9-65.1.
C. No other repairs are authorized.

b. Pull end of outlet duct (8, figure 9-2.1) from out-
let shroud (7) on aft end of starter generator.
9-68.5. Deleted.
c. Remove clamp and detach flexible hose (2) 9-68.6. Installation - Starter Generator.
from inlet shroud (3) on forward end of starter
generator. Loosen two bolts on left side and slide a. Position outlet shroud (5, figure 9-2.1) on aft
shroud aft on starter generator to gain access to end of starter generator, secured with stainless steel
mounting studs. bolts and thin washers at clamping joint on right side.
Change 6 9-33
TM 55-1520-210-23-2
NOTE NOTE
When replacement starter generator is
Cement or glue (C25) washers to nuts
requisitioned, the possibility exists of re-
(previously removed from starter mount).
ceiving a different manufacturer’s compo-
Start nuts on studs for mounting starter
nent. If this occurs, wiring diagram and
generator. Due to limited accessibility use
interchangeability chart (Figure 9-2.2) is to
only five nuts and washers.
be utilized.
NOTE e. Carefully position starter generator on mounting
Mark serial number for starter-generator studs, with electrical terminals pointing to the seven
and end of case. This permits ease of o’clock position, making sure that shaft meshes properly
checking number after engine is installed with spines of shaft in gearbox. Rotate starter generator
in helicopter. Use a contrasting color and tighten mounting nuts. Torque nuts 160-190 inch-
paint. pounds.
b. If starter generator has provisions for end cover (7,
figure 9-2.1) and locating screws (6), these items must be f. Slide inlet shroud (3) forward to normal position.
installed as follows: Connect flexible (2) to inlet shroud and secure with
clamp. Tighten bolts at clamping joint.
(1) Align outlet shroud with locating holes in start-
er generator and install stainless steel screws, with thin
washers. Lockwire screws. g. Install new packing in groove around upper end of
outlet duct (8). Insert duct into shroud (5).
(2) Position end cover and install six screws, with
aluminum alloy washers. Lockwire screws in pairs. NOTE
c. Place inlet shroud (3) on forward end of starter If the tail rotor drive shaft tunnel was dis-
generator. Slide shroud far enough aft to permit position- connected for removal/installation of
ing starter generator on mounting studs. Install stainless starter/generator, reconnect the tunnel.
steel bolts, with thin washers, at clamping joint of shroud.
Tighten bolts only enough to temporarily hold shroud in
position, with inlet pointing to right. h. Connect electrical leads (figure 9-2). (Refer to Ap-
pendix F.) Connect battery.
d. Remove mounting pad cover. Inspect gasket for
serviceability; replace if necessary. Coat starter genera- i. Perform a voltage regulator check if a new or differ-
tor drive shaft, and pack female splines of shaft in gear- ent starter/generator is installed. Refer to paragraph
box 2/3 full, with lubricant (C161). 9-75.
CAUTION NOTE
When making electrical installation on
Caution must be used to avoid dropping
Bendix manufactured starter generator. If
generator or setting generator onto tail ro-
terminal stud length is found to be insuffi-
tor drive shaft tunnel. Denting of tail rotor
cient for proper installation, remove fur-
drive shaft tunnel may cause it to come
nished washer and replace with washer
into contact and chafe the tail rotor drive
P/N AN960D616L.
shaft.
9-34 Change 14
TM 55-1520-210-23-2
9-68.7 Deleted. d. Clean corroded contact pins and spring tabs with
a pencil eraser, on carbon pile regulators only.
9-69. GENERATOR SHUNT.
9-74. Inspection — Voltage Regulator.
9-70. Description — Generator Shunt. The standby a. Visually inspect regulator case for physical dam-
generator shunt (R1) and main generator shunt (R2) pro- age that could impair normal operation of the unit
vide a voltage drop, proportional to the current, to oper- (cracked case, damaged or corroded contact pins, loose
ate the standby generator loadmeter (M1) and main gen- terminals, etc.).
erator loadmeter (M4). Refer to paragraphs 9-5 through
9-11 for maintenance procedures. b. Check for secure mounting of regulator.
c. For regulators with separate base, inspect spring
9-71. VOLTAGE REGULATOR. tabs for security and condition.
9-72. Description — Voltage Regulator. The main 9-75. Adjustment — Voltage Regulator.
generator voltage regulator (VR1) and standby genera- NOTE
tor voltage (VR2) are located in the aft electrical compart-
Electrical components normally depend
ment on the left side of the helicopter. The voltage regula-
upon a constant voltage supply from the
tor controls the voltage output of the generator by
generator. The generator voltage output is
controlling the magnetic field strength within the genera-
controlled by the voltage regulator which
tor. Variation of the resistance which is in series with the
requires precision adjustment as follows:
generator’s shunt field coils controls shunt field current
to control generator voltage output. The voltage regula- a. Run aircraft engine at normal RPM/percent.
tor of the standby generator is set at a lower voltage than
b. Set BAT switch to ON position.
that of the main generator. Solid state voltage regulators
incorporate a circuit breaker which will open the field c. Set GEN switch to ON position.
circuit of the generator when regulated potential exceeds NOTE
30.5 volts.
Adjust each voltage regulator indepen-
9-73. Cleaning — Voltage Regulator. dently with other generator(s) turned off.
d. Close (on) all circuit breakers. Ensure all instru-
a. Remove moisture and dirt with a clean, soft cloth. ments and communications and navigation equipment
are on. This will provide a load for the aircraft DC bus.
WARNING NOTE
An AN/USM-451 voltmeter or equivalent
Dry cleaning solvent is flammable and its with a DC voltage scale accuracy of +/- one
fumes are toxic. Provide adequate ventila- percent should be used. If a +\- one per-
tion. Do not use near a flame. cent voltmeter is not available, and
b. Remove grease, fungus, and dirt with a clean AN\USM-223 or equivalent multimeter
lint-free cloth dampened with solvent (C261). may be used. However, the voltage regula-
tor should be readjusted using an AN/
c. Remove dirt from electrical terminals with a USM-451 or equivalent voltmeter at the
bristle brush (C62). earliest possible time.
Change 14 9-35
TM 55-1520-210-23-2
e. Connect the positive prober of a voltmeter to any h. Tum off an instruments and communications
convenient point on the battery/essential bus. Connect and navigation equipment The DC bus voltage reading
the negative probe to a convenient aircraft ground. should be the same as in step f. above. If the aircraft
DC voltage varies more than +/0.5 volt between the two
f. Read and record the voltage. readings, shut off aircraft engine (refer to TM 551520-
210-10) and replace regulator.
g. Adjust the voltage regulator according to the
seasonal average high (ambient ground level)
temperature settings in Table 9-4.2.
TABLE 9-4.2. Voltage Regulator Adjustment Settings.
SEASONAL AVERAGE HIGH VOLTAGE REGULATOR

(AMBIENT GROUND LEVEL) SETTING
TEMPERATURE (VOLTS)
Above 80’F (26’C) 27.0 +/- 0.2
Between 32’F (0’C) and 28.0 +/- 0.2
2 85-F (26’C)
Below 32’F (0’C)
NOTE
On standby/Auxiliary 28 VDC electrical system, adjust voltage regulators one volt
lower than normal system.
9-76. Removal Voltage Regulator.

b. Unlock snap clamps and remove regulator from
a. Ensure that all electrical power is off. base. For regulators without base, remove nuts and
Disconnect wires from terminal board of regulator. washers and remove regulator from shelf.
9-36 Change 10
TM 55-1520-210-23-2
1. Intake Fairing and Duct 5. Outlet Shroud

2. Flexible Hose 6. Locating Screws
3. Inlet Shroud 7. End Cover
4. Starter Generator 8. Outlet Duct
Figure 9-2.1.2. Standby Generator (Starter Generator)
Figure 9-2.2. Starter Generator Wiring
Page 9-38, Including Figure 9-2.3, has been deleted.

TM 55-1520-210-23-2
9-77. Repair or Replacement - Voltage Regula- terminal of the main generator reverse current relay.
tor. Other than repositioning spring tabs by bending Once tripped, the generator field control relay can be
them a small amount in the direction opposite from reset by placing the generator switch in the RESET
which contact pins on regulator applies pressure, no position. The standby generator field control relay
other repairs are authorized. (K15) is a different type than that in the main generator
system. The purpose of the standby generator field
9-78. Installation - Voltage Regulator. control relay is to open the standby generator shunt
field circuit whenever the coil is energized. Power is
a. Ensure that all electrical power is off. applied to the coil whenever the starter relay is ener-
gized by pressing the start switch. The shunt field cir-
cuit is completed through the relay when the start
b. Inspect and clean mounting surface in order to
switch is released. Refer to paragraphs 9-5 through
ensure good electrical bond.
9-11 for maintenance procedures.
c. Position regulators on mounting base and lock 9-80.1 Deleted.
snap clamps. For regulators without separate base,
insert regulator studs through mounting holes and
9-81. REVERSE CURRENT RELAY.
secure with washers and nuts.
9-82. Description - Reverse Current Relay. Two
d. Reconnect aircraft wires to terminals F+, L+, reverse current relays (K5 and K23) are mounted in the
and L-. Install jumper with legs suitable for the #10 reg- aft electrical compartment. Each is a part of two sepa-
ulator studs between terminals G+ and L+. rate generator systems. Its purpose is to automatically
connect and disconnect its own generator to or from
e. Adjust voltage regulator, refer to paragraph the dc bus. Automatic operation of the reverse current
9-75. relay is possible only when generator voltage is applied
to the SW terminal of the unit. Automatic connection of
9-79. GENERATOR FIELD RELAY. the generator to the dc bus is accomplished only when
the following conditions of the generator voltage are
9-80 Description - Generator Field Relay. Heli- satisfied: the polarity is correct, a minimum of 22 to 24
copters prior to S/N 66-746 have a field control relay volts dc is attained, and voltage at GEN terminal of
(K7) for only the main generator system located in aft reverse current relay exceeds voltage at its BAT termi-
electrical compartment. The above the subsequent nal by approximately 0.5 volt. Automatic disconnection
serial numbered helicopters have two generator field of the generator from the dc bus is accomplished by
control relays in the aft electrical compartment. The reverse current through the reverse current relay when
field control relay in the main generator system opens generator voltage decreases below the voltage of
the shunt field circuit between the voltage regulator another source connected to the bus. Refer to para-
and the generator whenever the over-voltage relay graphs 9-5 through 9-11 for maintenance procedures.
closes the circuit to the trip coil of the field control relay.
The tripped field control relay opens the circuit to SW 9-82.1 Deleted.
Change 7 9-39
TM 55-1520-210-23-2
9-83. BUS CONTROL RELAY. paragraphs 9-5 through 9-11 from maintenance proce-
dures.
9-84. Description - Bus Control Relay. Opera- 9-85. OVERVOLTAGE RELAY.

tion of the control relay (K4) is controlled through the
IND terminal of the main generator reverse current
N O T E
relay. Closing of the reverse current relay supplies The solid state voltage regulator is
power from the main generator to the coil of the bus protected from over voltage and over
control relay. With this coil energized the following current, by a manualy reset relay on the
events happen. The contacts between B2 and B3 voltage regulator. When either condi-
terminals open to remove power from the DC GENER- tion trips the relay, the affected genera-
ATOR segment on the caution panel to turn light off. tor cannot be reset from the cockpit.
The contacts between A2 and A1 terminals close to The reset can be accomplished when
allow main generator voltage to energize nonessential the aircraft is on the ground with access
bus relay. While the contacts between D2 and D3 ter- to the voltage regulators
minals open to disconnect stand by generator power
form the SW terminal of the reverse current relay. 9-86. Description - Overvoltage Relay. The
When the main generator reverse current relay opens, overvoltage relay (K6) is located in the aft electrical
the buss control relay coil is not energized; it moves to compartment. Voltage from the main generator is
its spring loaded position. This position supplies 28 applied to the coil of the overvoltage relay only when
Vdc to illuminate the DC GENERATOR segment on main generator switch is ON. The over voltage relay
the caution panel and removes 28 Vdc from the non- contacts are normally open, but 31-33 volts across its
essential bus relay coil which results in nonessential coil from the main generator will close the relay which
bus disconnecting from the main bus. Power from the connects power from the bus to the trip coil of the main
external power supply closes the nonessential relay generator field control relay. Refer to paragraphs 9-5
through the disengaged bus control relay. Refer to through 9-11 for maintenance procedures.
9-40 Change 7
TM 55-1520-210-23-2
9-87. NONESSENTIAL BUS RELAY. supplied. Power from the main generator will also
operate the nonessential bus relay through the bus
9-88. Description— Nonessential Bus Relay. The control relay when main generator reverse current
nonessential bus relay (K2) is mounted in the aft relay closes. Placing the nonessential bus switch in
electrical compartment. The nonessential bus relay is the manual position will also allow standby generator
an electrically operated switch between the main bus or battery power to close the relay. Refer to
bar and nonessential bus. It is operated by power from paragraphs 9-5 through 9-11 for maintenance
external power receptacle when external power is procedures.
SECTION Il. ALTERNATING CURRENT POWER DISTRIBUTION SYSTEM
NOTE power relay (K36), inverter relay (K27), ac failure relay

(K8), ac power panel (A2, includes inverter switch
Power loading charts and detail system (S39) and AC VM selector switch (S11 ), ac voltmeter
wiring diagrams are contained in (M3), 115 to 28 Vac autotransformer (T1), and the
Appendix F. Aviation Unit Maintenance power factor correction network. The inverter system
activities shall request AVIM for is powered from the 28 Vdc essential bus and is
electrical system repairs in accordance protected by the MAIN INVTR PWR, SPARE INVTR
with the Maintenance Allocation Charts PWR, and INVTR CONTROL circuit breakers.
Appendix B.
b. With the inverter switch (S39) positioned to
MAIN, dc power from the 28 Vdc essential bus is
routed through the main inverter power relay to the
9-89. ALTERNATING CURRENT main inverter. The ac output of the main inverter is
POWER DISTRIBUTION SYSTEM. routed through the inverter relay to the
autotransformer and various ac instrument circuit
9-90. Description — Alternating Current Power breakers. With the inverter switch positioned to
Distribution System. The alternating current power SPARE, dc power from the 28 Vdc essential bus is
distribution system provides all secondary power routed through the spare inverter power relay to the
(115 Vac) for operation of the ac instruments and spare inverter. The ac output of the spare inverter is
avionics systems. r o u t e d t h r o u g h t h e i n v e r t e r relay t o t h e
autotransformer and various ac instrument and
avionics circuit breakers. The autotransformer
9-91. COMMON ELECTRICAL reduces 115 Vac to 28 Vac for instrument power,
COMPONENTS (AC).
9-95. Functional Test — Inverter System. a. Open
9-92. Description — Common Electrical all circuit breakers and place all switches to their OFF
Components (AC). Common electrical components or NORMAL positions.
consist of the miscellaneous electrical components,
circuit breakers, and control panels. Refer to b. Connect a 28 Vdc power source to the
paragraphs 9-5 through 9-25 for description and external power receptacle (J97). Energize power
maintenance procedures. The AC circuit breaker source.
panel is located on the right side of pedestal base.
c. Close the MAIN INVTR PWR, SPARE INVTR
9-93. INVERTER SYSTEM. PWR, INVTR CONT, CAUTION LIGHTS, J2 CMPS IND
(applicable only on helicopters prior to S/N 66-
9-94. Description— Inverter System. a. The 16307), POWER FACTOR CORRECTION, and all ac
inverter system is a dual system consisting of a main circuit breakers in the pedestal breaker panel. Check
and spare inverter. The units are interchangeable and that INST INVERTER caution light illuminates.
are rated at 250 VA. They produce 115 Vac with a
frequency response of 400 Hz. The system is d. Position inverter switch (S39) to MAIN ON.
comprised of the main inverter (D1), spare inverter Check that main inverter and all ac instruments are
(D2), main inverter power relay (K35) spare inverter on and INST INVERTER light is extinguished.
9-41
TM 55-1520-210-23-2
e. Select each phase on the ac voltmeter and NOTE

check that voltmeter indicates 115 ±3 Vat, on each
phase when dc bus voltage is 28 volts. When inverter switch (S39) is moved
from SPARE ON to OFF, the ac bus
f. Position inverter switch (S39) to OFF and voltages will drop off immediately from
check that INST INVERTER light illuminates. the spare inverter output by the inverter
relay.
NOTE
When inverter switch (S39) is moved 9-96. Troubleshooting — lnverter System. U s e
from MAIN ON to OFF, the ac bus table 9-5 and perform checks as necessary to isolate
voltages decrease gradually because the trouble. In the following table, tripped circuit breakers
buses remain connected to the main and burned-out indicator lamps are omitted from
inverter output through the inverter relay indications of trouble. Such trouble is usually easily
contacts. If the MASTER CAUTION light detected and corrected. Broken wiring is always a
is reset during the time period in which probable cause of circuit malfunction or failure and
the main inverter is still decreasing in has not been included. (See figure F-21.)
speed, false MASTER CAUTION and
INST INVERTER indications may occur. NOTE
g. Position inverter switch (S39) to SPARE ON Before you use this table, be sure you
and check that ac voltmeter indicates 115 ±3 Vac on have performed all normal operational
each phase. checks.
Table 9-5. Troubleshooting Inverter System
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
‘1. Main inverter fails to operate.
STEP 1. With inverter switch (S39) positioned to MAIN, check for 28 Vdc essential bus voltage on terminals
1 and 2 of switch.
Replace switch if voltage is not present on terminal 1 (paragraph 9-5).
STEP 2. Ensure that actuating voltage is present across terminals X1 and X2 and that 28 Vdc essential bus
voltage is present at terminal Al of main inverter power relay (K35). Check for voltage at terminal A2.
Replace main inverter power relay if voltage is not present at terminal A2 (paragraph 9-5).
STEP 3. Check for 28 Vdc essential bus voltage at pins F and G of main inverter connector (P191 ). Ensure
that ground potential is present at pin E.
Replace main inverter (D1) if voltage is present on pins F and G of connector (paragraph 9-97).
2. Spare inverter fails to operate.
STEP 1. With inverter switch (S39) positioned to SPARE, check for 28 Vdc essential bus voltage on
terminals 2 and 3 of switch.
Replace switch if voltage is not present on terminal 3 (paragraph 9-5).
9--42
TM 55-1520-210-23-2
Table 9-5. Troubleshooting Inverter System (Cont)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
STEP 2. Ensure that actuating voltage is present across terminals X1 and X2 and that 28 Vdc essential bus
voltage is present at terminal A1 of spare inverter power relay (K36). Check for voltage at terminal A2.
Replace spare inverter power relay if voltage is not present at terminal A2 (paragraph 9-5).
STEP 3. Check for 28 Vdc essential bus voltage at pins F and G of spare inverter connector (P192). Ensure
that ground potential is present at pin E.
Replace spare inverter (D2) if voltage is present on pins F and G of connector (paragraph 9-97).
3. Inverter (D1 or D2) operates but no voltage to instruments.
STEP 1. Check continuity of inverter relay (K27) contacts; terminals A2 to A3 and B2 to B3 for main inverter
and terminals A1 and B1 to B2 for spare inverter (relay actuated for spare inverter operation).
Replace inverter relay if defective (paragraph 9-5).
STEP 2. Check for 115 Vac output from inverter at inverter relay terminals A3 and B3 (for main inverter) and
terminals A1 and B1 (for spare inverter).
Replace inverter (D1 and D2) if defective (paragraph 9-97).
4. Improper inverter output voltage or frequency.
STEP 1. Check for proper input voltage to inverter.
Correct primary voltage if low (paragraph 9-75).
STEP 2. Check inverter output voltage and frequency with voltmeter and frequency meters.
a. Frequency out of limits. Replace inverter (paragraph 9-102).
b. Low or high voltage. Adjust inverter output voltage (paragraph 9-101).
c. Unable to adjust inverter output voltage Replace inverter (paragraph 9-102),
Page 9-44, Including Table 9-5.1, has been deleted.

TM 55-1520-210-23-2
9-97. INVERTER. 9-99. Cleaning - Inverter. a. Remove moisture

and Ioose dirt with a clean, soft cloth.
9-98. Description - Inverter. The main and spare
115 Vac, 400 Hz, 250 VA, 3 phase inverter are in-
terchangeable. These units are located in the aft
eIectrical compartment on helicopters through
serial number 62-12366. On helicopters serial Dry cleaning solvent is flammable and its
number 63-8738 and subsequent the inverters are fumes are toxic. Provide adequate
located in the nose eIectrical compartment. All ventilation. Do not use near a flame.
three phases of the inverter are loaded equally as b. Remove grease, fungus, and dirt, with a
far as is practicable. Since loads are primarily in- clean, lint-free cloth dampened with solvent
ductive in nature, power factor correction capaci- (C261).
tors are mounted in the compartment with the in-
verters to maintain a power factor of 0.97 (Iag) c. Remove dirt from electrical connectors
under normal load. with a bristle brush (C62).
9-45
TM 55-1520-210-23-2
9-100. Inspection - Inverter. to decrease inverter output. Nominal setting of 115

a. Inspect case for cracks or damage. volts at full output load should produce an output fre-
quency within limits of 380 to 420 Hz.
b. Inspect electrical connectors for broken pins or
9-102. Removal - Inverter.
cracked connector inserts.
a. Ensure that all electrical power is OFF.
c. Check for bonding and security of mounting.
b. Disconnect electrical cable and protect con-
9-101. Adjustment - Inverter. nectors with cap or electrical tape (C270).
c. Remove mounting bolts and lift inverter from
N O T E
compartment.
To properly conduct the inverter check,
apply a regulated 28 Vdc external power 9-103. Repair or Replace - Inverter. Repair con-
source or ground run the helicopter to nectors, replace missing mounting bolts. Replace unit
assure an adequate source of dc power for any of the following conditions: Excessive vibration,
for inverter operation. Do not use heli- overheating, unusually noisy and for pitting and groov-
copter battery power. ing of the brush area on the commutator and/or slip
rings. (Refer to TM 11-61 25-220 -20.)
NOTE 9-104. Installation - Inverter.
Make sure aircraft AC voltmeter indi- a. Ensure all electrical power is off.
cates zero volt with no power applied to N O T E
aircraft. If it does not, turn “zero” adjust-
ing screw as required. When installing inverter P/N PU543A/B
two mount bolts may be installed from
a. Turn on inverter and actuate all ac circuits to the bottom up.
produce maximum demand on inverter. NOTE
b. Using multimeter (AN/PSM-6A, or equivalent) Check that inverter is set to operate
and frequency meter (JTB Model 33FS, or equivalent), using the pin connector. (Refer to TM
check output voltage and frequency at the 115 Vac bus 11-6125-220-20.)
(engine vibration receptacle (J115) or other convenient
monitoring point). b. Carefully position and secure inverter in
compartment with mounting bolts.
NOTE
c. Remove caps or electrical tape from plugs and
If aircraft AC voltmeter does not indi- receptacles.
cate 115 ±3V AC, replace voltmeter.
d. Connect electrical connectors to the inverter.
c. If the output voltage is 115 ±2.5 Vat, and the 9-105. MAIN INVERTER POWER RELAY.
frequency is between 380 and 420 Hz, no adjustment 9-106. Description - Main lnverter Power Relay.
is necessary. The main inverter power relay (K35) is located in the
aft electrical compartment on helicopters prior to S/N
62-12366 and in the nose compartment on helicopters
S/N 62-12366 and subsequent. The relay is used as a
remote controlled switch. When the relay is energized,
28 Vdc is routed from the essential bus through the
During removal and reinstallation of AC relay to the main inverter. Refer to paragraphs 9-5
voltmeter retain and reinstall AC voltmeter through 9-11 for maintenance procedures.
terminal covers.
9-107. SPARE INVERTER POWER RELAY.
d. If the output voltage is above or below the limits
prescribed in the preceding step, proceed as follows: 9-108. Description - Spare Inverter Power Relay.
Turn off dc power to inverter. Loosen hexhead jam nut The spare inverter power relay (K36) is located in the
securing adjustment screw. aft electrical compartment on helicopters prior to S/N
62-12366 and in the nose compartment on helicopters
e. Close all AC circuit breakers. Actuate all AC cir- S/N 62-12366 and subsequent. The relay is used as a
cuits. Turn on inverter power. Connect multimeter and remote controlled switch. When the relay is energized,
frequency meter at one of the test points described in 28 Vdc is routed from the essential bus through the
step b. and note reading. Turn inverter output adjust- relay to the spare inverter. Refer to paragraphs 9-5
ment screw clockwise to increase or counterclockwise through 9-11 for maintenance procedures.
9-46 Change 7
TM 55-1520-210-23-2
9-109. INVERTER RELAY. b. Inspect transformer case for damage.
9-110. Description - Inverter Relay. The inverter c. Inspect for damaged insulation between pins.
relay (K27) is used as a double-pole, double-throw
remote controlled switch. The relay is energized by 28 d. Check for discoloration that would indicate
Vdc when inverter switch (S39) is in SPARE position. internal shorting or excessive overload.
When energized, 115 Vac from the spare inverter is e. Check for security of mounting.
routed through the relay to the ac systems. When
de-energized, 115 Vac from the main inverter is routed 9-117. Removal-AC Transformer.
through the relay to the ac systems. Refer to para-
graphs 9-5 through 9-11 for maintenance procedure. a. Ensure all electrical power is off.
9-111. INVERTER FAILURE RELAY b. Disconnect wiring from transformer and protect
wire ends with tape (C270). Tag wires for proper identi-
9-112. Description - Inverter Failure Relay. The fication.
ac failure relay (K8) monitors the 115 Vat, phase C
c. Remove mounting screws and lift transformer
bus. When the bus is de-energized, the INST
from compartment.
INVERTER caution panel segment will illuminate to
warn the pilot that the 115 Vac bus is no longer ener- 9-118. Repair or Replacement -AC Transformer.
gized. Refer to paragraphs 9-5 through 9-11 for main-
tenance procedure. a. Replace transformer if case is damaged or
discolored.
9-113. AC TRANSFORMER.
b. Replace transformer if insulation between pins
9-114. Description - AC Transformer. The ac is damaged or broken, or contact pins are broken.
transformer (T1), which is an autotransformer,
reduces 115 Vac to 28 Vac for instrument power. c. Repair is limited to tightening or properly instal-
ling any loose or improperly installed mounting hard-
9-115. Cleaning - AC Transformer. ware.
a. Remove moisture and loose dirt with a clean, 9-119. Installation -AC Transformer.
soft cloth.
a. Ensure all electrical power is off.
b. Position transformer in compartment and
secure with mounting screws.
c. Remove tape from wire ends and connect
tagged wires to transformer.
9-120. ENGINE VIBRATION METER RECEP-
Dry cleaning solvent is flammable and its TACLE.
fumes are toxic. Provide adequate ventila-
tion. Do not use near a flame. 9-121. Description - Engine Vibration Meter
Receptacle. The engine vibration meter receptacle,
b. Remove grease, fungus, and dirt with a clean, powered from the 115 Vac essential bus, is used as
lint-free cloth dampened with dry cleaning solvent source of 115 Vac power for the vibration meter during
(C261). engine vibration tests. It is also used as a convenient
point to monitor ac voltage from the 115 Vac essential
9-116. Inspection-AC Transformer. bus during functional tests or troubleshooting. Refer to
paragraphs 9-5 through 9-11 for maintenance proce-
a. Inspect transformer for broken contact pins. dures.
Pages 9-48 through 9-51, including paragraphs 9-121.1 through 9-121.17.1 and table 9-5.2, have been
deleted.

TM 55-1520-210-23-2
regulator receives its voltage sensing signals ALTERNATOR and AC/DC CONVERTER caution
from the alternator terminals. Current transform- lights should extinguish.
er (T4) provides current sensing signals to the
control unit. The Alternator/External Power Re- b. Select each ALT phase on the AC voltmeter
lay (K70) selects either the alternator or external and check that voltmeter indicates 120±VAC on
power receptacle, for power to the AC bus. An each phase.
alternator switch (S250) is provided on the AC c . Place ALT switch in “OFF/RES”. The
power control panel to provide manual control ALTERNATOR and AC/DC CONVERTER caution
of the alternator. A warning light is provided on lights should illuminate.
the caution panel to indicate when the alternator
relay (K70) is not closed. d. Place ALT switch to “ON’”. The ALTERNATOR
9-121.12. Functional Test — Alternator. and AC/DC CONVERTER caution lights should
Perform functional test of alternator system as extinguish.
follows:
9-121.13. Troubleshooting — Alternator
System. Use Table 9-5.2 and perform checks as
NOTE necessary to isolate trouble. In the following table,
Before performing functional test of
lamps are omitted from indications of trouble. Such
alternator system, check operation of trouble is usually easily detected and corrected.
external AC power system. Broken wiring is always a probable cause of circuit
a. Start the helicopter engine and increase malfunction or failure and has not been included.
engine speed to approximately 6300 rpm. The (See Figure F-21.1.)
NOTE
Before you use this table, be sure you have performed all
normal operational checks.
Table 9-5,2 Troubleshooting Alternator System
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. ALTERNATOR light on caution panel not illuminated prior to engine start-up. BUS is energized by battery or
external power, and caution light circuit breaker is closed.
Determine if master caution panel (A4) is defective by disconnecting plug P24 from caution panel
and checking for DC voltage between C(+) and U(–). No voltage should be present. Replace lamps in
ALTERNATOR segment and reconnect plug (P24).
Replace master caution panel if light still does not illuminate (paragraph 9-12).
2. ALTERNATOR light on caution panel does not go out after engine start-up.
Determine if master caution panel (A4) is defective by disconnecting plug P24 from caution panel
and checking for DC voltage between C(+) and U(—). If voltage is present, replace master caution
panel (paragraph 9-1 2).
Replace alternator relay (K70) if light still does not go out (paragraph 9-5].
3 No output from alternator.

STEP 1. Determine if voltage is present on terminals A3, B3, and C3 of Alternator Relay (K70).
Replace alternator (G2) if no voltage is present.
9-49
TM 55-1520-210-23-2
Table 9-5.2 Troubleshooting Alternator System (Cont)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
STEP 2. If alternator voltage is 120 ± 2 Vac and 400 ± 10 Hz, check for 28 VDC on Alternator relay
connector P407 Pins P and J. Check continuity of jumper between P407 K and X and jumper.
Replace alternator relay if voltage is correct.
STEP 3. If alternator voltage is low or no voltage is present on alternator relay connector P407 Pin P or J.
Replace alternator control unit (VR5).
STEP 4. Check alternator switch for proper operation.
Replace alternator switch if defective (paragraph 9-5).
STEP 5. Determine if current transformer (T4) is defective.
Replace current transformer if defective (paragraph 9-5).
9-121.14. AC ALTERNATOR. c. Check drive splines for excessive wear by

rocking armature back and forth.
9-121.14.1 Description — AC Alternator. The
AC Alternator (G2) is mounted on drive quill on the 9-121.14.4. Removal — AC Alternator.
forward side of the main rotor transmission. Its
a. Open forward transmission fairing.
capacity is rated at 30 KVA and its voltage is
controlled by a voltage regulator which is part of the b. Tag wires to identify for reinstallation and
alternator system. The AC alternator is driven at disconnect from alternator.
twice the speed of the engine output shaft and has to c . Remove nuts and washers and pull alternator
be turned within a specific voltage range of speed to free of transmission drive. (Figure 9-2.3).
furnish rated current at normal regulated voltage.
9-121.14.5. Repair or Replacement — AC
9-121.14.2. Cleaning — AC Alternator. Alternator. No repairs are authorized.
a . Remove moisture with a clean, soft cloth. 9-121.14.6 Installation — AC Alternator.
a. Apply light coat of grease (C161) on
alternator shaft. Place gasket into position. Align
alternator with transmission drive, and slide
Dry cleaning solvent is flammable and alternator into drive spline.
its fumes are toxic. Do not use near a b. Position alternator on studs with terminals
flame. Provide adequate ventilation. centered on helicopter centerline and tighten
retaining nuts to attach alternator to drive pad.
b. Remove grease, fungus, and dirt with a
clean lint-free cloth dampened with solvent
c. Connect wires to alternator terminals.
(C261).
c. Remove dirt from electrical terminals with
d. Reinstall terminal board cover.
a bristle brush (C62).
9-121.14.3. Inspection — AC Alternator. 9-121.15 ALTERNATOR CONTROL UNIT
a. Visually inspect alternator for damage. 9-121.15.1. Description — Alternator Control
b. Check terminals for damage and terminal Unit. The alternator control unit (VR5) is located in
board to ensure that it is not warped or cracked. the left side of the cabin overhead. Its
9-50
TM 55-1520-210-23-2
SECTION Ill. STARTING SYSTEM.

9-122. STARTING SYSTEM. h. Actuate starter switch (S77) on copilot collec-
tive stick and check that voltage is present at the ends
9-123. Description - Starting System. The start- of disconnected wires.
ing system requires 24 Vdc to activate the starter por-
tion of the starter-generator during the starting cycle.
The 24 Vdc power may be supplied by the battery or i. Position starter-generator switch (S70) to STBY
by an external power source. The starting system con- GEN.
sists of the starter portion of the starter-generator (G6)
and the starter relay (K3).
j. Actuate starter switch (S77) and check that
9-124. Functional Test - Starter System.
starter relay (K3) does not close.
a. Disconnect wires K4B4 and K4D4 from termi-
nal C of starter-generator.
k. Open STARTER RELAY circuit breaker.
b. Position starter-generator switch (S70) to
START.
l. Reconnect wires K4B4 and K4D4 to terminal C
c. Close STARTER RELAY circuit breaker. of starter-generator.
d. Actuate starter switch (S6) on pilot collective
stick and check that starter relay (K3) closes and that
voltage is present at the ends of the disconnected 9-125. Troubleshooting - Starter System. Use
wires. table 9-6 and perform checks as necessary to isolate
trouble. In the following table, tripped circuit breakers
e. Position starter-generator switch (S70) to and burned-out indicator lamps are omitted from
STBY GEN. indications of trouble. Such trouble is usually easily
detected and corrected. Broken wiring is always a
f. Actuate starter switch (S6) and check that probable cause of circuit malfunction or failure and has
starter relay (K3) does not close. not been included. (See figure F-22.)
g. Position starter-generator switch (S70) to
START.
NOTE
NOTE
Starter switch (S77) is not installed on Before you use this table, be sure you
helicopters S/N 68-15214 and subse- have performed all normal operational
quent. checks.
Table 9-6. Troubleshooting Starter System
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. Starter (G6) fails to operate when starter switch (S6 or S77) is depressed with starter-generator switch (S70)
in START position.
STEP 1. Ensure that dc essential bus voltage is present and determine if STARTER RELAY circuit breaker
is defective.
(9-51 blank)/9-52 Change 7

TM 55-1520-210-23-2
Table 9-6. Troubleshooting Starter System (Cont)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
STEP 2. Check starter-generator switch (S70) for proper operation.
Replace switch if defective (paragraph 9-5).
STEP 3. With starter switch (S6) depressed, check for relay actuating voltage at terminal X2 of starter relay
(K3).
Replace switch (S6) if defective (paragraph 9-5).
STEP 4. With starter switch (S6) depressed, check for main dc bus voltage at terminal A2 of starter relay
(K3),
Replace relay if defective (paragraph 9-5).
STEP 5. Check for excessively worn starter-generator brushes.
Replace brushes as required (paragraph 9-67).
2. Starter fails to produce sufficient rpm during start cycle.
STEP 1. Check for excessive wear to armature bearings.
Replace starter if bearings are worn excessively (paragraph 9-68.3).
STEP 2. Check for low battery power.
Charge battery (TM 11-6140-203-14-2) or connect external power source.
3. Engine rotates when battery is turned on.

STEP 1. Check for defective starter relay (K3).
STEP 2. Check for defective starter switch (S6).
Replace starter switch if defective (paragraph 9-5).
9-126. STARTER GENERATOR. the engine compressor rotor during the start
cycle and also serves as a 300 amp, engine driven
standby generator at normal engine speeds. Refer
9-127. Description – Starter Generator. The
to paragraph 9-67 for maintenance procedures.
starter generator (G6) is mounted on the aft side of
the engine accessory drive gearbox. it serves to drive
9-53
TM 55-1520-210-23-2
9-128. STARTER RELAY. main bus bar and the starter-generator. It is energized
when the starter switch on the pilots or copilots stick
is depressed. Refer to paragraphs 9-5 through 9-11
9-129. Description — Starter Relay. The starter for maintenance procedures.
relay is located in the aft electrical compartment. This
unit is an electrically operated switch between the
SECTION IV. IGNITION SYSTEM.
9-130. IGNITION SYSTEM. (5) Repeat step (4) using copilots starter
switch (S77).
9-131. Description — Ignition System. Ignition to
the power plant is provided by the ignition unit (22), (6) Position starting fuel switch (S88) to ON.
furnished with and attached to the engine. This unit Place MAIN FUEL switch (S38) to OFF. Actuate pilots
provides a continuous ignition arc during engine start starter switch (S6) and check that neither the ignition
cycle. The start fuel solenoid valve (L1) located on the nor the solenoid valve operates.
engine also operates during this cycle to direct fuel to
the starting fuel nozzle during engine start. The (7) Repeat step (6) using copilots starter
circuits are energized when MAIN FUEL switch (S38) switch (S77). Reconnect starter wires.
located on the engine control panel (A3) and ignition
keylock switch located on right side of pedestal are b. For helicopter Serial No. 66-16034 and
placed to ON and the starter switch (S6) is depressed. subsequent, accomplish the following:
9-132. Functional Test — Ignition System. (1) Close IGNITION SYSTEM IGNITER SOL
circuit breaker. Position MAIN FUEL switch (S38) to
NOTE ON and ignition keylock switch to OFF. Actuate pilots
starter switch (S6) and check that ignition unit (Z2)
Ensure that wire K3D20 is disconnected and start fuel solenoid valve (L1) do not operate.
at starter relay (K3) and that terminal is
protected to prevent activation of (2) Repeat step (1) with ignition keylock switch
engine. ON. Check that both ignition unit and solenoid valve
operate.
a. Prior to helicopter Serial No. 66-16034,
accomplish the following: (3) Actuate copilots starter switch (S77).
Check that ignition unit and start fuel solenoid valve
(1) Close IGNITION SYSTEM IGNITER SOL are both operating.
circuit breaker. Position MAIN FUEL switch (S38) and
starting fuel switch (S88) to ON and ignition keylock (4) Position MAIN FUEL switch (S38) to OFF.
switch to OFF. Actuate pilot starter switch (S6) and Actuate pilots starter switch (S6) and check that
check that ignition unit (22) and start fuel solenoid neither the ignition unit nor the solenoid valve
valve (L1) do not operate. operates.
NOTE
(2) Repeat step (1) with ignition keylock switch Copilots starter switch (S77) is not
ON. Check that both ignition unit (22) and solenoid installed on helicopters S/N 68-15214
valve (L1) operate. and subsequent.
(3) Actuate copilots starter switch (S77). (5) Repeat step (4) using copilots starter
Check that ignition unit and start fuel solenoid valve switch (S77). Reconnect starter wires.
are both operating.
NOTE
(4) Position starting fuel switch (S88) to OFF.
Actuate pilots starter switch (S6) and check that For additional maintenance information,
ignition unit operates. refer to Chapter 4.
9-54
TM 55-1520-210-23-2
9-133. Troubleshooting — Ignition System. Use NOTE

table 9-7 and perform checks as necessary to isolate
trouble. In the following table, tripped circuit breakers Before you use this table, be sure you
are omitted from indications of trouble. Such trouble have performed all normal operational
is usually easily detected and corrected. Broken checks.
wiring is always a probable cause of circuit
malfunction or failure and has not been included.
(See figure F-23).
Table 9-7. Troubleshooting Ignition System

CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. Igniter or igniter solenoid valve fails to operate when starter switch is depressed.
STEP 1. Ensure that ignition keylock switch is ON and proper voltage is present on 28 Vdc bus. Determine
with a voltmeter if the IGNITION SYSTEM & IGNITER SOLENOID circuit breaker or keylock switch is defective
(paragraph 9-12, 9-5).
Replace circuit breaker or switch if defective (paragraph 9-12, 9-5).
STEP 2. Check MAIN FUEL switch (S38) for proper operation.
STEP 3. On helicopters prior to S/N 66-16034, check start fuel switch (S88) for proper operation.
STEP 4. Check starter switch (S6) for proper operation.
STEP 5. Check ignition unit for proper operation.
Replace ignition unit if defective (paragraph 9-1 34).
STEP 6. Check start fuel solenoid valve for proper operation.
Replace solenoid if defective (paragraph 9-5).
9-134. IGNITION UNIT. 9-136. START FUEL SOLENOID

VALVE.
9-137. Description — Start Fuel solenoid
9-135. Description — Ignition Unit. The igni- Valve. The start fuel solenoid valve (L1) is
tion unit is furnished with and attached to the installed on the engine and operates during the
engine. This unit provides a continuous ignition start cycle. It directs fuel to the starting fuel
arc during the engine start cycle. Refer to nozzles during engine start. Refer to TM 55-2840-
TM 55-2840-229-23 for maintenance procedures. 229-23 for maintenance procedures.
9-55
TM 55-1520-210-23-2
SECTION V. LIGHTING PROVISIONS
9-138. LIGHTING PROVISIONS. 9-144. Cleaning – Cockpit Lights. Refer to

paragraph 9-7 for cleaning procedures.
9-139. Description — Lighting Provisions.
Lighting provisions include all equipment necessary 9-145. lnspection — Cockpit Lights. Inspect light
for the illumination of instruments and switches; also for corroded lamp socket terminals, shorted or broken
interior and exterior lighting used for night operation wires, cracked lens, burned out lamp bulbs, and
of the helicopter. improper bonding to ground.
9-146. Functional Teat — Cockpit Lights. a. Close

COCKPIT LTS circuit breaker. Check that pilot and
9-140. INTERIOR LIGHTS SYSTEM,
copilot utility lights are operational in each mode.
9-141. Description - Interior Lights System. Inte- (ON-OFF, Dim-Bright and Spot-Flood on both red and
rior light circuits include the instrument lights, in- white (blue-green on NVG (Night Fix - Phase 1 )
strument secondary lights located on the glare modified UH-1H/V aircraft.)
shield, overhead console and pedestal panel b. Open COCKPIT LTS circuit breaker.
lights, dome light, and cockpit lights. The EH-1H
is equipped with three overhead mounted utility 9-146.1. functional Test - Operator Utility Lights
lights, one over each operator station. (figure F-24). Close CREW LIGHTS circuit break-
er. Check that each of the three operator utility
lights is operational in each mode, (ON-OFF,
9-142. COCKPIT LIGHTS.
DIM-BRIGHT, and Spot-Flood on both red and
white (blue-green on NVG (Night Fix - Phase 1 )
9-143. Description — Cockpit Lights. T h e modified UH-1H/V aircraft.)
cockpit lights (1 9 and 128) are multiple-purpose
utility lights designed to selectively provide red, 9-147. Troubleshooting — Cockpit Lights. U s e
white or blue-green illumination utilizing a narrow table 9-8 and perform checks as necessary to isolate
spotlight beam or a wide floodlight beam. Con- trouble. In the following table, tripped circuit breakers
trols necessary to obtain operational modes of and burned-out bulbs are omitted from indications of
trouble. Such trouble is usually easily detected and
ON-OFF, dim-bright, spot-flood, and red, white or
blue-green illumination are incorporated into the corrected. Broken wiring is always a probable cause
lamp body. of circuit malfunction or failure and has not been
included. (See figure F-24.)
NOTE
NOTE
An additional modified utility light is
installed aft of DC circuit breaker Before you use this table, be sure you
panel for aircraft equipped with have performed all normal operational
night vision goggle capability. checks.
9-56
TM 55-1520-210-23-2
Table 9-8. Troubleshooting Cockpit Lights
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. Switch fails to operate lights.
Use a multimeter to determine if switch or rheostat is defective.
Replace switch or rheostat if defective (paragraph 9-50).
2. One light dim or intermittent.
Check for proper circuit ground contact.
Rernove light and clean ground (paragraph 9-5).
9 - 5 7
TM 55-1520-210-23-2
Table 9-8. Troubleshooting Cockpit Lights (Cont)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
3. One light does not illuminate.
STEP 1. Check for corroded lamp socket.
Clean terminals or replace light (paragraph 9-50).
9-148. Removal – Cockpit Lights. a. Open burned out lamp bulbs, improper bonding to ground,
COCKPIT LTS circuit breaker. and broken or shorted wires.
b. Remove mounting hardware, lift out light 9-155. Functional Test — Dome Lights. a. Close
assembly, and disconnect light wire. DOME LTS circuit breaker. Position switch (S1) to
RED, Rotate rheostat (R21) clockwise from OFF.
9-149. Repair or Replacemant — Cockpit Lights. Check that the three aft dome lights are full bright
Light assembly may be repaired by replacing with (R21) in the full clockwise position.
damaged or defective component parts. If light case is
damaged beyond repair, complete unit must be b. Repeat step a. with switch (S1) positioned to
replaced. WHITE.
9-150. Installation — Cockpit Lights. a. Connect NOTE

light wire and install light assembly with mounting
hardware. Step c. is not applicable to Serial No. 66-
16034 and subsequent.
b. Close COCKPIT LTS circuit breaker and check c. Check that forward dome light is operational for
light for proper operation.
both RED and WHITE positions of switch (S35). NVG
(Night Fix - Phase 1) modified aircraft will have the for-
ward domelight disconnected.
9-151. DOME LIGHTS.
d. Open DOME LTS circuit breaker.
9-152. Description — Dome Lights. The aft dome
lights are designed to provide red or white 9-156. Troubleshooting — Dome Lights. Refer to
illumination as selected by switch (S1) on the aft paragraph 9-147; procedure is the same.
dome lights panel (A20). A rheostat (R21) on the panel
controls off-on-dimming of the aft dome lights. On
helicopters S/N 65-9565 through 66-16033, a 9-157. Removal — Dome Lights. a. Open DOME
forward dome light is installed and provides red or LTS circuit breaker.
white illumination as selected by forward dome light
switch (S35). On UH-1H/V aircraft modified for night vi- b. Remove mounting hardware, lift out light
sion goggles (NVG) (Night Fix-Phase 1), the forward assembly, and disconnect light wires.
domelight has been disconnected.
9-158. Repair or Replacement — Dome Lights.
9-153. Cleaning — Dome Lights. Refer to Light assembly may be repaired by replacing
paragraph 9-7 for cleaning procedure. damaged or defective component parts. If case is
damaged beyond repair, complete unit must be
9-154. Inspection — Dome Lights. Inspect lights replaced.
for corroded lamp socket terminals, cracked lens,
9-58
TM 55-1520-210-23-2
9-159. Installation — Dome Lights. a. Connect 9-161.3. Functional Test — 5-Volt Instru-
light wires and install light assembly with mounting ment Lighting System.
hardware.
a. Pilot 5-volt power supply — close INST
b. Close DOME LTS circuit breaker and check PANEL LIGHTS and PILOT 5V LIGHTS circuit
light for proper operation. breakers. Rotate pilot instrument panel lights rhe-
ostat R4 clockwise from OFF. Check that instru-
ment light on lD-998/ASN Indicator comes on
and increases in brightness with clockwise rota-
9 - 1 6 0 . INSTRUMENT, CONSOLE, tion of the rheostat. Brightness should vary in
AND PEDESTAL LIGHTS. the same intensity as the other pilot instrument
lights.
9-161. Description — Instrument, Console, and b. Copilot 5-volt power supply — close CO-
Pedestal Lights. The instrument, console, and PILOT 5V LIGHTS circuit breaker. Rotate the
pedestal lights are energized by the 28 Vdc essential copilot’s instrument lights rheostat RIO clock-
bus and protected by INST SEC LTS, INST PANEL LTS, wise from OFF. Check that AAU-32\A Altimeter
and CONSOLE & PEDESTAL LTS 5 ampere circuit light comes on and increases in brightness with
breakers. Six rheostats on the instrument lights panel clockwise rotation of the rheostat. Brightness
(A6) control off-on-dimming of pilot instrument, should vary in the same intensity as the other
copilot instrument, engine instrument, pedestal, copilot instrument lights.
instrument secondary, and console lights.
9-161.4 Troubleshooting — 5-Volt instru-
ment Lighting System. Use table 9-4.2 and
9-161.1. 5-Volt Instrument Lighting System. perform checks as necessary to isolate trouble.
In the following table, tripped circuit breakers
9-161.2. Description — The 5-Volt instrument and burned-out indicator lamps are omitted from
lighting system consists of two 5-volt power indications of trouble. Such trouble is usually
supplies, a terminal board, and wire harness. easily detected and corrected. Broken wiring is
The power supplies are located on either side of always a probable cause of circuit malfunction
the lower left enclosure in the nose radio com- or failure and has not been included. (See figure
partment. The pilot 5-volt power supply provides F-26.1)
a lighting source for the lD-998/ASN Indicator.
The copilot 5-volt power supply provides a light- N O T E
ing source for the AAU-32A Altimeter. The 5-volt
Before you use this table, be sure
power supplies are controlled by the pilot and
you have performed all normal oper-
copilot instrument light rheostats. Refer to para-
ational checks.
graphs 9-5 through 9-11 for maintenance proce-
dures.
9-59
TM 55-1520-210-23-2
Table 9-8.1 Troubleshooting 5-Volt Instrument Lighting System.
CONDITION
TEST OF INSPECTION
CORRECTIVE ACTION.
1. Pilot or copilot instrument light rheostats fail to operate lights. Other instrument lights operating
properly.
STEP 1. Check for defective power supply.
Replace power supply.
2. Lights do not vary in brightness with same intensity as other instrument lights.
STEP .1 Check for improper output voltage.
Adjust potentiometer R27 (external control) on power supply to obtain correct

brightness.
9-161.5 Removal — 5-Volt Instrument Light- compass, pilots RMI and copilots RMI). The cock-
ing Power Supplies. pit and post lights have been modified with blue-
green lenses. In addition, the following have also
a. Be sure all electrical power is OFF. been modified with blue-green lenses: Master
Caution Panel segments, copilots crew light and
b. Disconnect electrical connector to power all press-to-test lights. The Master Caution light,
supply. RPM Warning light and Fire Detection Warning
light have been modified with blue-green lens
c. Remove screws securing power supply to covers. The instrument secondary lighting rheo-
mounting plate and lift power supply from com- stat and circuit breaker have been reidentified
partment. as NVG.
9-162. Cleaning — Instrument, Console, and
9-161.6 Installation — 5-Volt Instrument Pedestal Lights. Refer to paragraph 9-7 for cleaning
Lighting Power Supplies procedure.
a. Position power supply in compartment 9-163. Inspection — Instrument, Console, and

and install mounting screws. Pedestal Lights. Refer to paragraph 9-8 for
inspection procedure.
b. Connect electrical connector to power
supply.
9-164. Functional Test — Instrument, Console,
NOTE and Pedestal Lights. a. Close INSTR PANEL LIGHTS
circuit breaker. Rotate pilots instrument lights
Aircraft modified for night vision rheostat (R6) clockwise from OFF. Check that all
goggles capability will contain an instrument lights on the pilots side of the panel,
emergency lighting switch and guard in including the standby compass and collective stick
right hand overhead dc circuit breaker light, come on and increase in brightness with
panel. When switch is in the normal clockwise rotation of the rheostat.
position (guard closed) light will
operate normally. With guard raised b. Rotate engine instrument lights rheostat (R9)
and switch activated, pilot/copilot clockwise from OFF. Check that all engine instrument
instrument panel, console and pedestal lights come on and increase in brightness with
lights will be inoperative. clockwise rotation of the rheostat.
9-161.7. Description — Night Vision Goggles c. Rotate the copilots instrument lights rheostat
(NVG) (Night Fix — Phase 1) Lighting System. (RI O) clockwise from OFF. Check that all instrument
The NVG lighting system consists of a glare- lights on the copilots panel come on and increase in
shield extension (mounted on the glareshield), 5 brightness with clockwise rotation of the rheostat.
cockpit lights (mounted on glareshield exten-
sion) and 3 post lights (mounted next to standby d. Open INST PANEL LIGHTS circuit breaker.
9-60
TM 55-1520-210-23-2
e. Close CONSOLE PED LIGHTS circuit breaker. 9-168. Installation — Instrument, Console, and
Rotate pedestal lights rheostat (R8) clockwise from Pedestal Lights. Refer to paragraph 9-11 for
OFF. Check that all edge lit panel lights on the installation procedure.
pedestal come on and increase in brightness with
clockwise rotation of the rheostat. 9-169. CAUTION LIGHT SYSTEM.
f. Rotate console lights rheostat (R6) clockwise
from OFF. Check that all edge lit panel lights in the 9-1700 Description – Caution Light System. The
overhead console plus the aft dome lights panel and caution light system includes a master caution panel
crew ICS panel lights come on and increase in (A4) located in the pedestal and a master caution light
brightness with clockwise rotation of the rheostat. (II 3) located on instrument panel. The caution panel
contains a number of internally lighted capsules that
g. Open CONSOLE PED LIGHTS circuit breaker. illuminate when associated switches, located at
different places in the helicopter, actuate to complete
h. Close INST SEC LIGHTS (or NVG LIGHTS) circuits thus indicating malfunctions in respective
circuit breaker. system. The panel is energized from 28 Vdc essential
i. Rotate instrument secondary lights rheo- bus and protected by a 5 ampere circuit breaker
stat (R5) or NVG lights rheostat (R5A) clockwise located in the dc circuit breaker panel in the overhead
from OFF. Check that instrument secondary console.
lights come on and increase in brightness with
clockwise rotation of the rheostat. 9-171. Functional Test – Caution Light System.
j. Open INST SEC LIGHTS (or NVG LIGHTS)
circuit breaker. NOTE
9-165. Troubleshooting — lnstrument. Console,
The following paragraphs cover
and Pedestal Lights. Refer to paragraph 9-147;
procedure is the same. (See Figure F-25.) functional tests of all caution light
circuits. All circuit breakers shall be open
9-166. Removal – Instrument, Console, and before making tests. The master caution
Pedestal Lights. Refer to paragraph 9-9 for removal light should illuminate each time a
procedure. caution panel segment illuminates and
shall be reset each time in readiness for
9-167. Repair or Replacement — Instrument, another fault indication.
Console, and Pedestal Lights. Refer to paragraphs
9-10 and 9-24 for repair or replacement criteria.
9-61
TM 55-1520-210-23-2
a. . Master Caution Panel.

Co. P/N 575-1337, or Cook Electric Co.
(1) Apply external power to helicopter. P/N 712-0063 fuel pump pressure
switch is installed on the engine.
(2) Close CAUTION LIGHTS AND GOV CONT
circuit breakers. Check that MASTER CAUTION light NOTE
illuminates and that each caution light segment ***Light will remain OFF when fuel tanks are
operates as follows: full.
(3) Reset the master caution light. Test the
lights using the test switch on the panel. Push the dim
switch to DIM and release. Check that caution lights
do not dim.
(4) Rotate pilots instrument lights rheostat
(R4) clockwise from OFF. Again actuate the dim
ON/OFF switch and check that lights dim and hold.
Caution Light Condition
(5) Rotate rheostat (R4) counterclockwise to
ENGINE OIL PRESS ON OFF and check that lights return to bright,
*ENGINE ICING OFF
*ENGINE ICE DETECTOR ON b. Engine Oil Pressure Light.
LEFT FUEL BOOST ON
RIGHT FUEL BOOST ON (1) Connect a pressure gun to the engine oil
**ENG FUEL PUMP ON pressure switch and apply pressure. Check that
***20 MINUTE FUEL ON ENGINE OIL PRESSURE segment extinguishes with
AUX FUEL LOW OFF increasing pressure at 27 ± 1 psi,
XMSN OIL PRESS ON
XMSN OIL HOT OFF (2) Relieve pressure on engine oil pressure
HYD PRESSURE ON switch. Check that ENGINE OIL PRESSURE segment
INST INVERTER ON illuminates before 25 psi decreasing pressure
DC GENERATOR ON (paragraph 8-60).
EXTERNAL POWER ON
FUEL FILTER OFF c. Engine Icing and Engine Ice Detector
GOV EMER OFF Lights. (Helicopters not equipped with particle
CHIP DET OFF separator).
ENGINE CHIP DET OFF
ENGINE INLET AIR OFF (1) Connect test box, wired similar to that
IFF OFF shown in figure 9-3, into the engine harness at the
EBX AC/DC CONVERTER ON hot air valve and ice detector. (See figure F-30.)
EBX AC ALTERNATOR ON
EBX lNOP/ALQ-144 OFF (2) Position test switch to ENG OFF or ICING
x FUEL BOOST ON and close ANTI-ICE ENG circuit breaker, Check that
x ECM ANTENNA OFF PROBE DEICER test light (L1) is off. PROBE HEATER
test light (L2) should remain on as long as power is
NOTE applied to the system.
*These caution lights not applicable on (3) Position hot air valve switch (S81) on the
helicopters equipped with particle engine control panel to the closed position. Check
separator . that HOT AIR VALVE test light (L3) illuminates.
NOTE (4) Simulate the engine operating condition

by positioning test switch to NORMAL. Check that the
**ENG FUEL PUMP caution light will be light (L1) remains off and the ENGINE ICE DET
illuminated only when a Hydra-Electric segment on the caution panel extinguishes,
Company, P/N 40210, Cook Electric indicating the system is armed.
9-62
TM 55-1520-210-23-2
(5) Simulate icing condition by placing test ICE DET segment illuminates, indicating that the
switch in the ENG OFF or ICING position. Check that system is disarmed. This condition is similar to the
ENGINE ICING segment on the caution panel engine off condition or to losing electric power to the
illuminates, indicating an icing condition in the ice detection system.
engine and that test light (L1) illuminates, indicating
power is applied to the probe deicing heater element.
d. Left and Right Fuel Boost Lights.
(1) Disconnect wire Q42A20 from terminal

board (TB38) terminal No. 2 at left hand fuel cell and
Do not leave test switch in ENG OFF or check that LEFT FUEL BOOST segment extinguishes.
ICING position for more than 10 seconds
before returning it to the NORMAL (2) Disconnect wire Q40A20 from terminal
position. board (TB35) terminal No. 2 at right hand fuel cell and
check that RIGHT FUEL BOOST segment
(6) Return test switch to NORMAL. Check that extinguishes.
test light (L1) and the ENGINE ICING segment
extinguish. (3) Reconnect wires to correct terminals.
(7) Simulate a failure of the ice detector probe e. Engine Fuel Pump Light.
by placing test switch in ENG OFF or ICING position.
After 11 to 18 seconds, check that test light (L1) and (1) Disconnect both pressure ports at the fuel
ENGINE ICING segment extinguish and that ENGINE pressure switch on the engine. Determine the
Figure 9-3. Icing System Test Box Schematic
9-63
TM 55-1520-210-23-2
manufacturer and the manufacturer’s part number of (c) Reduce pressure applied to the bottom
the fuel pressure switch, then accomplish following port and check that ENGINE FUEL PUMP segment
steps (2) and (3) as applicable. illuminates at 56.5 ± 3.5 psi decreasing pressure.
NOTE (d) Apply a steady pressure of 70 psi to the

bottom port of the switch and allow pressure applied
Cook Electric P/N 575-684, Hydraulic to the top port to decrease to atmospheric pressure.
Research P/N 96025, and Gorn Electric Check that ENGINE FUEL PUMP segment illuminates.
P/N GP2B-30001 pressure switches are
differential types which are activated (e) Maintain pressure applied to the bottom
only when a pressure imbalance exists port at 70 psi and increase pressure applied to top port
between the fuel pump elements. Equal of the switch. Check ENGINE FUEL PUMP segment
pressures, whether low or high, have no extinguishes by the time that the pressure applied to
effect on the caution indicator. the top port is 65 psi.
(f) Reduce pressure applied to the top port.

NOTE Check that ENGINE FUEL PUMP segment illuminates
at 56.5 ± 3.5 psi decreasing pressure. Relieve
Cook Electric Co. P/N 575-1337, Cook pressure applied to both ports and reconnect the
Electric Co. P/N 712-0063 and Hydra- pressure hoses to the switch.
Electric P/N 40210 pressure switches
are not of a differential type and are
normally closed. The caution light f. Twenty Minute Fuel Light.
remains illuminated until both pumps
have reached operating pressure, Low (1) W i t h 2 0 M I N U T E F U E L s e g m e n t
pressure from either or both fuel pump illuminated (no fuel in tanks) disconnect wire E12A20
elements will close the switch and cause at terminal 1 of terminal board (TB38) under the left
the caution light to illuminate. fuel cell and check that 20 MINUTE FUEL segment
extinguishes.
(2) To test Cook Electric Co., Part No. 575-684;
Hydraulic Research and Mfg. Co., Part No. 96025; or (2) When 20 MINUTE FUEL segment is
Gorn Electric Co., Part GP2B-3000-1, proceed as extinguished (fuel in tanks) connect wire E12A20 to
follows: ground and check that 20 MINUTE FUEL segment
illuminates.
(a) Apply pressure to a single port at a time
and check that ENGINE FUEL PUMP segment
(3) Reconnect wire E12A20 to terminal 1 of
illuminates at 56.5 ± 3.5 psi increasing differential
terminal board (TB38).
pressure at either port.
(b) Relieve any applied pressure and

reconnect the pressure hoses to the switch.
g. Auxiliary Fuel Low Light.
(3) To test Cook Electric Co. P/N 575-1337,
Cook Electric Co. P/N 712-0063, or Hydra-Electric (1) Close the FUEL TRANSFER PUMP circuit
Co., Part No. 40210, the ENGINE FUEL PUMP breaker and test auxiliary fuel low light in accordance
segment shall be illuminated when both pressure with following steps (2), (3) or (4), as applicable.
ports are exposed to atmosphere pressure.
(2) Test internal auxiliary fuel tank provisions
(a) Apply a steady pressure of 70 psi to the for auxiliary fuel low light indication as follows:
top pressure port of the switch and check that
ENGINE FUEL PUMP segment remains illuminated. (a) Connect a jumper wire from pin E of the
internal auxiliary fuel tank receptacle (J148) to
(b) Maintain a pressure of 70 psi at the top ground.
pressure port of the switch and apply an increasing
pressure to the bottom pressure port. Check that (b) Position right hand fuel transfer pump
ENGINE FUEL PUMP segment extinguishes by the switch (S46) to ON and check that the AUX FUEL LOW
time that the pressure on the bottom port is 65 psi. segment illuminates.
9-64
TM 55-1520-210-23-2
(c) Connect another jumper wire from pin A segment illuminates at 28 to 32 psi decreasing pres-
of receptacle (J148) to ground. Check that AUX FUEL sure.
LOW segment extinguishes. Remove both jumper
wires and position switch (S46) to OFF. i. Transmission Oil Hot Light.
(1) Connect stud on top of the transmission oil
(d) Connect a jumper wire from pin E of the temp switch (located on transmission) to ground and
internal auxiliary fuel tank receptacle (J147) to ground. check that XMSN OIL HOT segment illuminates.
Position left hand fuel transfer pump switch (S45) to
ON. Check that AUX FUEL LOW segment illuminates. (2) Remove ground from transmission oil temp
switch and check that XMSN OIL HOT segment extin-
(e) Connect another jumper wire from pin A guishes.
of receptacle (J147) to ground. Check that AUX FUEL
LOW segment extinguishes. Remove both jumper j. Hydraulic Pressure Lights.
wires and position switch (S45) to OFF.
(1) Apply external hydraulic pressure to
(3) Test for auxiliary fuel low light indication with hydraulic system and check that HYD PRESSURE
internal auxiliary fuel tank installed as follows: segment extinguishes at 800 ± 100 psi increasing
pressure.
(a) Position the right hand fuel pump transfer
(2) Relieve pressure applied to hydraulic
switch (S46) to ON. Check that AUX FUEL LOW
segment illuminates. system and check that HYD PRESSURE segment
illuminates at 500 ± 100 psi decreasing pressure.
(b) Return switch (S46) to OFF and position k Instrument Inverter Light. The instrument
left hand fuel transfer pump switch (S45) to ON. Check
inverter light is checked as a part of the inverter system
that AUX FUEL LOW segment illuminates.
(paragraph 9-95).
(4) Test external auxiliary fuel tank provisions l. DC Generator Light. The DC generator light
for auxiliary fuel low light indication as follows: is checked as a part of the main generator system
(paragraph 9-58).
(a) Connect a jumper wire between pins K m. External Power Light.
and M of the right hand external fuel tank receptacle
(J1024). Check that AUX FUEL LOW segment illumi- NOTE
nates.
Disconnect external power from the
(b) Remove jumper wire and place it helicopter before performing external
between pins K and M of the left hand external fuel tank power light test.
receptacle (J1017). Check that AUX FUEL LOW
segment illuminates. (1) Turn battery switch ON. Open external
power access door and check that EXTERNAL
h. Transmission Oil Pressure Light. POWER segment illuminates. External power indica-
tor light should illuminate only when the external power
(1) Apply pressure at the transmission oil access door is open.
pressure switch and check that XMSN OIL PRESS
segment extinguishes at 33 to 37 psi increasing (2) Close external power access door and
pressure. check that EXTERNAL POWER segment extin
guishes.
(2) Relieve pressure on transmission oil
pressure switch and check that XMSN OIL PRESS m.1. Deleted
Change 7 9-65
TM 55-1520-210-23-2
n. Fuel Filter Bypass Light. o. Transmission Oil Level Light.
(1) Disconnect plug (P156) from fuel filter (1) Close both BATTERY VM circuit breakers.
bypass switch. Short pin A to pin B and check that
FUEL FILTER segment illuminates. (2) Actuate push button switch (S4) on cabin
bulkhead at station 123 and check operation of the
(2) Remove short between pins A and B of indicator through the sight glass in the cabin
plug (P156) and check that FUEL FILTER segment bulkhead adjacent to the switch.
extinguishes. Reconnect plug (P156).
9-66
TM 55-1520-210-23-2
p. Governor Emergency Caution Light. s. Engine Air Filter Control (Helicopters Prior to
66-16868 only).
(1) Verify that GOV CONT circuit breaker is closed.
Position governor switch on the engine control panel to (1) Open all circuit breakers and position all
AUTO. Check that GOV EMER segment light is extin- switches to OFF.
guished.
(2) Close ENG AIR FILTER CONT circuit breaker.
(2) Move governor switch to EMER position. Check Press ENGINE INLET FILTER CLOGGED indicator (172)
that GOV EMER segment is illuminated. Governor emer- (press-to test type) and observe that the indicator il-
gency light should be on only when governor emergency luminates.
switch is in GOV EMER position.
(3) Using a manometer and clean air source,
q. Transmission and Tail Rotor Gearbox Chip apply pressure to switch (figure 9-4).
Detector Light.
(1) Check that CHIP DETECTOR segment is ex-

tinguished with the CHIP DET selector switch in the BOTH
position.
Do not exceed applied pressure of 15 inches
(2) On helicopters without ODDS, short transmis- of water.
sion magnetic chip detector output wire to ground. On
helicopters with ODDS, short pin 1 of debris monitor cable (4) Relieve applied pressure and observe that EN-
plug to ground. Position CHIP DET selector switch to each GINE INLET FILTER CLOGGED indicator (172) extin-
of its three positions and check that CHIP DETECTOR guishes.
segment illuminates with the switch in the BOTH and
XMSN positions only. Remove short. t. Engine Inlet Air Detector Light (S/N 6616868
and Subsequent).
(3) On helicopters without ODDS, short tail rotor
shaft chip detector (in 42” gearbox) output wire to ground. (1) Open all circuit breakers and position all
On helicopters with ODDS, short pin 1 of chip detector switches to OFF.
cable plug to ground. Position CHIP DET switch to each of
its three positions and check that CHIP DETECTOR seg-
ment illuminates with the switch in the BOTH and TAIL
ROTOR position only. Remove short.
(4) On helicopters without ODDS, short tail rotor Do not exceed an applied pressure of 15 in-
chip detector (in 90° gearbox) output wire to ground. On ches of water.
helicopters with ODDS, short pin 1 of chip detector cable
plug to ground. Position CHIP DET selector switch to (2) Close CAUTION LIGHTS circuit breaker.
BOTH and TAIL ROTOR and check that CHIP DETEC- Using a manometer and clean air source, apply pressure
TOR segment illuminates in both positions. Remove short. to switch.
r. Engine Chip Detector Light. (3) Relieve applied pressure and observe that EN-
GINE INLET AIR caution segment extinguishes.
(1) Check that ENGINE CHIP DET segment is ex-
tinguished. u. Fire Detection.
(2) Short engine magnetic chip detector output (1) Close FIRE DET circuit breaker.
wire to ground. Check that ENGINE CHIP DET segment
illuminates.
(2) Depress fire detector test switch (S20) on the
instrument panel. Check that fire detection control relay
(3) Remove short and observe that ENGINE CHIP actuates and causes the FIRE WARNING light to il-
DET segment extinguishes. luminate.
Change 5 9-67
TM 55-1520-210-23-2
v. Deleted. (3) Reconnect wire Q42A20and chock that FUEL

BOOST segment is on.
w. Deleted.
(4) Reconnect wire Q40A20.
X. INOP/ALQ-144 Light. The INOP/ALQ-144 Light
is checked as apart of the AN/ALQ-144 System. Z. ECM Antenna Light. The INOP/ECM antenna
light is checked as a part of the mission antenna actuator
Y. Fuel Boost Light. system.
(1) Disconnect wire Q-42A20 from terminal board

(TB 38) terminal No. 2 at left hand fuel cell and check that
FUEL BOOST segment is on.
(2) Disconnect wire Q40A20 horn terminal board

(TB35) terminal No. 2 at right hand fuel cell and check that
FUEL BOOST segment extinguishes.
9-68 Change 5
TM 55-1520-210-23-2
9-177. Troubleshooting — Master Caution Panel.

Refer to schematic diagram (figure F-26) and trace
malfunctioning circuit or loop, using standard
electronic troubleshooting procedures and standard
t e s t e q u i p m e n t . Localize malfunctioning
components, and repair or replace as required.
9-178. Removal — Master Caution Panel. a .

Loosen fasteners and lift caution panel from panel.
b. Disconnect electrical connector.
9-179. Disassembly, Repair or Replacement —

Master Caution Panel (AVIM).
NOTE
Disassemble only to extent necessary to
accomplish replacement of damaged
parts, as determined by inspection or
troubleshooting procedure.
a. Disassembly.
(1) Turn three fasteners (1, figure 9-5) to

remove cover (5) from assembly to obtain access to
interior of unit.
Figure 9-4. Engine Air Filter Switch (2) If malfunction has been traced to a
component of one of the printed circuit board
assemblies (7, 8, or 9), remove the circuit board
9-172. Troubleshooting – Caution Light involved by removing screws (6) and unplugging
System. Refer to schematic diagram and trace board from electrical connector (29, 30, or 31).
malfunctioning circuit or loop, using standard
electronic troubleshooting procedures and standard (3) Before disconnecting any electrical leads,
test equipment. Localize malfunctioning switch tag wire leads to aid in replacement of wiring at
components, and repair or replace as required. (See reassembly.
figure F-26.)
b. Cleaning.
9-173. MASTER CAUTION PANEL. (1) Remove dust or dirt from exposed
surfaces, using dry compressed air
pressure of 10 psig.
9-174. Description — Master Caution Panel. The
master caution panel contains a number of internally
lighted segments that illuminate when associated
switches, located at different places in the helicopter,
actuate to complete circuits, thus indicating
malfunctions in respective systems. The panel is
energized by the 28 Vdc essential bus and protected
fumes are toxic. Provide adequate
by the CAUTION LTS circuit breaker.
ventilation. Do not use near a flame.
9-176. Cleaning — Master Caution Panel. Refer
to paragraph 9-7 for cleaning procedure.
(2) Remove corrosion, dirt or other foreign
9-176. Inspection — Master Caution Panel. Refer matter from parts with solvent (C261), using a
to paragraph 9-22 for impaction procedure. clean, lint-free cloth or a soft bristle brush (C62).
9-69
TM 55-1520-210-23-2
(3) Thoroughly dry all parts after cleaning with (1) Plug circuit board assembly (7, 8, or 9,
a clean, lint-free cloth or with compressed air at 10 figure 9-5) into electrical connector (29, 30, 94 31)
psig. and install screws (6).
(2) Position cover (5) and attach to assembly
c. Inspection. by turning three fasteners (1).
(1) Inspect all components for security of f. Test Procedure. Perform functional test of
connections and bent or broken pins, contacts, and master caution panel. Refer to paragraph 9-171 for
terminals. functional test procedure.
9-180. Installation — Master Caution Panel. a .

(2) Inspect wiring and connections to all parts
Connect electrical connector.
looking for loose connections, burned or broken wires
and insulation, and proper grounding. b. Position panel in mount, being careful not to
damage wiring.
(3) Inspect resistors for evidence of loose or c. Engage fasteners.
broken terminals and wire leads, burned or swollen
bodies, or other visual signs of damage. 9-181. RPM LIMIT WARINING SYS-
TEM.
(4) Inspect coils for evidence of damage. If
necessary, check continuity of coils with an 9-182. Description — RPM Limit Warining
ohmmeter. System. The rpm limit warining system includes
the RPM WARN SYSTEM circuit breaker located
(5) Inspect removed printed circuit boards for in the overhead console, rpm limit warning de-
broken leads, short, or damaged components. Inspect tector (DSI), rpm warning light (145), AUDIO
relays and diodes for broken glass envelopes. RPM switch (S93) and related wiring and con-
nectors. The rpm warning detector, operating on
d. Repair or Replacement. dc power, senses and interprets rotor and en-
gine rpm through connection to tachometer cir-
(1) Repair of the mastor caution panel is cuits. If the rotor rpm exceeds normal limit,
limited to minor repairs, such as soldering loose warning light will illuminate. When either rotor
connections and straightening bent connector pins. or engine rpm reaches low limit, a warning light
Damaged or malfunctioning electronic parts shall be is illuminated. If BHC Model, Saturn Model, or
replaced with no attempt at repair of such items. SDI Model rpm limit warning detectors are in-
stalled, and either rotor or engine rpm reaches
the lower limit, an audio signal is produced in
NOTE pilot and copilot headsets and the red RPM limit
warning light is illuminated. If BHT Model 205-
In each case, replace components in tho 074-033-103 rpm limit warning detector is in-
exact location from which the replaced stalled, when both rotor and engine rpm reach
part was removed.
the low limit, an audio signal is produced in pilot
and copilot headsets, and RPM limit warning
light is illuminated. For starting and ground oper-
(2) Refer to master caution panel schematic ation, audio tone can be turned off by the AUDIO
diagram in Appendix F when installing new electronic RPM switch.
components or wiring. NOTE
(3) If new parts are installed, trim excess wire Before installation, the rpm warn-
ends after soldering. ing system detector is adjusted. Re-
adjustment may be required
(4) Replace lamps in indicators of the whenever a tachometer generator
rototellite assembly by rotating the indicator to reach is replaced, due to tolerances on
the lamps in base of the unit. Lamps are held in place tachometer components. Replace-
by spring clips. ment of an engine tachometer gen-
erator will not require a check of
e. Assembly. rotor high rpm setting.
9-70
TM 55-1520-210-23-2
Figure 9-5. Master Caution Panel — Exploded View (Sheet 1 of 2)
9-71
TM 55-1520-210-23-2
1. Fastener 23. Screw

2. Grommet 24. Bracket
3. Plate, identification 25. Nut
4. Plate, schematic 26. Washer, lock
5. Cover 27. Screw
6. Screw 28. Stiffener
7. Printed circuit board assy 29. Connector, electrical
10. Light, panel 32. Connector, electrical
11. Switch 33. Nut
12. Nut 34. Screw
13. Screw 35. Stiffener
14. Panel 36. Rail
15. Nut 37. Screw
16. Roto-tellite 38. Rail
17. Spring 39. Rivet
18. cup 40. Spring
19. Fastener 41. Bracket clamp,
20. Plate cable bus bar,
21. Nut light ground
22. Washer, lock
Figure 9-5. Master Caution Panel - Exploded View (Sheet 2 of 2)
9-183. Functional Test — RPM Limit Warning (5) Adjust for an engine speed below 6000
System. rpm (corresponds to 295 rotor rpm), the rpm limit
warning light should be illuminated, but the audio
NOTE warning signal should not be audible in the pilot and
copilot headsets.
Test the rpm limit warning system with
engine running after replacement of rpm (6) Increase the engine speed and verify that
limit warning detector, rotor tachometer the rpm limit warning lights extinguishes within the
generator, or engine tachometer limits of 6200 ± 100 engine rpm (corresponds to
generator. 305 ± 5 rotor rpm). The audio rpm switch should
automatically return to ON position.
a. Low Rpm Limit Test.
b. High Rotor Rpm Warning Test.
(1) Position the audio rpm switch (S93) on the
pilots engine control panel to ON. (1) Position the audio rpm switch (S93) to the
ON position.
(2) Adjust for an engine speed of
approximately 6300 rpm (corresponds to 310 rotor
rpm) and check that the red rpm limit warning light on
the instrument panel is off and that the audio warning
signal is not audible in the pilot or copilot headsets. Do not exceed 15 psi torque pres-
sure, (L-13).
(3) Decrease engine speed very slowly to the NOTE
point where the rpm limit warning light illuminates For this test/alignment only, a
and a swept-frequency audio warning signal (series steady state rpm of up to 6900 out-
of audio bursts) is audible in the pilot and copilot put shaft speed is permissible and is
headsets. This point should be at an engine speed of not to be considered an engine over-
6200 ± 100 rpm (corresponds to 305 ± 5 rotor rpm.
speed as long as 15 psi torque meter
pressure (L-13) is not exceeded. The
(4) Position the audio rpm switch (S93)to OFF.
collective pitch must be at full down
The audio signal in the headsets should cease.
position at all times during this
check.
9-72
TM 55-1520-210-23-2
(2) Wkh the rotor in flat pitch and the GOV detector is necessary the engine should
AUTO/EMER governor switch set to EMER, slowly be shut down, the detector detached
increase throttle until the rpm warning light from the helicopter, and the 1560 -UH-1 -
illuminate. The warning light should illuminate at a 772-1 extender cable or equivalent used
rotor speed of 334 ± 5 rpm (corresponds to an engine to align the detector with the repairman
speed of 6800 ± 100 rpm) and the audio warning strapped in one of the aircraft seats
signal should not be audible in the pilot and copilot during the engine run. See figure 9-9 for
headsets. cables to align rpm limit warning
9-184. Alignment — RPM Warning System. detector.
If the rpm limit warning system does not meet the
requirements of the high and low rpm warning
tests, align the system in accordance with the
following paragraphs. Determine the model of
the detector and test point location from figures
9-6, 9-7, 9-8, and 9-8A. Use table 9-9 to properly Use caution in making adjustments as
isolate each circuit for alignment of BHC Model, excessive turning of screw or slotted
Saturn Model, and SDI Model rpm limit warning adjustment can damage box.
detectors. No special isolation procedures are
necessary for BHT Model 205-074-033-103 NOTE
rpm limit warning detectors. On BHC Model, Saturn Model, and
SDI Model, to increase the rpm at
which the warning light will illumi-
nate, turn slotted adjustments clock-
wise. One half turn of the
potentiometer shaft will cause a
change of 5 rotor rpm or 100 engine
rpm. Do not adjust R4 and R5. These
If alignment of RPM limit warning are bench check adjustments.
Table 9-9. Isolation of Circuits for Alignment — RPM Limit Warning Detector Models
TO ALIGN DISABLE B.H.C. Model SATURN Model S.D.I. Model
R3 ROTOR To CONNECT TP1 Through CONNECT ENGINE Switch — NORMAL

ENGINE CIRCUIT 10,000 Ohm RESISTOR to TP6 to TP8 ROTOR Switch — DISABLE
LOWER +28 VDC, Jumper TP1 to With Jumper
LIMIT AUX JACK
or E-N-R Switch — ENGINE
See figure 9-9
R1 ENGINE CONNECT CONNECT ENGINE Switch — DISABLE

ROTOR CIRCUIT TP1 to TP2 TP7 to TP8 ROTOR Switch — NORMAL
LOWER With Jumper With Jumper
LIMIT or E-N-R Switch — ROTOR
a. Alignment of RPM Lower Limit. warning detector, there will be no

audio tone until jumper is removed
NOTE and both engine and rotor RPM are
On modified Saturn Model RPM limit below limits set.
9-73
TM 55-1520-210-23-2
(1) Disengage the RPM WARN SYSTEM (2) Disconnect ship’s harness from detector,
circuit breaker, detach detector from helicopter, and install 1560-
UH1-772-1 extender cable or equivalent between
detector and ship’s harness.
9-74
TM 55-1520-210-23-2
Figure 9-7. Saturn Model RPM Limit Warning Detector
9-75
TM 55-1520-210-23-2
Figure 9-8A. BHT Model 205-074-033-101 Rpm Limit warning Detector
9-76
TM 55-1520-210-23-2
Figure 9-9. Cables for Alignment of Rpm Limit Warning Detector
9-77
TM 55-1520-210-23-2
Figure 9-10. Bench Test Set Up for BHC Model, Saturn Model,
and SDI Model Rpm Limit Warning. Detector
9-78
TM 55-1520-210-23-2
(3) Loosen screws and open cover of the that light illuminates at 305 ± 5 rotor rpm (cor-
responds to 6200 ± 100 engine rpm). If not,
detector.
repeat steps (11), (12), and (13).
(4) Engage t h e R P M W A R N S Y S T E M
(14) For BHC, Saturn, and SDI models,
circuit breaker and position LOW RPM AUDIO reset switches to NORMAL or remove jumper.
switch to the AUDIO position. An audio warn- Extender cable will remain connected for align-
ing should be present in both pilot and copilot ment of rpm high limit.
headsets.
(5) Start the helicopter engine and increase b. Alignment of Rpm High Limit.
engine s p e e d t o a p p r o x i m a t e l y 6 3 0 0 r p m
(corresponds to 310 rotor rpm). The audio signal in (1) The high limit uses rotor rpm. only, and
the headsets should cease. disabling the engine circuit is not necessary to
align R2 ROTOR HIGH LIMIT,
(6) For BHC, Saturn, and SDI
models, set switch or connect jumper to (2) With the rotor in flat pitch and the GOV
align R3 ENGINE LOWER LIMIT in ac- switch set to EMER, slowly increase throttle un-
cordance with table 9-9. (Not applicable for til the rotor speed is 334 ± 5 rpm (corresponds to
BHT Model 205-074-033-103). engine speed of 6800 ± 100 rpm).
(7) Decrease the engine speed to 6200 rpm NOTE

(corresponds to 305 rotor rpm).
A rotor rpm of 329-334 (engine rpm of
(8) If, following step (7), the RPM limit
6700-6800) is preferable to increase the
warning light is illuminated, turn R3 slowly
margin of overspeed warning.
counterclockwise until the light just ex-
tinguishes and then very slowly clockwise until
the light again illuminates. If following step (7), (3) If, following step (2), the RPM limit
the RPM limit warning light is extinguished, warning light is illuminated, turn R2 clockwise
turn R3 very slowly clockwise until the light until the light just extinguishes, then very slowly
just illuminates. counterclockwise until the light just illuminates.
If, following step (2), the RPM limit warning light
(9) Vary the engine speed slowly above and is extinguished, t u r n R 2 v e r y s l o w l y
below 6200 rpm (corresponds to 305 rotor rpm) while counterclockwise until the light-just illuminates.
observing the RPM limit warning light. Verify
that the light illuminates at an engine speed of (4) Vary the engine speed to verify that the
6200 ± 100 rpm (corresponds to 305 ± 5 rotor RPM limit warning light illuminates and that
rpm); if not, repeat steps (7), (8), and (9). audio warning does not occur at 334 ± 5 rotor
rpm (corresponds to 6800 ± 100 engine rpm). If
(10) For BHC, Saturn, and SDI the RPM limit warning light does not illuminate,
models, reset switches or reconnect jumper repeat steps (2), (3) and (4).
to align R1 ROTOR LOWER LIMIT in ac- (5) Disengage the RPM WARN SYSTEM
cordance with table 9-9. (Not applicable for circuit breakers.
BHT Model 205-074-033-103).
(6) Reset switches to normal, remove any test
(11) Adjust for a rotor speed of 305 rpm leads, close detector cover and secure.
(corresponds to 6200 engine rpm.)
(7) After engine shutdown, remove extender
(12) If, following step (1 1), the RPM limit cable and reinstall the rpm limit warning detector.
warning light is illuminated, turn R1 slowly
counterclockwise until the light just ex- (8) Engage the RPM WARN SYSTEM circuit
tinguishes, then very slowly clockwise until the breaker.
light again illuminates. If, following step (11), the
RPM limit warning light is extinguished, turn R1
very slowly clockwise until the light just il- 9-185. Troubleshooting Rpm Limit Warning
luminates. System. Use table 9-10 and perform checks as
(13) Vary the rotor speed above and below necessary to isolate trouble. In the following table,
305 rpm (corresponds to 6200 engine rpm) while lamps are omitted from indications of trouble. Such
observing the RPM limit warning light. Verify
trouble is usually easily detected and corrected.
218-260 0- 88 - 8 9-79
TM 55-1520-210-23-2
Broken wiring is always a probable cause of circuit N O T E

malfunction or failure and has not been included. Before you use this table, be sure you
(See figure F-27.) have performed all normal operational
checks.
Table 9-10. Troubleshooting Rpm Limit Warning System
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. No audio tone is present in pilot or copilot headsets; engine not running and RPM limit warning light is
illuminated.
STEP 1. Check for defective LOW RPM AUDIO switch (S93).
STEP 2. Check for defective rpm limit warning detector (DS1).
Replace rpm limit warning detector if defective (paragraph 9-186).
2. Placing LOW RPM AUDIO switch (S93) to OFF does not eliminate audio tone in headsets.
STEP 1. Check for defective LOW RPM AUDIO switch (S93).
3. RPM limit warning light (145) does not illuminate when engine is not running. Audio tone present in
headsets.
4. RPM limit warning light (145) does not illuminate, no audio tone present in headsets when engine is not
running.
STEP 1. Check for defective RPM WARN SYSTEM circuit breaker.
9-186. RPM LIMIT WARNING connection to tachometer circuits. If rotor exceeds

DETECTOR. normal limit, power is furnished through the detector
to illuminate the rpm warning light(145). If either-
BHC, Saturn, or SDI model rpm limit . warning
9-187. Description — RPM Limit Warning detector is installed and either rotor or engine rpm
Detector. The rpm limit warning detector (DS1), reaches low Limit, the detector produces an audio
operating on dc power from the 28 Vdc essential bus, signal in the pilot and copilot headsets and il-
senses and interprets rotor and engine rpm through luminates the rpm warning light. If BHT Model
9-80
TM 55-1520-210-23-2
205-074-033-103 rpm limit warning detector is installed, NOTE

when both rotor and engine rpm reach the lower limit, an
audio signal is produced in the pilot and copilot headsets The rpm limit warning detector test set maybe lo-
and the red RPM limit warning light illuminates. cally fabricated. See figure F5 and F6 for internal
schematic.
9-188. Cleaning- Rpm Limit Warning Detector. a.
Remove moisture and loose dirt with a dean, soft cloth. The pilot and copilot audio outputs are loaded
within the test set so that an oscilloscope may be
used to monitor audio signals. The scope input
cable is connected to a scope input switch that al-
lows selection of pilot or copilot audio output.
Dry cleaning solvent is flammable and its fumes (1) Use table 9-9 to isolate circuits in different
are toxic. Provide adequate ventilation. Do not models of rpm detectors.
use near aflame.
(2) Use equipment shown in figure 9-9 and F-5
b. Remove grease, fungus, and dirt with a dean, lint- and test each rpm limit warning detector as follows:
free cloth dampened with solvent (C261).
(a) Loosen detector cover strip screws and move
c. Remove dirt from electrical connector with a bristle cover strips to expose test points and adjustment poten-
brush (C62). tiometers.
9-189. Inspection - Rpm Limit Warning Detector. (b) Connect detector to the bench test equip-
ment as shown in figure 9-10. Set initial control positions
a. Inspect detector for cracked or distorted case. on the test set as follows:
CONTROL POSITION
b. Check for bent or broken connector pins.
PWR ON/OFF OFF
c. Check for proper operation.
ENGINE SPEED FULLY COUNTER
9-190. Bench Test and Adjustment - Rpm Limit Warn- CLOCKWISE
ing Detector. (AVIM)
ROTOR SPEED FULLY COUNTER
NOTE CLOCKWISE
Step a. applies to BHC, Saturn and SDI model AUDIO ON/OFF ON

rpm limit warning detectors. Step b. applies to
BHT Model 205-074-033-103 rpm limit warning SCOPE INPUT PILOT
detector.
(c) Energize the test equipment and allow a suf-
a. BHC Model, Saturn Model, and SDI Model rpm limit ficient warmup period.
warning detectors:
(d) Apply 27.5 Vdc power to the DC power packs
TEST EQUIPMENT REQUIRED on the front of the test set. Observe that the warning light
on the test set is illuminated and that a sweeping audio
Rpm Limit Warning Locally Fabricated signal is displayed on the osilloscope for both the PILOT
Detector Test Set (see figures 9-10 and and COPILOT positions of the scope input switch.
F5 and F6)
(e) Connect a headset to the COPILOT phone
oscilloscope AN/USM-281A jack and determine that the aural signal is of good quality.
Disconnect headset.
28 Vdc Power Supply,
1 ampere (f) Repeat step (e) with headset plugged into the
PILOT phone jack.
Change 5 9-81
TM 55-1520-210-23-2
(g) Disable engine circuit to align R1 ROTOR (q) With the simulated rotor speed still at
LOWER LIMIT in accordance with table 9-9. 315 rpm, adjust for a simulated engine speed of 6200
rpm. If the warning light is illuminated adjust R3-
(h) Adjust test for a similated rotor speed of ENGINE LOWER LIMIT counterclockwise until the
305 rpm and an engine speed of 6200 rpm. If the light just extinguishes,
warning light is illuminated, adjust R1 ROTOR
LOWER LIMIT counterclockwise until the light just (r) Adjust R3-ENGINE LOWER LIMIT
extinguishes. clockwise until the light just illuminates. While the
warning light is illuminated, observe that audio signal
is displayed on the oscilloscope for both the PILOT
(i) Adjust R1-ROTOR LOWER LIMIT
l nd COPILOT positions of the scope input switch.
clockwise very slowly until the light just illuminates.
With the light illuminated, an audio signal must be
(s) Adjust for a simulated engine speed of
displayed on the oscilloscope for both the PILOT and
6400 rpm. Observe that the warning light is
COPILOT positions of the scope input switch.
extinguished and that the audio signal is not
displayed on the oscilloscope for either the PILOT or
(j) Position audio ON\OFF switch to OFF. COPILOT positions of the scope input switch.
The sweeping audio signal must cease.
(k) Slowly increase simulated rotor speed

NOTE
through 305 rpm. Observe that the audio switch
automatically returns to the ON position when the
warning light extinguishes. Step (t) checks proper function only. The
engine high limit potentiometer R4 is
(l) Increase simulated rotor speed to 334 factory adjusted fully clockwise and is
rpm. It the warning light is illuminated, adjust R2- not to be adjusted.
ROTOR HIGH LIMIT clockwise until the light just
extinguishes. (t) Repeat step (s) at a simulated engine
speed of 7000 RPM.
(m) Adjust R2-ROTOR HIGH LIMIT very
slowly counterclockwise until the light just NOTE
illuminates. Observe that an audio signal is not
displayed on the oscilloscope for either PILOT or For Saturn detectors, step (u) checks the
COPILOT positions of the scope input switch. audio portion of the rotor channel
tachometer failure circuit. For other
(n) Adjust for a simulated rotor speed of 315 models go to step (v).
rpm. Observe that the warning light is extinguished
and that audio signal is not displayed on the (u) Momentarily adjust the simulated rotor
oscilloscope for either the PILOT or COPILOT speed to 0 rpm. Observe that the warning light is
positions of the scope input switch. illuminated and that audio signal is displayed on the
oscilloscope for both PILOT and COPILOT positions of
NOTE the scope input switch.
For Saturn detectors, step (o) checks the (v) Remove jumper or reposition switch used
engine channel tachometer failure cir- to disable rotor circuit in step (p). Adjust rotor and
cuits. For other models go to step (p). engine speed controls on test set fully
counterclockwise.
(o) Momentarily adjust for a simulated (w) Position scope input switch to PILOT and
engine speed of O rpm. Observe that the warning light adjust R5-AUDIO for a waveform of 0.5 volt peak-to-
illuminates and that audio signal is displayed on the peak. Position scope input switch to COPILOT and
oscilloscope for both PILOT and COPILOT positions of observe that the indicated waveform is not less than
the scope input switch. 0.25 volt peak-to-peak, and not more than 0.75 volt
peak-to-peak.
(p) Remove jumper or reposition switch used
to disable engine circuits in step (g) and disable rotor (x) Disconnect detector from test set and
circuit to align R3-ENGINE LOWER LIMIT in reassemble unit.
accordance with table 9-9.
9-82
TM 55-1520-210-23-2
b. BHT Model 205-074-033-103 rpm limit warning (c) With RPM limit warning light (figure F-6) il-
detector: luminated (high rotor limit), depress RPM LIMIT WARN
TEST switch for 30 seconds minimum. Note that RPM limit
TEST EQUIPMENT REQUIRED warning light extinguishes while RPM LIMIT WARN TEST
switch is depressed and illuminates when switch is
Rpm Limit Warn- Locally Fabricated released.
ing Detector (See figures 9-1OA
Test Set and F-6 (d) With CR12 illuminated, adjust rotor signal
generator frequency downward until CR12 (figure 9-1OA)
Signal Generator H-P Model is extinguished. The difference between this frequency
(two required) 202C and the high rpm limit frequency established shall not be
more than 2 Hz.
28 Vdc Power Supply,
1 ampere (e) Adjust rotor signal generator for a frequency
of 66 ±l Hz and an amplitude of 18 ±1 peak voltage.
NOTE
(f) Adjust R1 of the rpm limit detector
The rpm limit warning detector test set maybe lo- counterclockwise to extinguish CR20, if it is illuminated.
cally fabricated. See figure F6 for internal Slowly adjust rotor signal generator frequency up until
schematic. CR20 extinguishes and then back down until CR20 is il-
luminated. The frequency of the signal generator shall be
The pilot and copilot audio output circuits are 66 ± 1 Hz.
loaded within the test set to simulate impedance
of headset. (g) With CR20 illuminated, adjust rotor signal
generator frequency up until CR20 is extinguished. The
(1) Connect rpm limit warning detector and test difference between this frequency and the low rpm limit
equipment as shown in figure 9-10A and F6. frequency established shall not be more than 2 Hz.
(2) Apply electrical power to test equipment and (h) Adjust engine signal generator for a frequen-
power supply. Allow one minute for stabilization. cy of 66 ± 1 Hz and an amplitude of 18 ±1 peak voltage.
(3) Set initial control positions on the test set as fol- (i) Adjust R3 of the rpm limit detector
lows: counterclockwise to extinguish CR22, if it is illuminated.
Slowly adjust R3 clockwise until CR22 illuminates. Adjust
CONTROL POSITION engine signal generator frequency up until CR22 extin-
guishes and then back down until CR22 is illuminated. The
frequency of the signal generator shall be 66 ± 2 Hz.
PWR ON
ON (j) With CR22 illuminated, adjust engine signal

AUDIO ON/OFF
generator frequency up until CR22 is extinguished. The
difference between this frequency and the low engine limit
AUDIO OUT PILOT frequency established shall not be greater than 2 Hz.
RPM LIMIT WARN TEST OFF (k) Adjust both rotor and engine Signal gener-
ators down in frequency to approximately 50 Hz. Note that
(4) Test rpm limit warning detector as follows: RPM limit warning light (figure F-6) is illuminated. Place
AUDIO OUT switch in PILOT position. Check that
(a) Adjust rotor signal generator for a frequency the audio level at J7 (on rpm warning test set) is
of 73.5 ± 1 Hz and an amplitude of 18 ± 1 peak voltage. adjustable, by adjustment of R5, from 0 to 300 millivolts
rms. Repeat check with AUDIO OUT
(b) Adjust R2 (figure 9-10A) clockwise to extin-
guish CR12 if it is illuminated. Slowly adjust R2
counterclockwise until CR12 illuminates. Adjust rotor sig-
nal generator frequency down until CR12 extinguishes
and then up until CR12 is illuminated. The frequency of the
signal generator shall be 73.54 ± 1 Hz.
Change 5 9-83
TM 55-1520-210-23-2
Figure 9-10A. Bench Test Set Up for BHT 205-074-033-101 Rpm

Limit Warning Detector
9-84
TM 55-1520-210-23-2
switch in COPILOT position. Set R5 (figure 9-10A) for an b. Connect electrical connector.
audio level of 300 millivolts rms of J4 with AUDIO OUT
switch In PILOT position. 9-193.1 OIL DEBRIS DETECTION SYSTEM (ODDS)
(1) Adjust rotor and engine signal generators for 9-193.2. Description. The oil debris detection system
normal operation (frequencies of approximately 70 Hz and (ODDS) provides for prediction/detection of impending
amplitude to 18 ± 1 peak voltage). RPM limit warning light failures of oil-wetted components: engine, transmission, and
(figure F-6) should be extinguished and audio should not be 42- and 90-degree tall rotor gearboxes. The system also
heard in either PILOT or COPILOT positions of AUDIO improves oil filtration, reduces wear on seals, reduces
OUT switch. unscheduled removal of oil-wetted components, and reduces
nuisance chip indications caused by normal-wear particles
(m) Adjust engine signal generator down in on detector gaps. Twenty-eight volt dc for system operation
frequency to approximately 50 Hz. Check that RPM limit is obtained horn the essential bus through 5-ampere ODDS
warning light is illuminated, but audio is not heard in either circuit breaker.
position of AUDIO OUT switch.
NOTE
(n) Return to normal operation (refer to step 1).
All hardware associated with ODDS system
(o) Adjust rotor signal generator down in which is utilized on a replaceable assembly (i.e.
frequency to approximately 50 Hz. Check that RPM limit 42, 90 degree gear boxes, transmission, etc.) must
warning light is illuminated, but audio is not heard in either be removed prior to assembly being evacuated to
position of the AUDIO OUT switch. depot. ODDS items shall be reinstalled on the
new assembly.
(p) Return to normal operation (refer to step 1).
a. Powerplant oil system components:
(q) Adjust both rotor and engine signal generators
for frequency of approximately 50 Hz and amplitude of 18 (1) Oil separator (Lubriclone) in engine service com-
peak voltage. Note that RPM limit warning light is illumi- partment (paragraph 4-100.2).
nated and audio is heard in either position of the AUDIO OUT
switch. (2) Oil filter, which has a 3-micron element, in
engine service compartment (paragraph 4-100.13).
(r) Place AUDIO ON-OFF switch to OFF posi-
tion. Note that audio is not heard in either position of AUDIO (3) Chip detector at bottom of oil separator. Detector
OUT switch. is wired to ENGINE CHIP DET caution capsule.
(s) Return AUDIO ON-OFF switch of ON b. Drive system components:

position. Check that audio is heard at J7 in either position of
AUDIO OUT switch. (1) Debris monitor in transmission sump. Monitor
replaces pre-ODDS conventional filter.
9-191. Removal — Rpm Limit Warning Detector. a.
Remove attaching hardware and disconnect electrical con- (2) External filter, which has 3-micron element, in
nector. cargo sling compartment. Filter replaces pre-ODDS 25-
micron filter.
b. Remove detector.
(3) Three chip detectors, one in debris monitor and
9-192. Repair or Replacement — Rpm Limit Warning one each in 42 and 90-degree gearboxes. Detectors are wired
Detector. a. Tighten or repair any loose or defective to CHIP DET caution capsule.
mounting hardware or electrical connector.
c. Electrical system component: Power module, over-
b. Replace detector if any other inspection requirements head in front of cabin, provides electrical power to pulse
are not met. (burn) away ferrous (iron or steel) debris less than 0.005 inch
in cross section. Larger debris will not puke away, but
9-193. Installation — Rpm Limit Warning bridges chip gap and closes the circuit to caution capsule.
Detector. a. Position detector into place and install mount-
ing hardware.
Change 5 9-84.1/(9-84.2 blank)

TM 55-1520-210-23-2
9-193.3 Functional Test — ODDS (10) Disconnect cable plug from chip detector.
a. Apply external power to helicopter. (11) Install and connect chip detector probe.
b. Check that ODDS and CAUTION LIGHTS circuit Safety wire each chip detector connector with lockwire
breakers are closed. (C155).
c. Set CHIP DET switch on pedestal to BOTH. 9-193.4 ODDS POWER MODULE
d. At each chip detector or debris monitor listed be-
9-193.5 Description — A power module (8, figure 9-2)
low (four locations), perform functional test as follows:
for oil debris detection system (ODDS) is overhead on
(1) Disconnect cable plug. the web just aft of the cockpit at butt line 23R. Power
(2) Remove chip detector. module responds to iron or steel chips across four chip
detectors by pulsing them. If chips are less than about
(3) Connect chip detector to cable plug. 0.005 inch in cross section, the module will pulse (burn)
(4) Ground body of detector to clean unpainted them away before caution capsule can respond. If chips
surface of airframe. Use a jumper wire. are larger, they will not burn away; they will bridge the
chip gap and light a caution capsule. The power module
(5) Place paper clip or similar iron or steel ob- is connected to chip detectors in oil system or oil supply
ject across chip gap of detector. The paper clip will draw of engine, transmission, and two tailrotor gearboxes.
a spark; caution capsule listed and MASTER CAUTION Components of power module are encapsulated in a 3 x
light shall come on. 3 x 1-1/2-inch black box. Twenty-eight-volt dc for opera-
tion is obtained from essential bus through ODDS circuit
Chip Caution breaker. Connections to circuits are made through a 12
Detector Location Capsule pin electrical receptacle.
1 D851 * Transmission CHIP DET 9-193.6 Removal — Power Module
(two chip
gaps) a. Disconnect cable plug.
b. Remove four screws, eight washers, and four nuts
1B833 42° Gearbox CHIP DET
and remove power module.
1B833 90° Gearbox CHIP DET NOTE
When the ODDS Power Module is not
84443B Engine ENGINE CHIP DET
installed, use Chip Light procedures es-
* Test each chip gap separately. tablished for non-ODDS equipped aircraft.
If there is any uncertainty about the type of
debris found, the normal procedures pre-
(6) Set CHIP DET switch to position which scribed in the TM and TB 1-1520-243-20-26
matches chip detector being tested, XMSN or TAIL RO- should be followed.
TOR. Caution capsule shall remain on.
(7) Set switch to opposite position. Capsule 9-193.7 Installation — Power Module
shall go out. a. Position the power module overhead on the web
(8) Set switch to position which matches cap- (station 75, butt line 23R).
sule. Caution capsule shall come on. b. Install four screws, washers, and nuts.
(9) Remove paper clip. Caution capsule shall c. Connect the cable plug to the power module.
go out. MASTER CAUTION light will go out when
pressed. Separate chip detector from ground. d. Test the system (paragraph 9-193.3).
Change 13 9-85
TM 55-1520-210-23-2
b. Connect electrical connector. NOTE

9-194. EXTERIOR LIGHTS SYSTEM. Aircraft modified for night vision gog-
9-195. Description — Exterior Lights System. gles capability, functionally test light
The exterior lights system includes the landing and and make sure that light does not ex-
searchlights, anticollision light, navigation lights, tend beyond approximately 90 de-
navigation lights flasher, and transmission oil level grees arc on retract to full up position.
light.
b. Perform functional test of searchlight as
9-196. LANDING AND SEARCHLIGHT follows:
SYSTEM.
9-197. Description – Landing and Searchlight
System. One landing light and one searchlight are
located on the underside of the cabin. Each has
individual control and power circuits which are Do not operate searchlight in areas of
powered from essential bus and protected by circuit combustible material, such as tall grass.
breakers. Control switches for both lights are located etc.
on the pilots collective stick, They consist of four
switches, two that control power to the lamps, and (1) Close SEARCHLIGHT PWR and LOG &
two that control the positions of the lights. SEARCHLIGHT CONT circuit breakers. Position lamp
control switch (S75) to ON and check that searchlight
NOTE
illuminates. Return switch to OFF.
Aircraft modified for night vision gog- (2) Position four-way switch (S12) to EXT (fwd
gles capability the copilot collective position). Check that light extends and is stopped by
stick contains additional landing light extend limiter switch at approximatley 120 degrees
control switches wired in parallel with extension.
pilot landing light switches. (3) Position switch (S12) to RETR (aft position).
Check that light retracts.
9 - 1 9 8 . F u n c t i o n a l T e s t — Landing and
(4) With light partially extended, position
Searchlight System. a. Perform functional test of
switch (S12) to “L” and check that light rotates to the
landing light as follows:
left.
(5) Position switch (S12) to “R” and check that
light rotates to the right.
(6) With light extended and rotated, position
Do not operate landing light in areas of switch (S75) to S L STOW. Check that light retracts
combustible material, such as tall grass. and is stopped by the retract limit switch and then
etc. rotates to its level stowed position and stops.
9-199. Troubleshooting — Landing a n d
(1) Close LDG LT PWR and LDG & Searchlight System. Use table 9-11 and perform
SEARCHLIGHT CONT circuit breakers. Position lamp checks as necessary to isolate trouble. Tripped circuit
control switch (S76) on the pilots collective stick to breakers are omitted from indication of trouble since
ON and check that landing light illuminates. Return such trouble is usually easily detected and corrected.
switch (S76) to OFF. Broken wiring is always a probable cause of circuit
(2) Position extend-retract switch (S25) to malfunction or failure and has not been included.
EXTEND (fwd position). Check that light extends and (See figure F-28.)
is stopped by the extend limit switch at approximately NOTE
120 degrees extension.
(3) Position switch (S25) to RETRACT (aft Before you use this table, be sure you
position). Check that light retracts and is stopped in have performed all normal operational
the stowed position by the retract limit switch. checks.
9-86
TM 55-1520-210-23-2
Table 9-11. Troubleshooting Landing and Searchlight System
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. Landing light (I16) inoperative.
STEP 1. Ensure that voltage is present on 28 Vdc bus. Check for defective LDG LT PWR and/or LOG &
SEARCHLIGHT CONT circuit breakers.
Replace circuit breaker(s) if defective (paragraph 9-12).
STEP 2. Check for defective landing light switch (S76).
Replace switch if defective (paragraphs 9-5 through 9-11).
2. Landing light dim, constantly or intermittently.
STEP 1. Place temporary jumper from bare metal on lamp to metal frame and then turn on. If lamp burns
brightly constantly, check mounting of lamp for corrosion and/or paint.
Clean as necessary to provide a good electrical ground (paragraph 9-7).
STEP 2. Check for loose power lead or corroded terminal.
Tighten or clean connection in power circuit (paragraphs 9-7, 9-10).
STEP 3. Check for burned relay contacts.
Replace relay if defective (paragraphs 9-5 through 9-11).
3. Searchlight (I11) inoperative.
STEP 1. Ensure that voltage is present on 28 Vdc bus and check for defective SEARCHLIGHT PWR and/or
LOG & SEARCHLIGHT CONT circuit breakers.
Replace circuit breaker(s) if defective (paragraph 9-12).
STEP 2. Check for defective searchlight switch (S75).
4. Searchlight dim, constantly or intermittently.
STEP 1. Place temporary jumper from bare metal on lamp to metal frame and then turn on. If lamp burns
brightly constantly, check mounting of lamp for corrosion and/or paint.
Clean as necessary to provide a good electrical ground (paragraph 9-7).
STEP 2. Check for loose power lead or corroded terminal.
Tighten or clean connection in power circuit (paragraphs 9-7, 9-10).
9-87
TM 55-1520-210-23-2
Table 9-11. Troubleshooting Landing and Searchlight System (Cont)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
STEP 3. Check for burned relay contacts.
9-200. LANDING AND SEARCHLIGHTS. c. Remove light mounting screws.
d. Remove terminal cover, disconnect, tag, and pro-

tect wires with electrical tape (C275).
Never look at searchlight when light is on and
e. Remove light assembly.
filter is not installed. Always look from side
with filter installed.
9-205. Repair or Replacement—Landing and
Searchlights. a. Accomplish replacement of sealed
9-201. Description-Landing and Searchlights.
beam lamp as follows: Remove three screws from
The landing light is controllable with extend and re-
lamp retainer ring, remove ring and gasket, lift lamp
tract motion. The searchlight is controllable with ex-
and disconnect wiring.
tend, retract, rotate left, and rotate right motion.
9-202. Cleaning—Landing and Searchlights. a. NOTE

Remove moisture and loose dirt with a clean, soft
cloth. Observe position of lamp before removal and
install new unit in same position using reverse
order of removal procedure.
b. Replace complete unit if inspection items in para-

graph 9-203, step b. are not met.
fumes are toxic. Provide adequate ventilation.
Do not use near a flame.
9-206. Installation—Landing and Searchlights.
a. Connect wires and install terminal cover and clamp.
b. Remove grease, fungus, and dirt with a clean,
lint-free cloth dampened with solvent (C261).
b. Position light on mounting plate; secure with
mounting screws.
c. Remove dirt from electrical connectors with a
c. Position plate and light assembly on fuselage
and secure with mounting screws.
9-203. Inspection-Landing and Searchlights. a.
Check light for defective or broken sealed beam unit.
d. Check light for proper operation.
b. Check for loose connections and damaged or
9-207. ANTICOLLISION LIGHT SYSTEM.
defective component parts (terminal strips, limit
switches, drive motors, relays, etc.).
9-208. Description—Anticollision Light System.
Anticollision light system consists of a circuit breaker,
9-204. Removal-Landing and Searchlights. a.
a switch, and the anticollision light assembly.
Ensure all electrical power is OFF.
b. Remove attaching screws from light assembly

mounting plate; lower light and plate.
9-88 Change 4
TM 55-1520-210-23-2
Anticollision light is installed on tailpipe fairing. are omitted from indication of trouble since such
Circuit breaker and switch are on overhead console. trouble is usually easily detected and corrected.
9-209. Functional Test - Anticollision Light malfunction or failure and has not been included.
System. a. Close ANTI-COLL LT circuit breaker. (See figure F-29.)
b. Position ANTI-COLL LT switch (S59) to ON
NOTE
and check that lamp(s) illuminate and that the
light flashes 70 ± 30 flashes per minute, single
bulb 90 ± 9 flashes per minute, dual bulb.
9-210. Troubleshooting — Anticollision Light checks.
System. Use table 9-12 and perform checks as
necessary to isolate trouble. Tripped circuit breakers
Table 9-12. Troubleshooting Anticollision Light System
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. Anticollision light (I40) fails to operate with anticollision light switch (S59) in ON position.
STEP 1. Ensure that voltage is present on 28 Vdc bus and check for defective ANTI-COLL LT circuit breaker.
STEP 2. Check for defective anticollision light switch (S59).
2. Anticollision light fails to rotate with anticollision light switch (S59) in ON position.
Check for proper operating voltage at pin B of connector (P111).
Replace anticollision light if defective (paragraph 9-211).
9-211. ANTICOLLISION LIGHT.
9-212. Description — Anticollision Light. Dry cleaning solvent is flammable and its
The anticollision light may have one or two bulbs. fumes are toxic. Provide adequate
The internal assembly is motor driven and rotates ventilation. Do not use near a flame.
to produce a flash effect.
b. Remove grease, fungus, and dirt with a
clean, lint-free cloth dampened with solvent
(C261).
9-213. Cleaning — Anticollision Light. a. Remove c. Remove dirt from electrical connectors
moisture and loose dirt with a clean, soft cloth. with bristle brush (C62).
9-89/(9-90 blank)
TM 55-1520-210-23-2
9-214. Inspection — Anticollision Light. a. amber/clear light in the vertical fin of the aft section
Inspect light for broken cover, lens or open lamp assembly The navigation lights system also Includes
filament. three fuselage white lights [one above each cabin
door and one on bottom right side of cabin) On UH -
b. Inspect light for damaged case or broken 1 D/H serial number 65-9565 and subsequent, the
connector pins. white Ilghts are protected by a separate circuit
c. Inspect motor for damage and proper

operation. 9-220. Functional Test – Navigation Lights
System. a. Close FUS LIGHTS circuit breaker. Place
9-215. Removal - Anticollision Light. a. Ensure navigation lights switch (S13) to STEADY. Position
that all electrical power IS OFF. dim-bright switch (S14) to BRT. Check that the two
upper and one lower fuselage lights are on bright
b. Remove mounting screws around base of
light, lift light up, and disconnect electrical connector.
b. Position switch (S14) to DIM and check that
the fuselage lights specified in step a. are on dim.
9-216. Repair or Replacement — Anticollision
Light. a. Loosen screw securing lens cover retaining
c. Close NAV LIGHTS circuit breaker. Check that
ring, lift lens from light base. Install and secure lamp,
the two red (left side) and the two green (right side)
lens or cover in reverse order of removal procedure.
navigation lights and the tail light are illuminated and
are on dim.
b. R e p l a c e c o m p l e t e u n i t i f i n s p e c t i o n
requirements are not met.
d. Position switch (S14) to BRT. Check that all
c. If drive gear is loose on motor shaft, secure
lights specified in steps a. and c. are on bright.
with sealing compound (C 187.5)
d. Deleted. e. Position switch (S13) to FLASH. Check that
the two red and two green navigation lights and the
9-217. Installation — Anticollision Light. a. tail light flash at a rate of approximately 85 ± 15
Connect electrical connector to light and secure with times a minute
lockwire.
b. Place light in recess and install mounting 9-221. Troubleshooting — Navigation Lights
screws. System. Use table 9-13 and perform checks as
necessary to isolate trouble. Tripped circuit breakers
c. C h e c k light for proper operation. are omitted from indication of trouble since such
trouble is usually easily detected and corrected.
9-218. NAVIGATION LIGHTS malfunction or failure and has not been included
SYSTEM. (See figure F-29)
9-219. Description — Navigation Lights System.
NOTE
The navigation lights system consists of circuit
breaker, two selector switches, flasher, two red lights
on the left side and two green lights on the right side
(one each above and below the cabin door), three
checks.
fuselage white lights (one above each cabin door and
(one each above and below the cabin door), and one
Change 2 9-91
TM 55-1520-210-23-2
Table 9-13. Troubleshooting Navigation Lights System
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. Fuselage lights (white) fail to burn bright with switch (S13) to STEADY and switch (S14) to BRT.
Check for defective switch (S14).
2. Fuselage lights (white) fail to dim with switch (S14) to DIM.
3. One fuselage or navigation light dim or intermittent.
Check for poor electrical ground at light.
Remove light and clean ground (paragraph 9-5).
4. Navigation lights (red, green, and amber/clear) fail to burn bright with switch (S13) to STEADY and switch
(S14) to BRT.
5. Navigation lights (red, green, and amber/clear) fail to dim with switch (S14) to DIM.
STEP 1. Check for defective switch (S14).
STEP 2. Check for defective dimming resistor (R7).
Replace resistor if defective (paragraph 9-5).
6. Navigation lights (red, green, and amber/clear) fail to flash when switch (S13) is placed to FLASH.
STEP 2. Check for defective flasher (Z3).
Replace flasher if defective (paragraph 9-229).
9-92
TM 55-1520-210-23-2
9-222. NAVIGATION LIGHTS. c. Lens Modification (Refer to Figure 9-10.1)

9-223. Description - Navigation Lights. The naviga- (1) Both upper and lower red and green lenses
tion lights consist of the upper and lower fuselage lights, need to be modified. Leave position dome lens in assem-
upper and lower navigation lights and the tail light. The bly.
fuselage light units have two bulbs which furnish dim or (2) Determine the horizontal center line of the
bright white light. The navigation lights installed on the position lights by drawing or making from the center of
right side of the helicopter furnish green light, the lights the phillips and cone point of the light cover and
installed on the left side of the helicopter furnish red light, extend across dome lens through the raised letter or dim-
and the tail light furnishes amber or clear light. ple located in the center of the lens (refer to Figure
9-10.1).
9-224. Clearing - Navigation Lights.
(3) For the upper right and left position lights, mark
a. Remove moisture and loose dirt with a clean, soft a line 1/8 inch below and parallel to the center line drawn
cloth. in step 2. The line should extend from the light cover to
the base of the lens. Note that the masking tape will just
cover the head of the phillips screw on the light assembly
covers.
Dry cleaning solvent is flammable (4) For the lower right and left position lights, mea-
and its fumes are toxic. Provide sure and mark 1/8 inch above and parallel to the center
adequate ventilation. Do not use line mark on the lens. Again, the line should extend from
near a flame. the light cover to the base of the lens. Place masking
tape on the lower part of the light assembly along the 1/8
b. Remove grease, fungus and dirt with a clean, lint- inch line above the center line. Again, note that the mask-
free cloth dampened with solvent (C261). ing tape just covers the head of the phillips screw on the
c. Remove dirt from electrical connectors with a Iight assembly covers.
bristle brush (C62). (5) Verify that slightly more then 1/2 of the top por-
tions of the exposed upper position lights are completely
9-225. Inspection - Navigation Lights. lnspect lights
masked, and slightly more than 1/2 of the bottom parts
for corroded lamp socket terminals, shorted or broken of the lower position lights are completely mashed.
wires, cracked lens, burned out lamp bulbs or improper
bonding of Iight case to airframe. Inspect lens for proper (6) To prevent overspray of the airframe CARC
painting IAW paragraph 9-228 c. paint, cut a piece of Stencil Board, Oil, NSN
9310-00-160-7858, approximately 16 inches long by 11
9-226. Removal - Navigation Lights. inches wide and locate center point. Place the position
a. Check that all electrical power is OFF. Iight template over the center point of the cut stencil
hoard (lengthwise) and draw around the template. Re-
b. Remove cover retaining screw. Remove screws move the template and (with a sharp instrument) art out
attaching light assembly to bracket, pull assembly from template area. The position light assembly will he ex-
helicopter, and disconnect electrical connector. Lift light posed to minimal overspray.
assembly from helicopter. Cover boss wire with taps
(C270). NOTE
9-227. Repair or Replacement - Navigation Lights. Roughing the exposed lens surfaces
with either steel wood or sandpaper
Replace faulty or damaged component parts (lens, lamp
bulbs, etc.). lf light case is damaged beyond repair, prior to painting may make applica-
complete unit must be replaced. Reinstall both upper tion easier and improve paint adhe-
and lower lenses. Ensure lenses are properly painted sion.
IAW paragraph 9-228 c. (7) Paint the exposed area of the lenses using
9-228. Installation - Navigation Lights. Lacquer, Olive Drab, 16 oz. aerosol can, NSN
8010-00-584-3149. Proceed until sufficient coats are
a. Remove any tape and tape residue, cleaning applied to prevent any bleeding of light through the
thoroughly before reinstalling navigation lights. painted area. Test the opacity of the painted area by turn-
ing on the position lights.
b. Remove tape from wire and connect wire to light.
Secure light to adapter bracket with screws. Install cover d. Check operation of light
with screw.
9-93 Change 12
TM 55-1520-210-23-2
9-229. NAVIGATION LIGHTS FLASHER. c. Remove dirt from electrical connectors with a
9-230. Description - Navigation Lights Flasher. The
navigation lights flasher is mounted in the aft electrical 9-232. Inspection - Navigation Lights Flasher.
compartment on UH-1H/V helicopters through serial Inspect flasher for dents or damage that would
number 64-13901. The flasher number will cause the white and impair not normal operation of the unit. Check connector for
colored navigation lights to flash alternately. On broken or corroded pins and cracked inserts.
UH-1H/V serial number 65-9596 and subsequent, the
flasher will cause only the colored navigation lights to 9-233. Remove - Navigation Lights Flasher.
flash.
a. Ensure all electrical power is Off.
9-231. Cleaning - Navigation Lights Flasher.
b. Disconnect the electrical connector. Remove
a. Remove moisture and loose dirt with a clean, soft mounting hardware and lift from compartment.
cloth.
9-234. Repair or Replacement - Navigation Lights
Flasher. Replace item if inspection requirements are
not met
Dry cleaning solvent is flammable
9-235. Installation - Navigation Lights Flasher.
and its fumes are toxic. Provide
adequate ventilation. Do not use a. Position flasher in compartment and install
near a flame. mounting hardware.
b. Remove grease, fungus and dirt with a clean, lint- b. Connect electrical connector. Check for proper
free cloth dampened with solvent (C261). operation.
9-94 Change 12
TM 55-1520-210-23-2
TOP POSITION LIGHT
BOTTOM POSITION LIGHT
Figure 9-10.1 Position Light Lens Modifications
9-94.1 Change 12
TM 55-1520-210-23-2
9-236. TRANSMISSION OIL LEVEL b. Press pushbutton switch (S4). Check

LIGHT. operation of the light through the sight glass in the
right hand transmission cowling.
9-237. Description - Transmission Oil Level
Light. The transmission oil level light (125) is located 9-239. Troubleshooting - Transmission Oil
inside the transmission cowling on the right ado of Level Light. Use table 9-14 and perform checks as
the helicopter. The light is used to illuminate the necessary to isolate trouble. Tripped circuit breakers
transmission sump area so that the transmission oil are omitted from indication of trouble since such
Ievel light gages will be visible when viewed through trouble is usually easily detected and corrected.
the transmission oil level sight glass. The light is Broken wiring is always a probable case of circuit
powered from the battery system through the BAT malfunction or failure and has not been included.
VM circuit breaker Pressing the XMSN OIL LVEL LT (See figure F-20.)
switch (S4). located beside the sight glass,
ilIuminates the Iight. Refer to paragraphs 9-5 through NOTE
9-11 for maintenance procedure.
9-238. Functional Test - Transmission Oil Level have performed all normal operational
Light. a. Close BAT VM circuit breaker checks.
TabIe 9-14. Troubleshooting - Transmission Oil Level Light
CONDITION
TEST OR INSPECTlON
CORRECTlVE ACTlON
1. Transmission oil level light (125) fails to illuminate.
STEP 1. Check for defective transmission oil level light switch (S4).
STEP 2. Chock for defective BAT VM circuit breaker.
STEP 3. Check for defective transmission oil level light assembly.
Replace Iamp assembly if defective (paragraph 9-5).
SECTION VI. MISCELLANEOUS EQUIPMENT
9-240. MISCELLANEOUS EQUIP- and accessories, flight control systems, blood

MENT. air heater, muff heater, heated blanket recepta-
cles, utility outlets, windshield wipers. mission
antenne actuator system, and cargo hook.
9-241. Description - Miscellaneous Equipment.
Miscellaneous equipment includes engine controls
9-94.2 Change 12
TM 55-1520-210-23-2
9-242. ENGINE CONTROLS AND 9 - 2 4 6 . F u n c t i o n a l T e s t — Engine De-ice

ACCESSORIES. Circuitry. a. Open all circuit breakers, and return all
switches to their normal positions.
b. Check that DE-ICE switch (S81) is in OFF

9-243. Description - Engine Controls and
position, then close ANTI-ICE ENG circuit breaker.
Accessories. Engine controls and accessories
Check that solenoid valve (L6) has actuated.
include engine de-icing, fuel valve, fuel boost pumps,
governor control, and idle stop solenoid circuitry.
c. Place DE-ICE switch (S81) in ON position.
Check that solenoid valve (L6) is not energized.
9-244. ENGINE DE-ICE CIRCUITRY.
d. Return DE-ICE switch (S81) to OFF position
and check that solenoid valve has actuated again.
9-247. Troubleshooting — Engine De-ice

9-245. Description — Engine De-ice Circuitry.
Circuitry. Use table 9-15 and perform checks as
The engine de-ice system is comprised of an engine
necessary to isolate trouble. (See figure F-30.)
hot air de-icing valve (L6) located on the engine, DE-
ICE switch (S81) located on the engine control panel,
NOTE
and is protected by a 15 ampere ANTI-ICE ENG circuit
breaker. Refer to TM 55-2840-229-24 and Before you use this table, be sure you
paragraphs 9-5 through 9-18 for maintenance have performed all normal operational
procedures. checks.
Table 9-15. Troubleshooting Engine De-ice Circuitry
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. De-icing solenoid valve (L6) fails to operate when DE-ICE switch (S81) is placed to OFF position.
STEP 1. Ensure that voltage is present on 28 Vdc essential bus and determine if ANTI-ICE ENG circuit
breaker is defective.
STEP 2. Check for loose connections or broken wiring.
Repair wiring and/or tighten connections.
STEP 3. Check for defective DE-ICE switch (S81).
STEP 4. Determine if de-icing solenoid valve (L6) is defective.
Replace hot air solenoid valve if defective. Refer to TM 55-2840-229-24.
9-95
TM 55-1520-210-23-2
9-248. FUEL BOOST AND FUEL VALVE (4) Connect another jumper wire between
CIRCUITRY. terminals 1 and 3 of terminal board (TB4) or ground
9-249. Description — Fuel Boost and Fuel terminal X1 of relay (K10). Check that relay (K10)
Valve Circuitry. The electrical portion of the fuel shuts off the pump and voltage is not present at pin D
control system consists of fuel shutoff valve, fuel of receptacle (J148) and pin A of plug (P57).
switch, left and right fuel cell boost pumps, left
(5) Remove jumper from terminals 1 and 3 of
and right auxiliary fuel pumps, fuel control relay,
terminal board (TB4) or remove ground from Xl of
RH fuel transfer pump switch, LH fuel transfer
relay (K10). Check that relay (K10) remains energized
pump switch, fuel transfer relay, associated inter-
and voltage is not present at pin D of receptacle (J148)
connecting wiring, terminal boards, fuel cells and
and pin A of plug (P57).
associated switches. The electrical power to the
fuel boost and fuel valve system is supplied
(6) Remove jumper from terminals 2 and 3 of
through, and protected by, the FUEL VALVE (5
terminal board (TB4) or remove ground from 61 of
ampere), FUEL TANK SUMP PUMP — RIGHT-
relay (K10). Check that relay de-energizes and that
HAND (7.5 ampere), FUEL TANK SUMP PUMP — voltage is present at pin D of receptacle (J148) and pin
LEFT-HAND (7.5 ampere) and FUEL TRANS A of plug (P57). Return switch (S46) to OFF.
PUMPS (10 ampere) circuit breakers. The entire
fuel boost and valve system serves to supply, (7) Repeat steps (1) through (6) using left side
regulate and control fuel for operation of the fuel transfer switch (S45) and left side internal
helicopter. Refer to paragraphs 9-5 through 9-18 auxiliary fuel tank receptacle (J147).
and Chapter 4 for maintenance procedures.
9-251. Troubleshooting — Fuel Boost and Fuel
9-250. Functional Test — Fuel Boost and Fuel
Valve Circuitry. Use system wiring diagram figure F-
Valve Circuitry.
31 and standard troubleshooting techniques to
isolate and correct trouble.
a . Fuel Valve.
(1) Close FUEL VALVE circuit breaker. 9-252. GOVERNOR CONTROL

Position fuel switch (S38) to ON and ensure that fuel SYSTEM CIRCUITRY.
valve is open. Repeat procedure with FUEL TANK
SUMP PUMP - LEFT-HAND circuit breaker. 9-253. Description — Governor Control System
Circuitry. The governor control system consists of an
(2) Position switch (S38) to OFF and check engine control solenoid valve located on engine; and
that fuel valves closes. a motor driven rpm actuator also located on engine.
Power is supplied by the 28 Vdc essential bus and
b. Fuel Pumps. protected by a 5 ampere GOV CONT circuit breaker
located in overhead console. The governor control
(1) Close FUEL BOOST RIGHT circuit breaker. actuator is energized either by GOV-RPM switch
Position fuel switch (S38) to ON. Check that the fuel (pilots) or by GOV-RPM switch (copilots). With the
pump is running and open circuit breaker. switch placed to INCR position the circuit to the
actuator motor is completed and allows motor to
(2) Close FUEL TRANSFER PUMP circuit move actuator arm in one given direction. With the
breaker. Position the right fuel transfer switch (S46) switch in DECR position polarity to the actuator motor
to ON. Check that auxiliary fuel pump is running. is reversed, allowing the actuator arm to move in the
When internal auxiliary tank is not installed, check for opposite direction. The fuel control solenoid valve is
voltage at pin D on the tank receptacle (J148) and pin energized by the governor AUTO EMER switch
A of external fuel control panel plug (P57). located on the engine control panel. Refer to
paragraphs 9-5 through 9-18 and Chapter 4 for
(3) Connect a jumper wire between terminals maintenance procedures.
2 and 3 of terminal board (TB4) on the access door of
the center aft fuel cell (or ground terminal B1 of the 9-254. Functional Test — Governor Control
fuel control relay (K10) in the electrical System Circuitry. a. Close GOV CONT circuit
compartment). Check for voltage at pin D of breaker. Position governor switch (S33) to AUTO.
receptacle (J148) and pin A of plug (P57). Check that fuel control solenoid valve L3 on the
9-96
TM 55-1520-210-23-2
engine is energized in the normal or automatic f. Repeat steps d. and e. using switch (S51) on
position (voltage at pin C of P90 on valve). copilots collective stick.
b. Position switch (S33) to EMER and check that

valve is energized in the bypass or emergency
position (voltage at pin A of P90) and that GOV EMER 9-256. Troubleshooting – Governor Control
indicator on caution panel is illuminated. System Circuitry. Use table 9-16 and perform
checks as necessary to isolate trouble. (See figure F-
c. Return switch (S33) to AUTO and check that 32).
GOV EMER indicator is extinguished.
NOTE
d. Position governor rpm switch (S37) on pilots
collective stick to INCR and vernor rpm actuator on Before you use this table, be sure you
the engine retracts. have performed all normal operational
checks.
e. Position switch (S37) to DECR and check that
actuator extends.
Table 9-16. Troubleshooting Governor Control System Circuitry
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. Governor actuator (B12) fails to respond when either RPM switch (S37) or (S51) is placed to INCR
or DECR position.
STEP 1. Check for faulty wiring or loose connections.
Repair wiring or tighten connections (parapaph 9-10).
STEP 2. Check for defective switch.
STEP 3. Check for defective governor actuator.
Replace actuator if defective [paragraph 4-128).
2. Governor Actuator (B12) operates in reverse.
Check for reversed wiring at switch (S37 or S51) and actuator (B12).
Reconnect wiring if reversed. (See figure F-32.)
3. Fuel control solenoid valve (L2) fails to operate when GOV SW (S33) is actuated.
9-97
TM 55-1520-210-23-2
Table 9-16. Troubleshooting of Governor Control System Circuitry (Cont)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
Repair wiring and tighten connections paragraph 9-10).
STEP 3. Check for defective fuel control solenoid valve (L2).
Replace valve if defective. Refer to TM 55-2840-229-23.
4. Solenoid valve operates in reverse
Check for reversed wiring at switch (S33) or solenoid valve (L2)
Reconnect wiring if reversed. (See figure F-32.)
9-256. IDLE STOP SYSTEM CIRCUITRY. 9-262. FORCE TRIM SYSTEM CIRCUITRY.
9-257. Description-Idle Stop System Circuitry.

The idle stop system consists of an idle stop release 9-263. Description-Force Trim System Circuitry.
solenoid, an idle stop release switch located on pilots The force trim system consists of an antitorque force
collective stick and a 7.5 ampere IDLE STOP RE- trim magnetic brake, a fore and aft force trim magnetic
LEASE circuit breaker which protects the system brake, a lateral force trim magnetic brake, pilot and
against overload. Refer to paragraphs 9-5 through 9- copilot force trim switches, and a master force trim
18 and 4-113 for maintenance procedures. switch located on the hydraulic control panel. The mag-
netic brakes are wired in parallel. The force trim
9-258. Functional Test—Idle Stop System Cir- switches are all series wired. The system is protected
cuitry. a. Close IDLE STOP REL circuit breaker. by a 5 ampere FORCE TRIM circuit breaker located in
overhead console. The entire system serves to return
b. Actuate the idle stop release switch (S50) on the pilot and copilot cyclic sticks to desired initial position
pilots collective stick and check that solenoid retracts when master force trim switch is set to ON. Pilot and
when power is applied. copilot force trim switches may be triggered to re-
energize brakes and eliminate centering force. Refer
9-259. Troubleshooting-Idle Stop System Cir- to paragraphs 9-5 through 9-18, 11-37, and 11-63 for
cuit. Refer to system wiring diagram, figure F-32, and maintenance procedures.
use standard troubleshooting procedures to isolate and
correct malfunctions. 9-264. Functional Test—Force Trim System Cir-
cuitry. a. Close FORCE TRIM circuit breaker. Position
9-260. FLIGHT CONTROL force trim switch (S68) to ON. Check the cyclic stick
SYSTEMS (ELECTRICAL). and pedals for centering force.
b. Depress force trim switch (S18) on the pilots cy-
9-261. Description—Flight Control Systems clic stick. Check that the three magnetic brakes
(Electrical). The flight control systems include the force reenergize and that there is no centering force in the
trim and hydraulic control systems. cyclic stick and pedals.
9-98 Change 4
TM 55-1520-210-23-2
c. Repeat step b. using switch (S10) on the NOTE

copilots cyclic stick.
9-266. Troubleshooting — Force Trim System have performed all normal operational
Circuitry. Use table 9-17 and perform checks as checks.
necessary to isolate trouble. (See figure F-33.)
Table 9-17. Troubleshooting Force Trim System Circuitry
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. All magnetic brakes fail to energize with FORCE TRIM switch in ON position.
Repair wiring or tighten connections (paragraph 9-10).
STEP 2. Check for defective FORCE TRIM switch.
2. Any magnetic brake fails to energize with FORCE TRIM switch in ON position.
Check for defective magnetic brake.
Replace magnetic brake if defective (paragraphs 11-37 and 11-63).
3. Magnetic brakes fail to de-energize when pilot or copilot FORCE TRIM switch is depressed.
STEP 1. Check for defective FORCE TRIM switch.
STEP 2. Check for shorted wiring.
Repair wiring (paragraph 9-10).
9-266. HYDRAULIC CONTROL normally de-energized in ON position. This valve

SYSTEM CIRCUITRY. closes off hydraulic pump pressure to the flight
control servos and allows unrestricted fluid flow to
and from the servos when the control switch is in the
9-267. Description — Hydraulic Control System closed (OFF) position. Manual operation of flight
Circuitry. The hydraulic system is composed of a controls is then possible.
hydraulic solenoid valve mounted on the lift beam of
the transmission. The valve is controlled by the HYD
CONT switch on the hydraulic control panel and 9-268. Functional Test — Hydraulic Control
protected by a 5 ampere hydraulic control circuit System Circuitry. a. Close HYD CONT circuit
breaker located on the overhead console. The valve is breaker. With external hydraulic pressure applied,
9-99
TM 55-1520-210-23-2
position hydraulic control switch (S7) to OFF. Close 9-269. Troubleshooting — Hydraulic Control
CAUTION LIGHTS circuit breaker and check that HYD System Circuitry. Use table 9-18 and perform
PRESSURE caution light illuminates. checks as necessary to isolate trouble. (See figure F-
33).
b. Operate the cyclic, collective and directional
controls with switch (S7) in the ON and OFF positions. NOTE
Check that controls require more force to operate Before you use this table, be sure you
with switch (S7) in the OFF position than in the ON have performed all normal operational
position. checks.
Table 9-18. Troubleshooting Hydraulic Control System Circuitry
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. Hydraulic solenoid fails to actuate when hydrualic control switch is placed to OFF position.
STEP 1. Check for defective HYD CONT circuit breaker.
Repair wiring or tighten connections (paragraph 9-10).
STEP 3. Check for defective hydraulic control switch (S7).
STEP 4. Check for defective hydraulic bypass solenoid valve (L4).
Replace solenoid valve if defective (paragraph 7-60).
9-270. BLEED AIR HEATING SYSTEM 9-272. Functional Test — Bleed Air Heating
CIRCUITRY. System Circuitry. a. Prior to helicopter Serial No. 66-
16868, accomplish the following:
9-271. Description — Bleed Air Heating System (1) Close CABIN HEATER CONT circuit
Circuitry. The bleed air heating circuitry includes breaker. Actuate bleed air switch (S83) from off to
bleed air switch (S83) overheat switch (S73), bleed air positions 1, 2, 3, and 4. Check that bleed air valve
valve (B34), overheat relay (K46), aft outlet valve opens to a maximum at position 4.
(L15), door post outlet valve actuator (L14), aft outlet
switch (S85), aft outlet limit switch (S87), and on (2) Actuate aft outlet switch (S85)from OFF to
helicopter S/N 66-16867 and subsequent, variable position 1, 2, and 3. Check that the door post outlet
mixture solenoid valve (L21). The circuitry is valve opens to a maximum at position 3.
protected by the CABIN HEATER CONT and CABIN
HEATER OUTLET VALVE circuit breakers. Refer to (3) With switch (S85) in position 3, move the
paragraphs 9-5 through 9-18 and chapter 4 for manual defrost lever to the full ON position. Check
maintenance and troubleshooting procedures. (See that the door post outlet valve returns to its closed
figure F-34.) position.
9-100
TM 55-1520-210-23-2
(4) Move manual defrost lever slightly toward the 9-273. MUFF HEATER SYSTEM CIRCUITRY.
OFF position. Check that the door post outlet valve switch 9-274. Description - Muff Heater System Circuitry.
returns to position 3. The muff heater circuitry utilizes same components as
bleed air heater circuitry with the addition of aft outlet
(5) Place switch (S83) in any position (1, 2, 3, or 4) valve. Refer to paragraph 9-271 for description. Refer to
except OFF. Obtain access to relay (K46) behind heater paragraphs 9-5 through 9-18 and paragraph 13-39 for
panel in overhead console. Find wire H110A20 attached to maintenance and troubleshooting procedures. (See figure
a terminal of relay (K46). Temporarily jump this relay ter- F-34.)
minal to ground, thus simulating on overheat condition.
Check that the bleed air valve returns to the off or closed 9-275. Functional Test— Muff Heater System Cir-
position. cuitry. a. For helicopters prior to Serial No. 66-16868, ac-
complish the following:
(6) Remove the temporary jumper. Check that the
bleed air valve returns to its preset position. (1) Check that wire H86A20 is connected to ter-
minal 16 (position 3) instead of terminal 13 of switch (S85).
b. For helicopter Serial No. 66-16868 and subsequent, Close CABIN HEATER CONT circuit breaker.
accomplish the following:
(2) Move switch (S85) to OFF and then in turn to
(1) Close CABIN HEATER AIR VALVE and positions 1, 2, and 3. Check that the door post outlet valve
CABIN HEATER OUTLET VALVE circuit breakers. and the aft outlet valve are closed when switch (S85) is in
the OFF position and full-on when switch (S85) is in posi-
(2) Actuate bleed air switch (S83) to the ON position 3.
tion and then to OFF. Check that variable mixture solenoid
valve (L21) makes an audible click when switch (S83) is (3) With switch (S85) in position 1 or 2, move the
switched to both ON and OFF positions. manual defrost lever to the full-on position. This actuates
switch (S87). Check that the doorpost outlet valve and the
(3) Actuate aft outlet switch (S85) from OFF to aft outlet valve are at the off or closed position.
positions 1,2, and 3. Check that the doorpost outlet valve
opens to a maximum at position 3. (4) Move manual defrost lever slightly toward the
OFF position so that switch (S87) is deactivated. Check
(4) With switch (S85) in position 3, move the aft that the door post outlet valve and the aft outlet valve
outlet limit lever to the full ON position. Check that the door return to their preset positions.
post outlet valve returns to its closed position.
(5) Place switch (S83) in any position (1,2,3, or 4)
(5) Move the aft outlet limit lever slightly toward the except OFF. Obtain access to relay (K46) behind heater
OFF position. Check that the door post outlet valve switch panel in overhead console. Find wire H110A20 attached to
returns to position 3. a terminal of (K46) relay. Temporarily jump this relay ter-
minal to ground, thus simulating an overheat condition.
(6) Position bleed air switch (S83) to ON. Obtain Check that bleed air valve returns to the off or closed posi-
access to relay (K46) behind heater panel in overhead tion.
console. Find wire H110A20 attached to a terminal of relay
(K46). Temporarily jump this relay terminal to ground, thus (6) Remove the temporary jumper. Check that the
simulating an overheat condition. Check that the variable bleed air valve returns to its preset position.
mixture solenoid (L21) makes an audible click, thus sig-
nifying the off or closed position. (7) Move switch (S83) to OFF and then in turn to
positions 1, 2, 3, and 4. Check that the bleed air valve is
(7) Remove the temporary jumper. Check that the closed when switch (S83) is in the OFF position and full-on
variable mixture solenoid valve makes an audible click, when switch (S83) is in position 4.
thus signfying its return to the on or open position.
Change 5 9-101
TM 55-1520-210-23-2
b. For helicopter Serial No. 66-16868 and b. Check for 28 Vdc at each receptacle mounted in
subsequent, accomplish the following: the cabin roof. (Six receptacles on all aircraft prior to
(1) Check that wire H86A20 is connected to Serial No. 66-16034 and two receptacles on Serial No.
terminal 16 (position 3) instead of terminal 13 of switch 66-16034 and subsequent).
(S85). Close CABIN HEATER AIR VALVE circuit
breaker. 9-279. Troubleshooting Heated Blanket Receptacles.
(2) Move switch (S85) to OFF and then in turn Refer to system wiring diagram figure F-35 and use
to positions 1,2, and 3. Check that the door post outlet standard troubleshooting procedures to isolate and
valve and the aft outlet valve are dosed when switch correct malfunction.
(S85) is in the OFF position and full-on when switch
(S85) is in position 3. 9-280. WINDSHIELD WIPER SYSTEM CIRCUITRY.
(3) Move switch (S85) to position 1 or 2.
Then the aft outlet lever to full-on position. This actuates 9-281. Description Windshield Wiper System
switch (S87). Check that the door post outlet valve is in Circuitry. The windshield wiper system includes
the full-open position and the aft outlet valve is in the windshield wiper switch (S23), selector switch (S124),
closed position. right and left resistor panels (A-13), pilot windshield wiper
(4) Move aft outlet limit lever slightly toward motor (B7), and copilot windshield wiper motor (B8).
the OFF position so that the door post outlet valve and Power for the system is furnished by the 28 Vdc
the aft outlet valve return to their preset positions. essential bus and protected by 10 ampere WINDSHIELD
(5) Position switch (S83) to ON. Obtain WIPER PILOT and WINDSHIELD WIPER COPILOT
access to relay 0(K-46) behind heater panel in overhead circuit breakers. Refer to paragraphs 9-5 through 9-18
console. Find wire H110A20 attached to a terminal of and Chapter 12 for maintenance and troubleshooting
(K-46) relay. Temporarily jump this relay terminal to procedures. (See figure F-36.) 9-282. Functional Test
ground, thus simulating an overheat condition. Check Windshield Wiper System Circuitry.
that the bleed air valve (B34) closes.
(6) Position switch (S82) to OFF and then ON. a. Suitably protect windshield against scratching by
Check that bleed air valve (B34) remains closed. wiper blades.
(7) Remove temporary jumper. Check that
the bleed air valve (B34) opens. b. Close WINDSHIELD WIPER PILOT and
(8) Position switch (S82) to OFF. Check that WINDSHIELD WIPER COPILOT circuit breakers.
the bleed air valve (B34) closes. Position wiper selector switch (SI24) to BOTH. Position
windshield wiper switch (S23) to LOW. Check that pilot
9-276. HEATED BLANKET RECEPTACLES. and copilot wipers operate at low speed.
9-277. Description Heated Blanket Receptacles. c. Position switch (S23) to MED position. Check
Heated blanket receptacles are provided in the cabin that both wipers operate at medium speed.
interior, right and left side cabin roof. These utility
receptacles are supplied by the 28 Vdc nonessential bus d. Position switch (S23) to HIGH. Check that both
and protected by the 35 ampere HEATED BLANKETS wipers operate at high speed.
R/H and HEATED BLANKETS L/H circuit breakers.
Refer to paragraphs 9-5 through 9-18 for maintenance e. Position switch (S23) to PARK. Check that both
procedures. wipers move at high speed to their park positions and
stop.
9-278. Functional Test Heated Blanket Receptacles.
f. Open WINDSHIELD WIPER COPILOT circuit
a. Close both HEATED BLANKET circuit breakers. breaker. Position selector switch (S124) to PILOT.
9-102 Change 10
TM 55-1520-210-23-2
g. Open WINDSHIELD WIPER PILOT circuit 9-288. Functional Test - Rescue Hoist System
breaker. Close WINDSHIELD WIPER COPILOT Circuitry.
circuit breaker. Position selector switch (S124) to
COPILOT. Check that copilot wiper operates with a. Check that wire M20A20 is connected to
wiper switch (S23) in the LOW, MED, HIGH, and PARK HOIST PWR circuit breaker (1 ampere).
positions. Position wiper switch (S23) to OFF and open b. Check that wires M21A20 and M22A20 are
the WINDSHIELD WIPER COPILOT circuit breaker. connected to HOIST CONT circuit breaker (10
ampere).
9-283. CARGO HOOK SYSTEM CIRCUITRY.
c. Check that wire M25A20 is connected to
HOIST CUT circuit breaker (5 ampere).
9-284. Description - Cargo Hook System Cir-
cuitry. The cargo hook system circuitry includes NOTE
cargo release switch (S36), cargo release armed light
(I44), copilot cyclic stick release switch (S78), pilot The following checks are basically volt-
cyclic stick release switch (S32), and cargo hook age (28 Vdc) checks between the desig-
release relay (K24). Power for the system is supplied nated pin of connector (J119) and
by the 28 Vdc essential bus and protected by the 10 ground (pin X of J119).
ampere CARGO HOOK REL circuit breaker. Refer to
paragraphs 9-5 through 9-18 and Chapter 14 for main- d. Close HOIST CONT circuit breaker and mea-
tenance and troubleshooting procedures. (See figure sure for 28 Vdc on pin G of connector (J119).
F-37.) e. Open HOIST CONT circuit breaker and mea-
sure for zero Vdc on pin G of connector (J119).
9-285. Functional Test - Cargo Hook System Cir-
f. Close HOIST CONT circuit breaker. Position
cuitry.
HOIST switch (S112) (located on pilot cyclic stick) to
DN. Measure for 28 Vdc on pin C of connector (J119).
a. Close CARGO HOOK REL circuit breaker.
Close and latch the hook. Position the cargo release g. Release HOIST switch (S112) and measure for
switch to ARM. Check that cargo release armed light zero Vdc on pin C of connector (J119).
on the instrument panel is illuminated. h. Position HOIST switch (S112) to RH/OUT, and
measure for 28 Vdc on pin D of connector (J119).
b. Depress cargo release switch (S32) on the pilot
i. Release HOIST switch (S112) and measure for
cyclic stick. Check that solenoid in the hook actuates
zero Vdc on pin D of connector (J119).
allowing the hook to fall open.
j. Position HOIST switch (S112) to UP, and mea-
c. Repeat step b. for switch (S78) on the copilots sure for 28 Vdc on pin E of connector (J119).
cyclic stick. k Release HOIST switch (S112) and measure for
zero Vdc on pin E of connector (J119).
9-286. RESCUE HOIST SYSTEM CIRCUITRY
(PROVISIONS). l. Position HOIST switch (S112) to LH/IN and
measure for 28 Vdc on pin F of connector (J119).
9-287. Description - Rescue Hoist System Cir- m. Release HOIST switch (S112) and measure
cuitry. The rescue hoist system circuitry includes for zero Vdc on pin F of connector (J119).
HOIST PWR, HOIST CONT, and HOIST CUT circuit n. Close HOIST CUT circuit breaker. Close
breakers, hoist switch (S112), cable cutter switch CABLE CUT switch (S96) (located on pedestal). Mea-
(S96), hoist power relay (K32), and overload sense sure for 28 Vdc on pin H of connector (J119).
control (S101). Refer to paragraphs 9-5 through 9-18
for maintenance and troubeshooting procedures. o. Open CABLE CUT switch (S96) and measure
(See figure F-38.) for zero Vdc on pin H of connector (J119).
Change 7 9-103
TM 55-1520-210-23-2
p. Close NON ESS BUS switch (S62). Close if ICS units are installed or infinite if ICS units are not
HOIST PWR circuit breaker and measure for 28 Vdc installed.
on pin W of connector (J119).
t. Position crew HOT MIC switch (S66) to ON and
q. Open HOIST PWR circuit breaker and mea- measure resistance between pins J and K of connector
sure for zero Vdc on pin W of connector (J119). (J119). The resistance should be zero ohms.
r. Position all circuit breakers and switches to u. Hold screw HOT MIC switch in MOM position
OFF. and measure resistance between pins J and K of con-
nector (J119). The resistance should be zero ohms.
s. Position crew HOT MIC switch (S66) to OFF
and measure resistance between Pins J and K of v. Position crew HOT MIC switch (S66) to OFF.
(J119). The resistance should be 500 ohms or greater Disconnect multimeter.
Paragraphs 9-289 through 9-292 have been deleted.

Pages 9-105 through 9-121, including paragraphs 9-293 through 9-329 and figures 9-11,9-12,9-13,
9-14, 9-15, 9-16, and 9-17, have been deleted.
9-104 Change 7
TM 55-1520-210-23-2
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Change 7 9-105
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9-106 Change 7
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Change 7 9-107
TM 55-1520-210-23-2
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9-108 Change 7
TM 55-1520-210-23-2
CAUTION
DELETED
Change 7 9-109
TM 55-1520-210-23-2
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9-110 Change 7
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Change 7 9-111
TM 55-1520-210-23-2
CAUTION
DELETED
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Change 7 9-113
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Change 7 9-121
TM 55-1520-210-23-2
CHAPTER 10
FUEL SYSTEM
SECTION 1. FUEL CELLS
10-1. FUEL CELLS — CRASHWORTHY (4) R e m o v e four bolts (17, figure 10-1)
(AVIM) and washers from fuel cell fitting (13).
10-2. Description — FueI Cells — Crash
worthy. The crashworthy fuel system incorpo- (5) From inboard side of bulkhead, remove nut
rates five crashworthy fuel cell assemblies. The (12) and washer (11) from vent valve (8).
crashworthy fuel cells are self-sealing to both
(6) From inboard side of bulkhead, remove bolt
.30 and .50 caliber projectiles in bottom 2/3 of
(1) and washer (2). For right side cell remove bolt (80)
the cells. Fittings on fuel cells are self-sealing
and washer (81), and bolt (89) and washer (90).
breakaway type at fuel and vent line locations
(figure 10-1).
(7) Remove screws (3) and remove access
10-3. Fuel Cells — Crashworthy. Helicopters cover (4) and preformed packing (5) from fuel cell.
with MWO 55-1520-210-30-43 incorporate roll-
over vent valves installed in the overboard vents (8) From inside fuel cell, remove bolt securing
of all three aft fuel cells (figure 10-3) to provide hose clamp to bulkhead. (Left side cell only).
fire hazard protection from fuel spillage in the
event of a helicopter rollover during a crash. (9) For right side cell, remove two bolts (75),
washers (76) and spacers (79). Remove aft fuel
10-4. Removal — Fuel Cells— Crashworthy. quantity transmitter (77).
a. Forward Fuel Cell.
(10) For right side cell, remove bolts (85),
washers (84) and spacers (82). Remove forward fuel
CAUTION
quantity transmitter (86).
When a cell which has contained fuel (11) Working through access port, remove
is to remain empty of fuel for more two bolts (18), washers (19) and nuts (32), attaching
than 10 days, inner liner should be ejector pump (20) to support (23). Allow ejector pump
fogged with light lubricating oil and attached hoses to lay in fuel cell.
(C167) to prevent deterioration from
drying-out and cracking or checking. (12) Remove two bolts (21) and washers (22)
securing support (23) to fuel cell, remove support.
NOTE (13) Remove nut (31) from hose assembly

(24).
Removal procedures given are for the left (14) From forward end (outside cell) remove
side cell, procedures for the right side cell clamp (26), washer (27) and seal (28). Remove
are identical unless noted. preformed packing (25) from hose assembly (24).
(15) On aft end of cell (outside), remove bolts
(1) Defuel system (paragraph 1-3).
(36), washers (35) and retainers (34) securing outlet
(2) Remove access panel over fuel cell. fitting (37) to fuel cell. Remove preformed packing
(38) from fuel cell (33).
(3) Remove sump assembly (paragraph (16) Remove fuel cell from helicopter.
10-137). b. Aft Outboard Fuel Cell.
Change 5 10-1
TM 55-1520-210-23-2
NOTE
Removal procedures given are for left side

cell; procedures are identical for right side cell
unless noted. If right side cell is to be removed,
Exercise extreme caution during removal/in-
engine oil tank must be removed (paragraph
stallation of vent bracket. Damage to bracket
4-84).
will occur from lower jaw of cresent or open
end wrench, if wrench is not applied to ftting
NOTE at a 90° angle. Do not exert undue pressure
on any part of assembly.
If right cell is to be removed, remove cap and
adapter or cosed circuit refueling receiver in (1) Defuel system (paragraph 1-3).
accordance with paragraph 10-80. If left side
cell is to be removed, fuel filter assembly must (2) Remove engine work deck access plate over
be removed (paragraph 10-22). center fuel cell.
(3) Remove center fuel cell cover plate (4, figure

NOTE
10-3).
Removal of aircraft center fuel cell requires
(4) Remove bolts and washers at left and right
removal of center aft cell bulkhead access
side cell interconnects.
door.
(5) Remove bolts (61, figure 10-1 ) and washers
(1) Defuel system (paragraph 1-3).
(62) securing bracket (63) to structure.
(2) Remove left or right side fuel cell access cover
(6) Remove bolts (74) and washers (73) securing
on engine work deck.
bracket to fittings (66).
(3) If bracket is installed, remove screws (49 figure
(7) Disconnect hose assemblies (64), (71) and
10-1) and washers (50).
(69).
(4) Disconnect hose assembly (58) from elbow (51).
(8) Unscrew breakaway valve (42) from fitting (48).
Remove packing (41 ) from breakaway valve (42).
(5) Remove center fuel cell cover plate (4, figure
10-3).
(9) Collapse cell and fold. Remove through aft
center cover plate opening. Cap all open lines and
(6) Working through center fuel cell opening, re- fittings.
move bolts and washers securing cell interconnect.
(10) Vent brackets will be inspected for crack
(7) Remove bolts (47 and 43), washers (46 and
damage and distortion on R/H side at fitting radius,
47) to disconnect hoses, and remove packings (45). if crack extends no further than inner side of bend
radius, stop drill with a # 30 drill bit at extremity of crack.
(8) Unscrew breakaway valve (42) from fitting (48). Distance from fitting hole to edge of drill hole to be no less
Remove packing (41) from breakaway valve (42). than 5/16 inch. Any overlap after straightening will be
trimmed and smoothed.
(9) Remove fuel cell. Cap all open lines and
fittings. 10-5. lnspection-Fuel Cells-Crashworthy. a.
Remove exterior surface dirt and grime by scrubbing
c. Aft Center Fuel Cell. the fuel cell with warm, soapy water using soap paste
(C 253). Air dry surface.
b. Purge fuel cell thoroughly with fresh air; scrub

with warm, soapy water; and rinse in clean, clear wa-
ter. Air dry.
Do not allow fuel cell to remain folded for
more than 30 minutes. Keep fuel cell at
room temperature and normal humidity.
10-2 Change 16
TM 55-1520-210-23-2
c. Inspect all interior and exterior surfaces for

loose seams, cuts, abrasions, scuffed surfaces, tears,
blisters, and for any area that appears to have be-
come soaked with fuel.
d. Inspect metal fittings to make certain protective

finishes are intact and the coil-type inserts are in-
stalled and in good condition.
e. The following damages are prohibited for field

repair and can be repaired only by depot:
(1) Pass-through holes (holes made by a

projectile that enters through one surface of the fuel
cell and exits through the opposite surface).
(2) Damage that extends into a corner or

stepped-off area, or that involves a cut longer than 4.0
inches, or that is caused by the seepage or diffusion
of fuel between the fabric plies.
10-6. Repair or Replacement — Fuel Cells —

Crashworthy.
NOTE
Fuel cells requiring fabric repair shall be

forwarded to depot.
a. Replacing Fitting Inserts. Standard main-

tenance procedures are adequate to replace the coil-
type inserts in each fuel cell fitting.
Change 2 10-2.1/(10-2.2 blank)

TM 55-1520-210-23-2
1. Bolt
2. Washer
3. Screw
4. Access Cover
5. Preformed Packing
6. Bolt
7. Washer
8. Packing
Figure 10-1. Fuel Cell Installation — Crashworthy (Sheet 1 of 4)
10-3
TM 55-1520-210-23-2
DETAIL C
6. Bolt 20. Ejector pump

7. Washer 21. Bolt
*8 Vent valve 22. Washer
9. Preformed packing 23. Support
10. Airframe bulkhead 24. Hose assembly
11. Washer 25. Preformed packing
12. Nut 26. Clamp
13. Fuel cell fitting 27. Washer
14. Drain valve 28. Seal
15. Preformed packing 29. Airframe bulkhead
16. Washer 30. Nylon sleeve
17. Bolt 31. Nut
18. Bolt 32. Nut
19. Washer
10-4
TM 55-1520-210-23-2
33. Fuel cell 47. Bolt

34. Retainer 48. Fitting
35. Washer 49. Screw
36. Bolt 50. Washer
37. Outlet fitting 51. Elbow
40. Screw 54. Cover plate
41. Preformed packing 55. Washer
*42. Breakaway valve 56. Screw
43. Bolt 67. Fitting
44. Washer 58. Hose assembly
45. Preformed packing 59. Washer
46. Washer 60. Bolt
10-5
TM 55-1520-210-23-2
61. Bolt 76. Washer

62. Washer 77. Fuel quantity transmitter
63. Bracket 78. Clamp
64. Hose assembly 79. Spacer
65. Elbow 80. Bolt
66. Fitting 81. Washer
67. Preformed packing 82. Spacer
68. Elbow 83. Clamp
69. Hose assembly 84. Washer
70. Preformed packing 85. Bolt
71. Hose assembly 86. Fuel quantity transmitter
72. Elbow 87. Clamp
73. Washer 88. Spacer
74. Bolt 89. Bolt
75. Bolt 90. Washer
Figure 10-1. Fuel Cell Installation - Crashworthy (Sheet 4 of 4)
10-6 Change 5
TM 55-1520-210-23-2
Figure 10-2. Rollover Protection Vent Valves — Aft Fuel Cells (Sheet 1 of 2)
10-7
TM 55-1520-210-23-2
DETAIL C
1. Cover 14. Bolt 27. Packing

2. Manifold 15. Packing 28. Gasket
3. Hose 16. Packing 29. Vent Valve
4. Hose 17. Packing 30. Washer
5. Cover 18. Gasket 31. Bolt
6. Elbow 19. Vent Valve 32. Plate
7. Elbow 20. Packing 33. Bolt
8. Elbow 21. Bolt 34. Washer
9. Hose 22. Washer 35. Packing
10. Hose 23. Flange 36. Packing
11. Washer 24. Bolt 37. Gasket
12. Bolt 25. Washer 38. Vent Valve
13. Washer 26. Cover
Figure 10-2. Rollover Protection Vent Valves — Aft Fuel Cells (Sheet 2 of 2)
10-8
TM 55-1520-210-23-2
b. Restoring Protective Fitting Finishes. come into contact with the hands,
body, or clothing. The solution is cor-
(1) Using a fine-toothed file or fine emery rosive and can injure personnel who
paper, carefully remove any roughness from the are working with it.
fitting to be refinished.
(4) Moisten fitting surface with clean pad
dampened in water.
(5) Using a narrow nylon brush, apply an

undiluted, unadulterated coat of alodine 1200
solution (C62) to the moistened area.
Cleaning materials are flammable and
toxic. Avoid skin contact and breathing (6) Allow solution to dry until a light, golden
of solvent vapors. coating appears on the fitting. When coating has
formed, remove excess solution by wiping the surface
(2) Clean metal surfaces of fitting using with clean pads dampened in water. Dry the restored
pads dampened with methyl-ethyl-ketone (C177). area with dry pads.
(3) Obtain a small container of alodine

1200 (C62) solution from stock. 10-7. Installation — Fuel Cells — Crashworthy.
a. Forward Fuel Cell.
(1) Vacuum or remove any foreign material

from fuel cell opening.
(2) Place fuel cell in opening.

In the following steps, do not allow
the alodine 1200 (C62) solution to
10-9
TM 55-1520-210-23-2
(3) Position vent valve (8, figure 10-1) through NOTE

bulkhead opening. Install washer (11) and nut (12) to
vent valve. Installation procedures are identical for left
and right cells except that after installation
(4) Install two bolts (17) and washers (16) at of the right fuel cell the oil tank (paragraph
cell drain valve location. For cell drain valve 4-90) and the closed circuit refueling equip-
installation, refer to paragraphs 10-27 thru 10-32a. ment (paragraph 10-92) must be installed.
After installation of the left fuel cell the fuel
(5) Install bolts (1) and washer (2) from inboard filter assembly must be installed
side of bulkhead. For left side cell install bolt (80) and (paragraph 10-26).
washer (81).
b. Aft Outboard Fuel Cell.
(6) Install bolt and washer through hose clamp
(inside fuel cell) to bulkhead. (Left side cell only). from fuel cell opening.
(7) For right side cell install aft fuel quantity (2) Position fuel cell in airframe.
transmitter (77), using two bolts (75) washers and (3) Install packing (39, figure 10-1) to
spacers (79) (figure 10-1, detail H). breakaway valve (42). Install valve to fitting of fuel cell
(33).
(8) For right side cell install forward fuel quanti- (4) Install packing and bolts at center fuel cell
ty transmitter (86) using bolts (85), washers (84), interconnect fitting.
spacers (82 and 88) and clamps (83 and 87).
(5) Install bracket (if used) using screws (49)
(9) From forward end of cell install hose and washers (50).
assembly with packing (25), seal (28), washer (27) and (6) Connect hose assembly (58) to elbow (51).
clamp (26). Install nut (31 ) from inside cell. Tighten nut (7) Install fuel cell access cover (engine deck),
(31). Seat seal (28) against bulkhead and tighten (paragraph 2-19).
clamp (26).
(8) Pressure test fuel cell (paragraph 10-19).
(10) Install support (23) using two washers (22) c. Aft Center Fuel Cell.
and two bolts (21 ).
(11) Attach ejector pump (20) to support (23)

using washers (19) and bolts (18).
(12) Install aft outlet fitting (37) to fuel cell with Do not allow fuel cell to remain folded for more
packing (38). Install retainers (34), washers (35) and than 30 minutes. Keep fuel cell at room tem-
bolts (36). perature and normal humidity.
(13). Install sump assembly (paragraph from fuel cell opening.
10-144).
(2) Fold and tie fuel cell and install through aft
access port.
(14) Deleted.
(3) Install packing and bolts at each
(15) Install access cover (4) with preformed interconnect location to aft outboard cells.
packing (5) and screws (3). (4) Install aft center access cover.
(5) Connect hose assemblies (71, figure 10-1)
(16) Install access panel over cell (paragraph and (64) to elbows (65 and 72).
2-33).
(6) Connect tube assembly (69) to elbow (68).
(17) Pressure test cell for leaks (paragraph (7) Install bracket (63) using bolts (74) and
10-19). washers (73).
10-10 Change 6
TM 55-1520-210-23-2
(8) install bolts (61) and washers (62) through

bulkhead and bracket.
(9) Install access cover plate (engine deck).
(10) Presssure test fuel cell (paragraph

10-19).
SECTION Il. FUEL SYSTEMS
10-8. FUEL SYSTEM. transmitter, pressure or flow switches, and float

switches, see applicable wiring diagrams (Appendix
F).
10-10. General Maintenance — Fuel System. a.
Aviation unit maintenance will consist of visual f. Conduct any defueling or drainage of fuel in
inspections, ground operational checks, cleaning accordance with applicable directives, and with
of filter and strainers, specified adjustment of extreme care to avoid fire hazards.
control linkage system, and replacements of pip- 10-11. HOSES — FUEL SYSTEM.
ing, fittings, and seals. Observe general notes and
precautions below, and procedures for replace- 10-12. Description — Hoses — Fuel System.
ment or adjustment of principal components in Flexible hoses are used in the fuel system to permit
subsequent paragraphs. Fuel lines and compo- easier maintenance. The crashworthy system uses
nents on the engine constitute the fuel control self-sealing flexible hoses to prevent fuel spillage in
system and will be found in TM 55-2840-229-23 event of a crash.
fuel system schematic (figure 10-4).
10-13. Removal — Hoses — Fuel System. a.
b. Intermediate maintenance will include more, Defuel fuel cell.
detailed procedures as indicated by (AVIM)
b. Loosen end fittings of hose.
throughout the chapters.
c. Remove any clamp and remove hose.
c. Before removing any line or hose, be sure it is
properly identified and its route understood for
d. Cap fittings to avoid foreign material entry
replacement in same manner.
into fuel system.
10-14. Inspection — Hoses — Fuel System. a.
Inspect hoses for damage and evidence of leakage
(TM 55-1500-204-25/1).
b. Inspect hoses for evidence of chafing.
Do not use masking tape to seal c. Inspect hose fittings for corrosion.
openings.
10-15. Repair or Replacement — Hoses — Fuel
Systems. Replace hoses with damage, evidence of
leakage, or corroded fittings.
d. Cap or cover any open lines, fittings, or
10-16. Installation — Hoses — Fuel System. a.
exposed opening in units (other than normal vents
Attach hose end fittings.
and drains) to protect fuel system from
contamination. Be sure vent lines are not obstructed.
b. Secure only clamps previously removed.
e. For electrical circuits of boost pump, shutoff
valve, fuel quantity gage system, pressure c. Service fuel system and check for leaks.
10-11
TM 55-1520-210-23-2
1. Fuel shutoff valve and check valve manifold l2. Flapper valve
2 Vent line 13. Cell drain valve
3. Fuel filter 14. Ejector pump
4. Cover plate — aft center fuel cell 15. Crossfeed Iine
5. Fuel quantity transmitter 16. Fuel quantity transmitters
6. Breakaway valve 17. Vent valve
7. Crossover hose 18. Fuel cell access
8. Outlet fitting 19. Electric boost pump
9. Low level float switch 20. Siphon breaker valve
10. Sump assembly 21. Fuel pressure transmitter
11. Flow switch 22. Closed circuit refueling receiver
Figure 10-3. Fuel Supply System - Crashworthy
10-12 Change 4
TM 55-1520-210-23-2
Figure 10-4. Fuel System Schematic
Change 4 10-13
TM 55-1520-210-23-2
10-17. Troubleshooting — Fuel System. a malfunction which is not listed in this

table is evident, notify the next higher
NOTE level of maintenance.
Before using this table, be sure to
perform all normal operational checks. If
Table 10-2. Troubleshooting — Fuel System
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. Electrical boost pump warning light illuminated, no pressure indicated on fuel pressure gage.
STEP 1. Ensure electrical boost pump iS operative
Replace boost pump if defective (paragraph 10-104).
STEP 2. Check for faulty wiring.
Correct wiring if defective (paragraph 9-5).
2. Electrical boost pump warning light Illuminated, pressure indicated on fuel pressure gage.
STEP 1. Ensure ejector pump iS operating correctly.
Replace ejector pump if defective (paragraph 10-118).
STEP 2. Check for foreign material in ejector pump and/or hoses.
Clean foreign material from ejector pump and/or hoses (Paragraph 10-119).
STEP 3. Check for defective check valve.
Replace check valve if defective (paragraph 10-153).
STEP 4. Check for defective flow switch.
Replace flow switch if defective (paragraph 10-148).
STEP 5. Check for grounded wire to warning light. Correct wiring if faulty.
STEP 6. Deleted.
3. Bleed air boost pump warning light illuminated, fuel pressure low or zero.
STEP 1. Check for inoperative bleed air fuel boost pump.
Replace boost pump if defective (paragraph 10-104).
10-14 Change 2
TM 55-1520-210-23-2
Table 10-2. Troubleshooting - Fuel System (Cont)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
4. Bleed air boost pump warning light illuminated, pressure normal on fuel pressure gage.
STEP 1. Check for defective ejector pump.
Replace ejector pump If defective (paragraph 10-118).
STEP 2. Check for foreign material in ejector pump and/or hoses.
Clean foreign material from ejector pump and/or hoses (paragraph 10-119).
STEP 3. Check for defective check valve.
STEP 4. Check for defective flow switch.
Replace flow switch i defective (paragraph 10-148).
STEP 5. Check for grounded wire to warning light.
Correct wiring If faulty (paragraph 9-6).
5. Engine fuel pump warning light illuminated.
STEP 1. Check for faulty fuel pressure switch.
Replace defective pressure switch (paragraph 4-147).
STEP 2. Check for faulty engine driven fuel pump (two).
Replace engine driven fuel pump if defective (TM 55-2840-229-23).
Correct wiring If faulty (paragraph 9-5).
6. Fuel filter warning light illuminated.
STEP 1. Check for dirty fuel filter.
Replace filter. If frequent filter changes are required, Investigate fuel source (paragraph 10-25).
STEP 2. Check for faulty pressure switch.
Replace switch If faulty (paragraph 9-5).
Correct wiring If faulty (paragraph 94).
Change 10 10-15
TM 55-1520-210-23-2
Table 10-2. Troubleshooting - Fuel System (Cont)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
7. Shut-off valve inoperative.
STEP 1. Check for defective valve or lack of electrical power.
Check for electrical power and ground at valve; n power and ground available, valve is defective
(paragraph 10-152).
8. 20 MIN FUEL light fails to illuminate.
STEP 1. Check for faulty low level switch, wiring, or lamp.
Replace defective switch, wiring, or lamp (paragraph 9-5).
9. 20 MIN FUEL light illuminates above/or below normal low level fuel quantity.
STEP 1. Check for faulty fuel quantity system.
Adjust, repair fuel quantity system as required (paragraph 8-241).
STEP 2 Check upper crossover for the forward under floor tanks to be open and reasonably unrestricted.
Clear restriction (paragraph 1042b).
STEP 3. Check forward crossover line and ejector pumps to be open and reasonably unrestricted.
Clear restrictions (paragraphs 1042a and 10-119).
STEP 4. Check flapper valves for leakage faster than ejector pumps can pump fuel to rear of cell. (Check flapper
valve in left forward cell if system activates with a higher than normal quantity, check flapper valve in right forward cell if
warning light activates with lower than normal quantity).
Adjust flapper valves for proper seating, replace or shim as necessary (paragraph 10-127).
10. Fuel pressure fluctuating, low, or zero with boost pump warning light not illuminated.
STEP 1. Check for faulty fuel pressure transmitter or indicator.
Replace defective transmitter or Indicator (paragraph 1037).
Replace defective wiring (paragraph 9-5).
11. Fuel leaking out tank vent tube during closed circuit refueling.
STEP 1. Check for deflector on back of closed circuit refueling receiver.
Install deflector if missing.
10-16 Change 10
TM 55-1520-210-23-2
10-18. Operational Check Fuel System. Test c. Perform operation check (paragraph 10-18) to
installation for leaks. Request maintenance to perform check when 20 minute fuel light goes out. Light should
air pressure-type test or add small, measured amount of go out between 130 and 240 Ibs of fuel indicated. If fuel
fuel and check for leaks. If no leaks are noted, add quantity indicated is below 130 lbs or above 240 lbs, take
additional measured amounts of fuel increments. Stop corrective action (Table 10-2).
fueling after each increment of fuel is added and check
for proper operation of low level fuel warning system, fuel d. Verify illumination of 20 minute fuel light.
quantity indicating system and boost pumps (paragraph
8-241). It is necessary to check operation of the low fuel (1) Add additional measure amounts of fuel
level warning system when fuel level is between 130 and until fuel quantity indicator reads above 240 lbs. Check
240 lbs. for illumination of 20 minute fuel light, if light illuminates
take corrective action (Table 10-2).
10-19. Pressure Test Fuel System.
(2) Defuel aircraft at measured amounts of
a. Defuel system (paragraph 1-3). fuel (approximately 5 gallons). Stop defueling after each
measured amount and operate electric fuel boost pumps
for approximately 5 minutes. Check for illumination of 20
minute fuel light and note fuel quantity indicated. Twenty
minute fuel light should stay illuminated after operating
Do not use masking tape to seal openings. electric fuel boost pumps when fuel quantity is between
130 and 240 lbs indicated. If 20 minute fuel light fails to
b. Cap main fuel line and vent connections. stay illuminated below 130 lbs, take corrective action
(Table 10-2).
c. Use regulated low pressure, filtered compressed
air source with a manometer or accurate pressure gage 10-20. FUEL FILTER ASSEMBLY.
and a shutoff valve.
10-21. Description Fuel Filter Assembly. The main
fuel filter has a micronic type element and electrical
means of indicating any impending bypass condition
Do not apply excessive pressure, as severe which may occur. Filter is a cylindrical unit, horizontally
damage to cell and structure may result. mounted on forward firewall in left side of engine
compartment. Piping connections to filter heads are: an
d. Apply pressure until gage indicates 2.5 psi in inlet line from shutoff valve of supply system, a drain line
cells and crossover tubes. Shutoff air source. Cells with manual valve, and an outlet coupling for engine fuel
should hold this pressure for 15 minutes. control hose. If a dogging condition should develop in
filter element, a normally-open switch is dosed by
e. Locate and correct any leakage indicated by loss differential pressure, lighting FUEL FILTER caution light
of pressure, and repeat tests until results are as warning that further I dogging may cause fuel to flow
satisfactory. through by-pass valve without filtration (figure 10-5).
f. Refuel system, if required. 10-22. Removal Fuel Filter Assembly.
a. Open engine cowling at left side.
b. Disconnect fuel hose from outlet coupling (7,

Do not operate electrical equipment while figure 10-5) on filter (8). Drain fuel from filter by opening
refueling or defueling aircraft valve (11) located under head (8).
10-19.1. Function Check Low Fuel Caution System. NOTE

Use suitable tool to depress self-closing
a. Defuel aircraft (paragraph 1-3). valve in filter outlet coupling, to admit some
air and allow drainage. Close valve (11).
b. Verify that the fuel quantity indicator is indicating
0 pounds of fuel (if not, refer to paragraph 8-241 for
corrective action).
Change 10 10-17
TM 55-1520-210-23-2
c. Remove filter element (3) for inspection and 10-25. Repair or Replacement Fuel Filter
replacement as follows: Assembly.
(1) Open coupling (5,figure 10.5). a. Replace element (3) if unserviceable or

damaged.
(2) Remove strainer body (1) with packing (6)
and element (3) from head assembly (8). b. Replace entire filter assembly if corrosion or
damage exists.
(3) Separate element (3) and packing (2) and
(4) from strainer body. 10-26. Installation Fuel Filter Assembly.
(4) Filter head (8) will normally remain in a. If removed, reinstall filter head (8, figure 10-5).
place but can be removed when necessary by Secure to firewall with four bolts and washers. Lockwire
disconnecting electrical cable plug (9), fuel line (10) and bolt heads. Connect fuel line tube to filter inlet hose (10),
drain line, and removing four bob with washers which and drain line to valve (11) at bottom of filter head.
secure head to firewall. Connect electrical cable plug.
10-23. Inspection Fuel Filter Assembly. Inspect filter b. Install filter element (3) and body (1) as follows:
element (3) for contamination to determine if any
corrective action is needed beyond replacement of (1) Place new packing (2, figure 10-5) on
element and packing. boss in bottom of strainer body (1).
10-24. Cleaning Fuel Filter Assembly. Clean filter (2) Place dean filter element (3) in strainer
body and head as necessary with cleaning solvent, body (1) seated firmly.
(C261). Protect electrical connections when cleaning
head. (3) Place new packing (4) around center boss
in filter head.
10-18 Change 10
TM 55-1520-210-23-2
1. Strainer body 10. Fuel inlet hose

2. Preformed packing (MS29513-24) 11. Filter drain valve
3. Filter element (204-040-760-13) 12. Bolt
4. Preformed packing (MS29513-24) 13. Elbow
5. Coupling 14. Coupling half, self-sealing, shearable
6. Preformed packing (MS29513-237) 15. Valve, self-sealing, breakaway
7. Fuel outlet to engine 16. Nut
8. Filter head 17. Packing
9. Electrical wiring to caution panel
Figure 10-5. Fuel Filter Assembly — Exploded View
10-19
TM 55-1520-210-23-2
(4) Install packing (6) around upper lip of filter b. Service fuel system and inspect valve for leak-
body (1) next to flange age.
(5) Install body assembly (1) into filter head (8), 10-33. PRESSURE TRANSMITTER.
pressing firmly to seat
10-34. Description—Pressure Transmitter. A pres-
CAUTION sure transmitter is located on the front of the engine
forward firewall and is accessible through the right aft
Do not overtorque clamp to prevent leak- pylon panel. The pressure transmitter relays fuel pres-
age; use new packing or filter if leakage sure to fuel pressure gage on instrument panel.
persists.
10-35. Removal—Pressure Transmitter.
(6) Install coupling (5) around mating flanges of
filter head and body. Ensure slot is at 6 o’clock position. a. Remove access panel on pylon bulkhead.
Torque clamp to 50 inch-pounds. b. Disconnect hose assembly (7, figure 10-6) from
c. Connect hose from engine fuel control inlet to transmitter
outlet coupling on filter c. Remove four screws (1) and four washers (2)
d. During next ground run-up check fuel filter and d. Disconnect electrical plug and remove transmit-
connections for leaks Also ensure FUEL FILTER caution ter.
panel does not light.
NOTE 10-36. Inspection—Pressure Transmitter.
Ensure engine inlet fuel system quick dis- a. Inspect transmitter for leaks, corrosion or dam-
connect couplings are tightened. age.
10-27. CELL DRAIN VALVE. b. Inspect transmitter for proper operation in accor-
dance with troubleshooting procedure. Refer to para-
10-28. Description—Cell Drain Valve. A cell drain graph 10-17.
valve (13, figure 10-3) is located in bottom of front section
10-37. Replacement—Pressure Transmitter.
in each forward fuel cell assembly. The valve is used to
drain residual fuel and water (moisture) from the system. a. Remove existing union (6) and packing (5) from
defective transmitter.
10-29. Removal—Cell Drain Valve.
b. Install new packing (5) on union (6) Install union
a. Defuel system. in replacement transmitter.
b. Remove valve (13) and packing. 10-38. Installation—Pressure Transmitter.
10-30. Inspection—Cell Drain Valve. Inspect valve a. Install transmitter (4) to mounting bracket (3). Se-
for nicks, scratches, corrosion and leakage. cure using four washers (2) and four screws (1).
10-31. Replacement—Cell Drain Valve. If valve fails b. Install hose assembly (7) to transmitter.
inspection requirements, replace valve. c. Connect electrical plug to transmitter
10-32. Installation—Cell Drain Valve. d. Install access panel on pylon bulkhead.
a. Install drain valve (13, figure 10-3) with packing 10-39. Test Procedures—Pressure Transmit-
to fuel cell opening. Torque drain valve to 50 inch pounds. ter. Ground run helicopter and check fuel pressure gage
Safety with lockwire (C155). for proper fuel pressure indication.
10-20 Change 14
TM 55-1520-210-23-2
1 Screw
2. Washer
3. Mounting bracket
4. Fuel pressure transmitter
6. Union
7. Hose assembly
Figure 10-6. Fuel Pressure Transmitter Installation
10-21
TM 55-1520-210-23-2
10-40. SHUTOFF VALVE — MOTOR (4) Discard packings (11 and 18)
DRIVEN.
10-43. Inspection — Shutoff Valve — Motor
10-41. Description — Shutoff Valve — Motor Driven. a. Inspect shutoff valve for leaks (no leak-
Driven. A motor-operated type gate valve (figure age allowed), damage and corrosion.
10-7), in main fuel line before filter, is mounted on
front of engine forward firewall and is accessible b. Inspect shutoff valve for proper operation
through a door on left side of pylon structure. (paragraph 10-46).
Valve is controlled by MAIN FUEL switch, and has
a manual override handle which also serves as a 10-44. Repair or Replacement — Shutoff
visual position indicator. A thermal relief valve Valve — Motor Driven. a. Assemble shutoff valve
allows internal bypass of fuel trapped on outlet (12) and check valve manifold (32) as follows:
side of shutoff valve, being set to crack at 90 to
120 psig and to reseat at 80 psig minimum. (1) Position flange (9) and packing (29) on
fitting (10) and install fitting in port of check valve
10-42. Removal — Shut-Off Valve — Motor manifold (32).
Driven. a. Open left engine cowling and remove
left lower access panel from pylon island. (2) Assemble fitting (14, figure 10-7), pack-
ing (18) and elbow (23). Install packing (22) and
b. Provide suitable container to catch fuel, and union (21) if removed.
disconnect fuel hose from union (21, figure 10-7).
Remove nut (19) and washer (20) from union. (3) Using packing (11 and 13) position fittings
(10 and 14) on shutoff valve (12). Install two bolts (15)
c. Disconnect electrical connector from shutoff with washers and nuts (7). Do not tighten nuts at this
valve (12) time.
d. Disconnect fuel inlet hoses from bottom of

10-45. Installation — Shutoff Valve — Motor
check valve manifold (32) and transmitter hose from
Driven. a. Remove (34) and washers from bolts (5).
restrictor (1 ).
Hold bolts (5) in place through firewall with spacers (4)
installed. Position shutoff valve and check valve
e. Remove bolts (24), nuts (7) and washers (8)
manifold assembly to firewall with bolts (5) through
securing shutoff valve to bracket (25).
mounting holes of check valve assembly and union
(21 ) through hole in firewell.
f. Remove nuts (34) and washers (6) from bolts
(5)
b. Position three washers (27) between mounting
g. Remove shutoff valve (12, figure 10-10) and holes of bracket (25) and each lower mounting hole of
check valve manifold (32). Reinstall washers (33) and flange (28). Install bolts (24), with washers and nuts
nuts (34) temporarily to retain spacers (4) and bolt (5) (7). Align elbow (23) and fuel valve manifold (32).
in place Tighten nuts (7) evenly.
h. Disassemble shutoff valve and check valve c. lnstall washers and nuts (34) on bolts (5).
manifold as follows:
d. Install washer (20) and nut (19) on union (21).
(1) Remove bolts (15), washers and nuts (7)
and separate shutoff valve from manifold (32).
e. Connect fuel inlet hoses to fittings on bottom of
(2) Remove elbow (23) from fitting (14) and valve manifold and hose from transmitter to restrictor
remove flange (28) from fitting. Do not remove union (1).
(21) from elbow (23) unless required for parts
replacement. f. Connect electrical connector to fuel shutoff
valve and Iockwire (C155).
(3) Remove fitting (10) and flange (9) from
check valve manifold (32). g. Connect fuel hose to union (21).
10-22 Change 2
TM 55-1520-210-23-2
Figure 10-7. Shutoff Valve - Motor Driven and Check Valve Manifold
Change 4 10-23
TM 55-1520-210-23-2
10-46. Test Procedures - Shutoff Valve - Motor 10-54. MANIFOLD ASSEMBLY.

Driven. a. Place BAT switch ON, move FUEL switch to 10.55. Description - Manifold Assembly. A check
ON. Check all disturbed points for fuel leaks. Observe that valve manifold (32, figure 10-7), is located at left front of
manual override handle on fuel shutoff valve moves to engine forward firewall and is connected into fuel pressure
open position. Move FUEL switch to OFF. Observe that lines ahead of shutoff valve. Manifold contains two
manual override handle moves to dosed position. Place separate valve elements at inlet ports, each consisting of
BAT Switch OFF. a check valve which prevents reverse flow except through
its thermal relief bypass of trapped fuel. Manifold also has
b. Close engine cowling and install access panel on an outIet port and a tap for fuel pressure gage transmitter
pylon island. at outlet side of check valves.
10-47. GOVERNOR BLEED CHECK VALVE. 10-56. Removal - Manifold Assembly. a Remove
10-48. Description - Governor Bleed Check Valve. fuel shutoff valve (12, figure 10-7) and manifold (32) as an
A governor bleed check valve is located in the governor assembly (paragraph 10-42).
bleed return line connected to center fuel cell assembly.
The governor bleed check valve allows separated air and b. Separate manifold (32) from fuel shutoff valve
fuel vapor to return to fuel tank and prevents reverse flow (paragraph 10-42).
of fuel.
c. Remove restrictor (1), nut (2), packing (3), plugs (30
10-49. Removal – Governor Bleed Check Valve. a. and 35) and packings (31 and 36). Discard packings.
Defuel system.
10-57. Inspection - Manifold Assembly. a Inspect
b. Working through access door (53, figure 2-18) dis- manifold assembly for damage, corrosion and leaks.
connect hose or tube assembly from check valve.
b. Inspect check valves in manifold for proper opera-
c. Remove nut, check valve and packing. tion (paragraphs 10-18 and 10-19).
10-50. Inspection - Governor Bleed Check Valve 10-58. Repair or replacement - Manifold Assembly.
Inspect check valve for corrosion, leaks and security. a. Assemble packing (3, figure 10-7), restrictor (1) and nut
(2) to manifold.
10-51. Repair or Replacement-Governor Bleed
Check Valve. Replace check valve if corroded, damaged b. Assemble plugs (30 and 35) and packings (31 and
or if leakage exists. 36) to manifold.
10-52. Installation - Governor Bleed Check Valve. a. 10-59. Installation - Manifold Assembly. a.
Install packing and nut to check valve and install in fuel Assemble manifold (32) to fuel shutoff valve (paragraph
cell. Tighten nut. 10-44).
b. Connect hose or tube assembly to check valve. b. Install manifold to firewall (paragraph 10-45).
10-53. Test Procedures - Governor Bleed Check c. Torque limits for installing valve seats (union) are .
Valve. Perform fuel system operational check (paragraph 150 to 210 inch-pounds.
10-18).
10-60. CROSSOVER ASSEMBLIES.
10-61. Description - Crossover Assemblies. Six
crossover assemblies (7, figure 10-3) interconnect forward
and aft fuel cells. Each crossover has a flange type fitting
for connection to fuel cell or crossover.
10-24 Change 5
TM 55-1520-210-23-2
NOTE
NOTE
It is critical to proper operation of the
“20 Minute Fuel Warning” and fuel Removal procedures are identical for
quantity indication that the aft cross- either side.
over line for the forward underfloor
tanks to open and reasonably unre-
stricted. If either or both ejector
pumps are inoperative, the forward a. Lower Forward Crossover.
crossover line must be open and rea-
sonably unrestricted. Restrictions can (1) Defuel system (paragraph 1-3).
be caused by kinked or collapsed lines
or hoses. Self-sealing hoses that are (2) Remove access panels (48 and 57, fig-
partially activated can cause bulges ure 2-18).
or restrictions to form in the inner
liner. An improper fitting, couplings, (3) Remove six bolts, six washers and packing
or connector might restrict flow. The from forward connection.
205-062-652-1 coupling could be ac-
(4) Remove four bolts, four washers, four nuts
tuated, partially actuated, or clogged.
and packing connecting lower forward crossover to
The crossover lines could also just be
upper crossovers.
clogged with contamination.
(5) R e m o v e lower forward crossover
10-62 Removal — Crossover Assemblies. assembly.
10-25
TM 55-1520-210-23-2
b. Upper Crossover Assemblies. 10-65. Installation — Crossover Assemblies.

(1) Defuel system (paragraph 1-3). a. Lower Forward Crossover.
(2) Remove four bolts, four washers and pack- (1) Connect lower forward crossover to forward
ing securing inboard crossover to center fuel cell. fuel cell using packing, six washers and six bolts.
(3) Remove four bolts, four washers and pack- (2) Connect opposite end to upper outboard
ing securing outboard crossover to outboard fuel cell. crossover using packing, four bolts, four washers and
four nuts.
(4) Remove four bolts, four washers and four
nuts connecting upper crossovers to lower forward b. Upper Crossover Assemblies.
crossover. (1) Connect upper outboard crossover to out-
(5) Remove upper crossovers. board fuel cell using packing, four washers and four
bolts.
10-63. Inspection - Crossover Assemblies. Inspect (2) Connect upper inboard crossover to center
crossover assemblies for nicks, scratches, damage, and fuel cell using packing, four washers and four bolts.
flow restrictions.
(3) Connect upper outboard crossover to lower
10-64. Repair or Replacement — Crossover Assem- forward crossover using packings, four bolts, four wash-
blies. ers and four nuts.
a. Burnish out scratches, nicks or burrs less than (4) Refuel fuel system and check for leaks.
0.005 inch deep on the mating surfaces and in sealing
groove of fitting using crocus cloth (C68). Treat repaired 10-66. SIPHON BREAKER VALVE.
area using brush alodine (C62).
10-67. Description — Siphon Breaker Valve. A si-
b. Repair damage exceeding 0.005 inch but not phon breaker (check) valve (1, figure 10-8) in the vent
more than 0.020 inch in depth as follows: system allows air to vent into the forward tanks through
(1) Isolate the damaged areas and sand, using overboard vent and prevents fuel from siphoning out of
180 grit sandpaper (C231). cells through overboard drain.
10-68. Removal — Siphon Breaker Valve.

WARNING a. Remove access cover.
Cleaning materials are flammable and tox-
ic. Avoid skin contact and breathing of sol- CAUTION
vent vapors. If aircraft has full tanks of fuel, siphon may
(2) Clean with P-D-680, Type II (C261), fol- be under pressure. If pressure is evident,
lowed by an isopropyl alcohol (C41) rinse. Ensure sur- resecure siphon and run aircraft or drain
face is dry before sealing. tank at least 6 inches below fuel cap to
relieve pressure.
(3) Air dry and apply adhesive (C29). Allow to
dry at room temperature for a minimum of 24 hours. b. Remove siphon breaker valve (1, figure 10-8)
and packing (2).
c. Replace any crossover assembly if damage is
extensive or if nicks, scratches, or burrs exceed 0.020 10-69. Inspection — Siphon Breaker Valve. Inspect
inch depth. valve for corrosion, leakage and damage.
10-26 Change 14
TM 55-1520-210-23-2
1. Siphon breaker valve

3. Fitting
4. Performed packing
5. Tee.
Figure 10-8. Siphon Breaker Valve Installation
10-70. Repair or Replacement — Siphon 10-72. COVER PLATE — AFT CENTER

Breaker Valve. If valve does not meet inspec- FUEL CELL.
tion requirements, replace valve.
10-73. Description — Coverplate — Aft Center
Fuel Cell. The aft center fuel cell incorporates a
10-71. Installation — Siphon Breaker Valve. coverplate (access) (3, figure 10-9), which allows
a. Install replacement valve (1) with packing (2) internal access to fuel cell and is used for re-
to fitting (3). moval/installation of fuel cell. A fuel quantity trans-
mitter (probe) and a float switch are mounted on
b. Install access cover (38, figure 2-13). coverplate.
10-27
TM 55-1520-210-23-2
4
5
1. Fuel quantity transmitter (probe) 7. Fuel quantity transmitter electrical connection

2. Preformed packing 8. Governor bleed valve tube connection
3. Cover plate (aft center fuel cell) 9. Retainer
4. Washer 10. Clamp
5. Screw 11. Bolt
6. Float quantity transmitter electrical connection 12. Bolt
Figure 10-9. Cover Plate Installation — Aft Center Fuel Cell

10-74. Removal—Coverplate—Aft Center Fuel Cell. 10-76. Repair or Replacement—Coverplate—Aft
a. Disconnect tube assembly at governor bleed Center Fuel Cell. Replace coverplate (3) if damage or
valve location. subsequent repair would interfere with the fit or function
of coverplate.
b. Disconnect fuel quantity transmitter and float
switch electrical connectors. NOTE
c. Remove screws (5), bolts (12), and washers (4)
securing coverplate (3) to structure. Fuel quantity transmitter support brack-
ets frequently become overstressed dur-
d. Remove clips and ty-rap security transmitter (1)
to coverplate (3). ing installation of the coverplate (3).
Brackets PN 5340-UH-1-6821 and
e. Carefully remove transmitter (1) and coverplate 5340-UH-1-6823 should be installed. In
(3). Remove packing (2) from fuel cell.
addition, clamp (10) must have bolthead
10-75. Inspection—Coverplate—Aft Center Fuel (11) installed toward coverplate. This will
Cell. Inspect coverplate (3) for cracks, nicks, corrosion ease installation of the cover plate (3) and
and damage. avoid overstressing the brackets.
10-28 Change 14
TM 55-1520-210-23-2
10-77. Installation — Coverplate — Aft Center Fuel 10-81. Deleted.

Cell.
10-82. Deleted.
a. Partially position coverplate (3) in fuel cell, secure
transmitter to coverplate using clips and ty-rap. Figure 10-10. Deleted.
b. Install (2) to fuel cell. 10-83. CLOSED CIRCUIT REFUELING RECEIVER
c. Secure coverplate using screws (5), bolts (12), ASSEMBLY.
retainers (9), and washers (4).
10-84. Description — Closed Circuit Refueling Re-
d. Install tube assembly at governor bleed valve ceiver Assembly. A closed circuit refueling receiver
location. may be installed in place of a cap and adapter assembly.
Receiver assembly is designed to accept a closed circuit
e. Connect transmitter and float switch connec- refueling nozzle. Receiver assembly provides for auto-
tions. Lockwire where applicable. matic shutoff of fuel flow at a predetermined level during
f. Pressure test fuel cell (paragraph (10-19). refueling operations. Lower portion of receiver assembly
may be rotated to allow refueling with standard type
g. Adjust per (paragraph (8-249). nozzle.
10-78. Deleted.
CAUTION
10-79. Deleted. Accomplish the following in a well venti-
lated area, ensuring helicopter is properly
10-80. Deleted. grounded.
Change 14 10-29
TM 55-1520-210-23-2
Figure 10-11. Closed Circuit Refueling Receiver.
10-85. Removal Closed Circuit Refueling Receiver a.1. Remove screws (5 figure 1 0-11) and washers
Assembly. (6) attaching receiver and grounding strap to helicopter
structure.
a. Disconnect battery or external power source.
Defuel system to a level below the refueling receiver b. Remove packing (1) and receiver (4).
assembly.
10-30 Change 10
TM 55-1520-210-23-2
10-86. Inspection Closed Circuit Refueling Receiver c. Remove receiver (4) and packing (5).
Assembly.
10-90. Inspection. If receiver has caused leaking out
a. Inspect closed circuit refueling receiver for tank vent tube during dosed circuit refueling or if receiver
damage, dents and corrosion. is new, check for sheet steel deflector between receiver
b. Inspect locking cover for proper locking. can and control module. If missing, install. Refer to
c. Inspect fuel cap lanyard cable for security. paragraph 10-86.
d. Inspect for grounding strap security.
e. Perform resistance check on ground strap by 10-91. Installation Deflector.
measuring the resistance from the ground strap to the
aircraft per TM 55-1500-323-24, paragraph 8-26 through a. Place cap and receiver assembly on clean
828. An equivalent multimeter may be used. surface with filler face down and control module turned
toward mechanic.
10-87. Installation. b. Hold deflector assembly in place with rivet
toward mechanic and rivet head facing down.
a. Position packing (1, figure 10-11) on receiver (4). c. With deflector spread open, insert and close
b. Secure receiver and grounding strap using deflector around four screws which secure control
washers (6) and screws (5). module to receiver assembly. Do not loosen screws,
c. Connect battery and refuel system. deflector is located between control module and receiver.
d. Holding deflector in place, bend locking tabs 30
10-88. Closed Circuit Refueling Receiver. to 40 degrees up locking deflector in place.
Helicopters modified by MVWO 55-1520-210-30-55 have NOTE

an improved dosed circuit refueling receiver instead of Deflector should freely move up and down
the original dosed circuit receiver. This receiver will on screws.
accept fuel at a rate of 65 gallons per minute. The
receiver will automatically shut off when the fuel system 10-92. Installation Closed Circuit Refueling Receiver.
is full or when fuel cell internal pressure exceeds 2.5 psi.
a. Install packing (5) in groove around fuel cell
10-89. Removal Closed Circuit Refueling Receiver. opening.
b. Position receiver (4) and retainer (3) over
a. Disconnect battery or external power source. packing (5).
Defuel system as required. c. Install screws (1) with washers (2).
b. Remove screws (1, figure 10-12), washers (2), d. Connect battery and refuel system.
and retainer (3).
Change 10 10-30.1/(10-30.2 blank)

TM 55-1520-210-23-2
10-93. FLOAT – 20 MINUTE FUEL WARNING 10-95. Removal - Float Switch - 20 Minute Fuel
SYSTEM. Warning System.
10-94. Description – 20 Minute Fuel Warning
a. Defuel system.
System. A float is located on the left fuel cell sump
assembly. The float switch illuminates the 20 MINUTE
b. Disconnect battery.
FUEL caution light located in the pedestal caution
panel. Illumination occurs when fuel quantity
c. Remove left fuel cell sump assembly
decreases to 185 (±55) pounds.
(paragraph 10-137).
NOTE
It is critical to proper operation of the “20 d. Unscrew float switch from standpipe, pull
Minute Fuel Warning” and the fuel quantity switch and wires through standpipe.
indication that the aft crossover line for the
forward underfloor tanks be open and
reasonably unrestricted. If either or both
ejector pumps are inoperative, the forward
crossover line must be open and
reasonably unrestricted. Restrictions can
be caused by kinked or collapsed lines or
hoses. Self-sealing hoses that are partially
activated can cause bulges or restrictions
to form in the inner liner. An improper fitting,
coupling, or connector might restrict flow.
The 205-062652-1 coupling could be
actuated, partially actuated, or clogged.
The crossover lines could also just be
clogged with contamination. It is normal for
one fuel boost pump to produce more
pressure that the other boost pump. The
stronger pump will supply all the fuel to the
engine. The aft crossover line balances the
tanks for proper lateral balance, fuel
quantity readings and “20 Minute Fuel
Warning” operation. If the crossover line is
not working, a strong left pump will produce
an early “20 Minute Fuel Warning” and a
strong right pump will produce a late “20
Minute Fuel Warning”. The problem is the
line, not the pumps.
Change 6 10-31
TM 55-1520-210-23–2
1. Screw
2. Washer
3. Retainer
4. Receiver
5. Packing
6. Deflector
Figure 10-12. Closed Circuit Refueling Receiver

(MMO 55-1520-210-30-55).
10–32 Change 6
TM 55-1520-210-23-2
10-96. Inspection — Float Switch — 20 10-100. FUEL BOOST PUMPS.

Minute Fuel Warning System. Inspect float
switch for cracks, damage and security. 10-101. Description — Fuel Boost Pumps.
An impeller type fuel boost pump is located in
each forward fuel cell sump assembly. The
10-97. Repair and Replacement — Float boost pumps are 28 Vdc electrically operated
Switch — 20 Minute Fuel Warning System. and deliver fuel under pressure to engine fuel
Replace float switch if inoperative or if damage control, passing through fuel manifold and fuel
exceeds inspection requirements. shutoff valve.
10-98. Installation — Float Switch — 20 NOTE

Minute Fuel Warning System. a. Install pack-
On helicopters prior to serial no. 69-
ing to float switch, thread float switch wiring
15292, a bleed air or an electrically
through standpipe and screw switch to stand-
operated boost pump may be installed in
pipe. left fuel cell sump assembly.
b. Reinstall fuel cell sump assembly (para-
graph 10-144). 10-102. Troubleshooting — Fuel Boost
Pumps.
C. Refuel system and connect battery.
NOTE
Before using table 10-3 ensure that all

10-99. Test Procedures — Float Switch — normal operational checks have been
20 Minute Fuel Warning System. Ensure elec- accomplished. If a malfunction is found
trical circuit is functioning properly and test which is not listed in this table, notify the
float switch in accordance with paragraph 10- next higher level of maintenance.
18.
Table 10-3. Troubleshooting — Fuel Boost Pumps
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. Electrical boost pump warning light illuminated, no pressure indicated on fuel

pressure gage.
STEP 1. Check boost pump for correct operation.
If boost pump is inoperative, replace boost pump (paragraph (10-104).
Correct wiring if defective (paragraph 9-5).
2. Electrical boost pump warning light illuminated, pressure indicated on fuel pressure
gage.
STEP 1. Check ejector pump for malfunction and foreign material in ejector pump and/or hoses.
Clean foreign material from ejector pump and/or hoses. Replace ejector pump
if inoperative (paragraph 10-118). Remove screen from crossfitting (paragraph
10-105).
Change 2 10-33
TM 55-1520-210-23-2
Table 10-3. Troubleshooting — Fuel Boost Pumps (Cont)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
STEP 2. Test check valve for proper operation.
STEP 3. Test flow switch for proper operation.
Correct wiring if faulty (paragraph 9-6).
3. Bleed air boost pump warning light illuminated, fuel pressure low or zero.
STEP 1. Check bleed air fuel boost pump for operation.
If boost pump is inoperative, replace boost pump (paragraph 10-104).
4. Bleed air boost pump warning light illuminated, pressure normal on fuel pressure
gage.
STEP 1. Check ejector pump for malfunction and foreign material in ejector pump and/or hoses.
Clean foreign material from ejector pump and/or hoses. Replace ejector pump
if inoperative (paragraph 10-118). Remove screen from crossfitting (paragraph
10-105).
STEP 2. Test check valve for proper operation.
STEP 3. Test flow switch for proper operation.
Correct wiring if faulty (paragraph 9-5).
NOTE
10-103. Removal — Fuel Boost Pumps.
Always cover any fuel cell openings
NOTE and cap all open fuel lines to prevent
contamination.
Removal procedures are identical for
right or left side fuel boost pump. NOTE
Mark position of fuel boost pump be-
a. Disconnect battery and electrical wiring.
fore removal to aid in installation.
On bleed air boost pumps, disconnect air hose.
10-34
TM 55-1520-210-23-2
NOTE
A cord may be used as a work aid to hold
cross fitting in place, while starting bolt (15).
Ensure aircraft has been defueled.
c. Pull crossfitting into place in pump and remove
b. Remove boost pump mounting bolts (13, figure guide bolt Install washer (17) packing (18), plug (19) and
10-13) and drop pump down approximately 2 inches. packing (20), on bolt (15). Install bolt (15) and torque to
c. Cut lockwire, remove bolt (15), washer (17), 50 Inch-pounds. Lockwire plug (16) to bolt (15).
packing (18), plug (19), packing (20) that secures cross
fitting (26) and hoses. Remove pump assembly.
10-104. Repair or Replacement Fuel Boost Pumps.

Do not place lock wire over electrical leads.
NOTE If installing the cartridge type boost pump
If cross fitting contains a conical screen, use following lockwire procedure. Lockwire
remove screen and discard. Reinstall cross plug (16) to one of the mounting bolts (13)
fitting without screen. and lockwire bolt (15) to one of the mounting
bolts (13).
a. Remove pump drain plug (16), packing (14) from
defective pump. d. Position boost pump in mounting port of sump
b. Replace all packings when reassembling pump. plate and secure boost pump to sump plate with bolts
c. Install packing (14) on pump drain plug (16). (13) and washers (12).
Install plug in drain port of pump.
10-105.1 Removal Boost Pump Cartridge
10-105. Installation Fuel Boost Pump. (Crashworthy).
a. Visually inspect that fuel bleed valve is installed a. Disconnect electrical wiring from fuel pump
on top of fuel pump housing (35, figure 10-13) on cartridge (38 figure 10-13).
cartridge type pumps.
A bent Inlet shut off valve arm may prevent

If fuel bleed valve is not installed, engine shut off valve from completely opening
surging/flameout will occur when fuel level is causing a restricted fuel flow.
below top of fuel boost pump housing and
the boost pump is off or inoperative.
b. Position pump (1) in mounting port of sump plate

(27) with gasket (10) in place. Start bolt (15) Apply pressure directly over valve spring
approximately 114 inch in cross fitting (26). when opening or closing valve stem
assembly. Trying to compress valve spring
NOTE from free end of valve arm will cause valve
If cross fitting contains a conical screen, arm to bend. When removing or installing
remove screen and discard. Reinstall cross shoulder screw, keep valve arm depressed.
fitting without a screen.
b. Remove lockwire and screw (39). Turn arm (38)
to extreme counterclockwise position.
c. Remove fuel pump drain plug (37) and drain

residual fuel into suitable container.
Change 10 10-35
TM 55-1520-210-23-2
d. Remove lockring (40) securing fuel pump NOTE

cartridge (36) to fuel pump housing (35). The fuel pressure gage is an AC powered
e. Remove fuel pump cartridge (36) from fuel pump instrument. An inverter must be operating in
housing (35) using cartridge removal tool (figure 10- order to provide gage Indications.
13.1). Discard packings (41).
a. Right fuel pump.
10-105.2 Installation Boost Pump Cartridge
(Crashworthy). (1) Turn electrical power ON.
a. Install packings (41, figure 10-13) insert fuel (2) Turn main fuel switch ON.
pump cartridge (36) into fuel pump housing (35) ensuring
arrows on fuel pump and fuel pump housing align. (3) Fuel boost circuit breaker IN.
b. Install lockring (40) securing fuel pump cartridge
(36) to fuel pump housing (35). (4) If RIGHT FUEL BOOST light is on, check
c. Install fuel pump drain plug (37) into fuel pump. fuel pressure gage for correct pressure.
Lockwire drain plug to drain plug adapter.
(a) If pressure is not indicated, electric
boost pump is inoperative.
(b) If pressure is indicated, check for

malfunction of ejector pump or check valve flow switch or
A bent inlet shut off valve arm may prevent existence of clogged screens in cross fittings.
shut off valve from completely opening
causing a restricted fuel flow. b. Left fuel pump (bleed air).
(1) Ground run helicopter engine (TM

551520-210-10 or 55-1520-247-10).
Apply pressure directly over valve spring (2) Position right electrical fuel boost pump
when opening or closing valve stem circuit breaker to "OFF’ position.
assembly. Trying to compress valve spring
from free end of valve arm will cause valve (3) If LEFT FUEL BOOST light is illuminated,
arm to bend. When removing or installing check fuel pressure gage for correct pressure.
shoulder screw, keep valve arm depressed.
(a) If pressure is low or zero, the bleed
d. Turn arm (38) clockwise, while pressing spring air fuel boost pump is inoperative.
loaded end of arm up, into alignment with hole for screw
(39). While holding arm (38) up, install negative ground (b) If pressure is normal, the ejector
lead between arm and cartridge. Install screw (39) and pump is malfunctioning; check valve or flow switch is
lockwire (Ci55). inoperative, or cross fitting screen is clogged with foreign
e. Connect electrical wiring to fuel pump cartridge material.
(36).
10-107. CROSS FITTING.
NOTE
If pressure is indicated, check for 10-108. Description -Cross Fitting. Across fitting (26,
malfunction of ejector pump or check valve figure 10-13) is installed in each boost pump.
flow switch or existence of clogged screens
in cross fittings. 10-109. Removal Cross Fitting.
10-106. Functional Test Fuel Boost Pumps and a. Remove the fuel cell sump assembly (paragraph
10-137).
Ejector Pumps.
b. Disconnect the fuel lines from inlet and outlet
ports of cross fittings (26, figure 10-13).
c. Cut lockwire and remove bolt securing cross
fitting to boost pump flange.
d. Remove rubber plugs from lower end of cross
fitting.
10-36 Change 10
TM 55-1520-210-23-2
1. Preformed packing 13. Bolt 25. Screen cover

2. Preformed packing 14. Preformed packing 26. Cross fitting
3. Check valve 15. Bolt 27. Sump
4. Ground wire 16. Pump drain plug 28. Sump drain valve
5. Washer 17. Washer 29. Defuel valve
6. Screw 18. Preformed packing 30. Preformed packing
7. Retainer (4 places) 19. Retaining plug 31. Preformed packing
8. Washer 20. Preformed packing 32. Union
9. Screw 21. Nut 33. Flow switch
10. Gasket 22 Washer 34. Fuel quantity connections
11. Electric boost pump 23. Bolt (right side sump only)
12. Washer 24 Washer 35. Fuel pump housing
36. Fuel pump cartridge
37. Pump drain plug
38 : Arm
39. Screw
40. Lockring
41. Packings
Figure 10-13. Forward Fuel Cell Sump Assembly – Typical
10-37
TM 55-1520-210-23-2
1. Bolt – 7/16-20 Hex Hd. x 6 in. long

2. Sliding weight — 7075 Aluminum Alloy
3. Nut – 7/16-20 Hex (2 ea)
Figure 10-13.1. Work Aid for Fuel Pump Cartridge Removal
10-38
TM 55-1520-210-23-2
10-110. Repair or Replacement-Cross Fitting. c. Loosen 16 bolts in access cover (1, figure 10-
Install new rubber plug and two packings in bottom of 14).
cross fitting as reassembly.
d. Gradually work cover (1) out of cell.
NOTE
e. Disconnect hoses (5 and 6, figure 10-14) from
ejector pump (2).
If cross fitting has a conical screen, remove
screen and install cross fitting without screen.
f. Remove bolts (3) that secure pump.
10-111. Installation-Cross Fitting. a. Install bolt
g. Remove ejector pump through access port in cell.
previously removed through boost pump 11, figure 10-
13) flange into cross fitting (26) and secure fitting to
10-119. Cleaning—Ejector Pump. Remove any
boost pump. Torque bolt to 50 inch-pounds and
obstructions from openings in ejector pump using com-
Iockwire (C155).
pressed air. If necessary, clean nozzle opening using
safety wire. Do not enlarge nozzle hole during clean-
b. Connect fuel lines to each side of cross fitting.
ing process.
c. Install forward fuel cell sump assembly (para-
10-120. Inspection-Ejector Pump. Inspect ejec-
graph 10-144).
tor pump for corrosion, damage and general condi-
tion.
10-112. FUEL QUANTITY
TRANSMlTTERS. 10-121. Installation—Ejector Pump. a. Install ejec-
tor pump through access port in forward fuel cell.
10-113. Description-Fuel Quantity Transmitter.
The fuel system incorporates three fuel quantity trans-
mitters (probes). One transmitter is located in aft cen- NOTE
ter fuel cell and two are located in right forward fuel
cell. Refer to paragraph 8-241 for fuel quantity testing. Fuel intake port of pump must be pointed toward
bottom of tank.
10-114. Removal—Fuel Quantity Transmitter.
Refer to paragraph 10-4 for removal of forward fuel b. Install bolts (3, figure 10-14) and washers (4)
cell and 10-74 for aft fuel cell. Broken or missing mount- that secure pump.
ing ring pins may be replaced with 3/16 inch diameter
Iexan or acrylic rod. Melt and spread rod ends with a c. Connect hoses (5 and 6) to ejector pump (2).
soldering iron to secure in place.
d. Install access cover (1) in fuel cell access port
10-115. Installation—Fuel Quantity Transmitter. and tighten bolts.
Refer to paragraph 10-7 for installation of forward fuel
cell and 10-76 for aft fuel cell. e. Replace floor panel.
10-122. FLAPPER VALVE.

10-116. EJECTOR PUMP.
10-123. Description—Flapper Valve. A flapper
10-117. Description-Ejector Pump. An ejector valve (16, figure 10-14 is located in forward fuel cell.
pump (2, figure 10-14) is located in forward end of The flapper valve is located on the baffle and pre-
each forward fuel cell. The ejector pump continually vents flow of fuel out of sump area when helicopter is
pumps fuel over fuel cell baffle into rear section of fuel in a nose down flight attitude.
cell, ensuring an adequate fuel level for the fuel boost
pump in all flight attitudes. 10-124. Removal-Flapper Valve. a. Disconnect
battery and all external power sources. Defuel sys-
10-118. Removal Ejector Pump. a. Disconnect tem.
battery and all external power sources. Defuel sys-
tem. b. Remove floor section directly above forward fuel
cell.
b. Remove floor section directly above forward fuel
c. Remove access cover to fuel cell sump assem-
tank.
bly.
Change 4 10-39
TM 55-1520-210-23-2
1. Access cover 6. Hose 11. Plate 16. Flapper valve

2. Ejector pump 7. Fitting 12. Plate 17. Washer
3. Bolt 8. Nipple 13. Shim washers 18. Nut
4. Washer 9. Bolt 14. Washer 19. Nut
5. Hose 10. Bolt 15. Nut 20. Hose
Figure 10-14. Fuel System Components
d. Disconnect lines on sump assembly.

NOTE
e. Remove bolts from sump assembly. Flapper valve is located on the aft side of
fuel cell baffle.
f. Remove sump assembly through access
opening.
i. Remove two bolts (9), nuts (18), and washers
g. Loosen bolts holding access port cover. (17) from flapper valve (16).
h. Gradually work cover out of opening. j. Remove flapper valve.
10-40
TM 55-1520-210-23-2
10-125. Inspection — Flapper Valve. I n s p e c t 10-132. Inspection — Flapper Valve Plates. in-
flapper valve (16) for cracks, warpage and dam- spect plates (11 and 12) for cracks and warpage.
age.
10-126. Repair or Replacement — Flapper 10-133. Repair or Replacement — Flapper
Valve. Replace flapper valve if damage exceeds Valve Plates. Replace plates if cracked or
inspection requirements. warped.
10-127. Installation — Flapper Valve. a. Insert 10-134. Installation — Flapper Valve Plates. a.
bolts (9, figure 10-14) through plates (11 and 12) Insert bolt (10) through plates (11 and 12).
and shim washers (13) on bolts (9), then install
flapper valve (16) on bolts. b. Place washer (14) on bolt (10) and thread
nut (15) on bolt. Tighten nut.
b. Check flapper valve to make sure it is flush c. Connect hoses (6 and 20, figure 10-14).
with opening. Proper clearance is obtained by
shimming with washers (13) as required on each d. Install flapper valve (16) (paragraph 10-
bolt (9) between plate (12) and flapper valve (16). 127).
e. Install remaining components (paragraph
c. Install nuts (18) on bolts (9) and check 10-127).
flapper valve (16) to be sure it is flush with open-
ing. If not, reshim as indicated in step b. 10-135. FUEL CELL SUMP ASSEM-
BLY.
d. Install access port cover. 10-136. Description — Fuel Cell Sump Assem-
bly. The fuel cell sump assemblies are mounted in
e. Tighten bolts in cover (1). openings on the underside of each forward fuel
tank. Removal of the sump assemblies from the
f. Install sump assembly through access tanks permits access for maintenance and re-
cover opening. placement of the boost pump, flow switch, check
valve and cross fittings (figure 10-13).
g. Install and tighten bolts in sump assembly. a. Sump drain valve (28, figure 10-13) can be
removed without removing fuel sump assembly.
h. Connect hoses to sump assembly. b. Removing and installing are the same as
i. Install access cover to fuel cell sump assem- cell drain valves (paragraph 10-29).
bly. 10-137. Removal — Fuel Cell Sump Assembly.
j. Apply bead of sealant (C237) to mating a. Disconnect battery and any external power
surface of floor panel, install floor panel. source. Defuel system.
10-128. FLAPPER VALVE PLATES.
b. Remove sump access panel from underside
10-129. Description — Flapper Valve Plates. of cabin by removing screws. Mark access panel
Two plates installed on the baffle provide for so it can be installed in same position.
mounting of the flapper valve and fuel fittings
(figure 10-14). c. Open sump drain valve (28, figure 10-13) to
10-130. Removal — Flapper Valve Plate. (Refer drain trapped fuel into suitable container.
to items 11 and 12, figure 10-14). a. For access
procedure (paragraph 10-124).
d. Disconnect tubes and electrical leads of
b. Disconnect hoses (6 and 20) from nipple units attached to sump (27).
(8). e. Remove screws, washers and retainers
c. Remove bolt (10), nut (15) and washer (14). from sump plate. Lower sump assembly (27) and
support it below mounting port. Reach through
d. Remove flapper valve (paragraph 10-124). opening to disconnect hoses from boost pump
(11) outlet, flow switch (33) outlet, and disconnect
10-131. Cleaning — Flapper Valve Plates. If fuel quantity gage tank unit electrical leads as
corroded, clean corrosion from plates. necessary.
10-41
TM 55-1520-210-23-2
f. Remove sump assembly (27). Remove pack- 10-139. Inspection — Sump Drain Valve. ln-
ing seal from groove around cell opening. Cover spect valve for nicks, scratches, corrosion and
opening immediately to prevent entry of foreign leakage.
matter. 10-140. Replacement — Sump Drain Valve. If
valve fails inspection requirements, replace valve.
10-138. Removal — Sump Drain Valve, a. De- 10-141. Installation — Sump Drain Valve. a.
fuel system. Install drain valve (28, figure 10-13) with packing
to sump opening.
b. Remove valve (28) and packing. b. Service fuel system and inspect valve for
leakage.
10-42
TM 55-1520-210-23-2
10-156. AUXILIARY FUEL PROVISIONS.
Permanently installed provisions for use of auxiliary

fuel tanks include drain, vent, and fuel transfer connec- When using the 300 Gallon Crashworthy
tions and a stowed transfer pump relay circuit, with two fuel Cells the auxiliary fuel system Is not
float switches in center aft fuel cell, to limit fuel level crashworthy unless the Crashworthy Aux-
during transfer (figure 10-16). iliary Fuel Cell Provisions are installed.
Change 7 10-44.1/(10-44.2 blank)

TM 55-1520-210-23-2
Figure 10-15. Coupling Assembly, Self-Sealing
Page 10-46, including Figure 10-15 (Sheet 2 of 2) has been deleted.
Change 10 10-45(10-46 blank)

TM 55-1520-210-23-2
Figure 10-15. (Sheet 2 of 2)
10-46
TM 55-1520-210-23-2
Table 10-4. Troubleshooting — Auxiliary Fuel System

CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. No fuel transfer from one auxiliary fuel cell.
STEP 1. Check fuel discharge hose coupling for proper seating.
Connect coupling properly or replace coupling.
STEP 2. Ensure check valve (fuel discharge line) is operating correctly.
If check valve is defective, replace check valve. Do not attempt to clean and reuse check
valve except in emergency conditions.
STEP 3. Check for defective fuel pump or fuel pump electrical circuit.
If electrical power is available at fuel pump, replace defective pump, otherwise check and repair
defective wiring (paragraph F-11).
10-47
TM 55-1520-210-23-2
Table 10-4. Troubleshooting – Auxiliary Fuel System (Cont)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
2. No fuel transfer from either auxiliary fuel cell.
STEP 1. Check for faulty transfer relay.
Repair or replace transfer relay (paragraph 9-9).
STEP 2. Check for faulty float switch or electrical circuit.
Replace float switch or repair faulty circuit (paragraph F-11).
3. Fuel overflows main cell vents during fuel transfer.
Check upper float switch (aft center fuel cell) to ensure it is actuating transfer relay.
Replace upper float switch or transfer relay, as required (paragraph 10.6).
4. Auxiliary cell collapsing during fuel transfer.
STEP 1. Check for clogged vent valve or vent line.
Replace vent valve or clean vent line (paragraph 10-6).
STEP 2. Check for defective low level float switch or electrical circuit.
Replace defective switch or faulty wiring (paragraph F-11).
10-48
TM 55-1520-210-23-2
AUXILIARY INTERNAL FUEL TANK CONNECTIONS:

1. Scupper drain line
2. Pump seal drain line
3. Tank vent line
4. Fuel line
5. Tank drain line
6. Scupper drain line
Figure 10-16. Auxiliary Fuel Provisions
10-49
TM 55-1520-210-23-2
1. Bolt 10. Lanyard 19. Lanyard

2. Washer 11. Cap Assembly 20. Packing
3. Gasket 12. Packing 21. Adapter
4. Shutoff Valve 13. Bolt 22. Washer
5. Packing 14. Washer 23. Bolt
6. Hose Assembly 15. Fuel Gage 24. Cap Assembly
7. Cap and Refuel Receiver Assembly 16. Packing 25. Cover Plate
8. Washer 17. Jumper 26. Washer
9. Bolt 18. Jumper 27. Bolt
Figure 1 0 - 1 7 . Auxiliary Fuel Cell — Crashworthy (Sheet 1 of 2)
10-50 Change 2
TM 55-1520-210-23-2
28. Hose assembly 40. Bolt

29. Drain valve 41. Jumper
30. Drain quick disconnect 42. Bolt
31. Discharge quick disconnect 43. Washer
32. Existing provisions 44. Cover
33. Electrical quick disconnect 46. Valve
34. Electrical harness 46. Nut
36. Hose assambly 47. Packing
36. Vent quick disconnect 48. Plug
37. Existing screw 49. Packing
38. Low Ievel float switch 50. Pump assembly
39. Washer 51. Packing
Figure 10-17. Auxiliary Fuel Cell — Crashworthy (Sheet 2 of 2)
10-51
TM 55-1520-210-23-2
10-157. FUEL PUMP - AUXILIARY FUEL refueling receiver. Repair crashworthy fuel cells in accord-
ance with paragraph 10-6,
CELL.
10-158. Description - Fuel Pump - Auxiliary Fuel Cell.
The electrically operated fuel pump is capable of pumping
approximately 600 pounds of fuel per hour at sea level. 10-163. Removal - Fuel Cell-300 Gallon Auxiliary.
The auxiliary fuel cell incorporates a float switch to give
CAUTION panel (AUX FUEL LOW) indication to the pilot
when fuel level is low. NOTE
10-159. Removal - Fuel Pump - Auxiliary Fuel Cell. Drain fuel from auxiliary cells before removing the
fuel cells.
N O T E a. Disconnect four fuel lines (fuel discharge, cell vent,
seal drain, and cell drain) and electrical connector at cabin
Turn battery switch to OFF. Drain all fuel from cell. floor.
a. Disconnect electrical connector and two fuel lines
b. Install protective devices, over ends of all lines and
(fuel discharge and seal drain) at access port in cabin
plugs, under deck and on cell.
floor.
c. Install cover plate over fuel line access hole on
b. Remove seven bolts and washers holding fuel
cabin floor.
pump and holding-strap fittings to fuel cell.
d. Disconnect auxiliary cell holding straps from studs
c. Carefully withdraw pump and packing from fuel cell
(18 points) at aft cabin bulkhead and transmission support
by pulling outward and upward on fuel pump base. Up-
structure.
ward movement is required in order to clear pump body
through opening in cell.
e. Unhook two nylon cord loops on top of cell.
10-160. Installation-Fuel Pump-Auxiliary Fuel Cell. a.
Install fuel pump and packing into cell with flat section of f. Carefully remove cell from helicopter.
mounting flange down, using reverse procedure to that
noted in step c. above.
NOTE
b. Install seven bolts and washers, two passing For repair, handling, and storage instructions of
through the fittings of cell holding strap. fuel cell, refer to TM 55-1500-204-25/1.
c. Torque bolts 50 TO 70 inch-pounds. g. If auxiliary cell is to remain out of the helicopter,

remove all fuel cell equipment kit items from aft cabin
d. Connect electrical connector and two fuel lines in bulkhead and transmission support structure and place in
access port in cabin floor. storage compartment in doorpost. Reinstall all troop seats
and litter fittings along sides of aft cabin bulkhead and
e. Check installation for leaks. transmission support structure.
10-164. Inspection - Fuel Cell -300 Gallon Auxiliary.

10-161. FUEL SYSTEM - 300 GALLON Inspect fuel cell for cuts, tears and damage.
AUXILIARY-CRASHWORTHY.
10-165. Repair or Replacement- Fuel Cell -300 Gal-
lon Auxiliary. Refer paragraph 10-6 for fuel cell repair
procedures.
This system is not considered crashworthy unless 10-166. Installation - Fuel Cell -300 Gallon Auxiliary.
MWO 55-1520-210-30/42, Crashworthy Auxiliary a. If installed, remove troop seats and litter fittings from aft
Fuel Tank Provisions, has been installed. The in- cabin bulkhead and sides of transmission support struc-
dication that the MWO has been installed is that ture.
the external fuel cell couplings have been
removed. b. Remove auxiliary fuel cell equipment kit items from
stowage in doorpost. Install 18 studs and washers into cap
10-162. Description - Fuel System -300 Gallon plates nuts on aft cabin bulkhead and transmission sup-
Auxiliary - Crashworthy. The crashworthy system in- port structure. Torque studs 50 TO 70 inch-pounds.
corporates a float type fuel guage and a closed circuit
10-52 Change 5
TM 55-1520-210-23-2
NOTE 10-170. Installation — Fuel Gage — Auxiliary

Fuel Cell — Crashworthy. a. Place packing
The long stud is used in third plate nut
(16, figure 10-17) on back of gage (15).
from bottom of transmission support
structure. b. Place guage (15) over hole in fuel cell, align
mounting holes
c. Install spacer, hook, washer, and bolt into
plate nut at top of transmission support structure. c. Secure guage (15) to cell with washers (14) and
Install like items in plate nut at top of aft cabin bolts (13), finger tight. Torque bolts (13) 45 To 55 inch
bulkhead. Torque bolts 50 TO 70 inch-pounds. pounds
d. Carefully lift cell into helicopter. 10-171. FILL CAP — AUXILIARY

FUEL CELL — C R A S H W O R T H Y .
e. Thread (0.187 inch) nylon cord through two
aft cell hangers and through hook on upper trans-
10-172. Removal — Filler Cap — Auxiliary
mission support structure. Tighten and tie cord in
Fuel Cell — Crashworthy.
such a manner as to retain fuel cell to support
structure. Repeat process to secure forward end of NOTE
fuel cell to aft cabin bulkhead, using cord through
delta ring hanger and hook on cabin bulkhead. Turn battery switch to OFF. Drain all fuel
from cell.
f. S n a p c e l l - h o l d i n g s t r a p s t o s t u d s o n
aft cabin bulkhead and transmission support a. Remove bolts (23, figure 10-17) and wash-
structure. ers (22) from adapter (21).
g. Remove cover over fuel lines access on top b. Remove jumper (18) from adapter (21)
of cabin floor; remove caps from all lines and
plugs. c. Lift adapter (21) from fuel cell and remove
lanyard (19) from cell.
h. Connect electrical connector and four lines
from cell. d. Remove cap assembly (24) and packing (20)
from adapter (21)
i. It will be necessary to check transmission
10-173. Replacement — Filler Cap — Auxiliary
oil level by use of mirror when auxiliary fuel cell is
installed.
a. Replace filler cap assembly (24, figure
10.167. FUEL GUAGE — AUXILIARY
10-17) if unserviceable.
FUEL CELL — C R A S H W O R T H Y .
10-174. Installation — FilIer Cap — Auxiliary
10-168. Removal — Fuel Gage — Auxiliary Fuel Cell — Crashworthy. a. Place packing
Fuel Cell — Crashworthy. (20, figure 10-17) on adapter (21).
NOTE .
b. Place end of lanyard (19) into fuel cell
Turn battery switch to OFF. Drain all
fuel from cell. c. Place adapter (21) on fuel cell and align
mounting holes
a. Remove bolts (13, figure 10-17) and
washers (14). d. Secure adapter (21) and jumper (18) to fuel
cell with washers (22) and bolts (23). Torque bolts (23)
b. Remove fuel gage (15) from fuel cell and 23 To 55 inch pounds
remove packing (16) from fuel gage.
WARNING
10-169. Replacement — Fuel Gage — Auxili-
ary Fuel Cell — Crashworthy. Replace fuel gage Failure to install required jumper (18)
(15, figure 10-17) if unserviceable. could result in a potential fire hazard.
10-53
218-260 0- 88 - 11
T M 55-1520-210-23-2
NOTE e. Place cover plate (25) over cell opening and

aligm mounting holes
Place jumper (18) under head of nearest
bolt (23). f. Secure cover plate (25) with washers (26) and
bolts (27) Torque bolts (27) 45 TO 55 inch pounds,
10-175. SHUTOFF VALVE — AUXILIARY
FUEL CELL — CRASHWORTHY.
10-179. REFUEL RECEIVER — AUXIL-
10-176. Removal — Shutoff Valve — Auxiliary IARY FUEL CELL — C R A S H W O R T H Y .
10-180. Removal — Refuel Receiver — Auxil-
iary Fuel Cell — Crashworthy.
NOTE
Turn battery switch to OFF. Drain all fuel NOTE
from cell. Turn battery switch to OFF. Drain all fuel
from cell.
a. Remove bolts (27, figure 10-17) washers
(26) from cover plate (25) on top of fuel cell.
a. Remove bolts (9, figure 10-17) and washers
b. Lift cover plate (26) from fuel cell and (8) from refuel receiver (27). Place jumper (17)
disconnect hose assembly (6) from shutoff valve (4). away from refuel receiver (7).
c. Remove cover plate (25), shutoff valve (4) and b. Remove refuel receiver (7) from fuel cell and
packing (5) from cell. Tie hose assembly (6) to top of packing (12) from refuel receiver (7)
cell
NOTE c. Remove cap assembly (11) from refuel
receiver (7) by Iifting flap and turning cap
Cover opening in cell to avoid counterclockwise. Open retaining pin on lanyard (10)
contamination. and remove cap
d. Remove bolts (1) and washers (2) from top 10-181. Replacement — Refuel Receiver —
center of cover plate (25) while holding shutoff valve Auxiliary Fuel Cell — Crashworthy. R e p l a c e
(4) cap assembly (11, figure 10-17) if unserviceable. If
refuel receiver (7) is unserviceable replace refuel
e. Remove shutoff valve (4) and gasket (3) from
receiver (7).
cover plate (25),
10-182. Installation — Refuel Receiver — A U X-
10-177. Replacement — Shutoff Valve — Aux-
iliary Fuel Cell — Crashworthy.
iliary Fuel Cell — Crashworthy. Replace shut-
off valve (4, figure 10-17) if unserviceable.
a. Place refuel receiver (7) in fuel cell, align bolt
holes, place jumper (17) under nearest bolt and
10-178. Installation — Shutoff Valve — Auxil-
secure refuel receiver (7) to fuel cell with bolts (9) and
iary Fuel Cell — Crashworthy. a. Place gasket washers (8) Torque bolts (9) 45 TO 55 inch pounds
(3, figure 10-17) and shutoff valve (4) on bottom
of cover plate (25) with hose connection pointing
outboard and mounting holes aligned. WARNING
Failure to install required jumper (17)
b. Secure shutoff valve (4) to cover plate (25) could result in a potential firehazard.
with bolts (1) and washers (2). Tighten bolts
b. Connect cap assembly (11) to lanyard (10)
c. Place packing (5) in groove around cell
with retaining pin.
opening.
d. Lower shutoff valve (4) enough to allow hose c. Place cap (11) over refuel receiver (7) opening,
assembly (6) to be connected to the shutoff valve (4) rotating clockwise and closing flap
10-54
TM 55-1520-210-23-2
10-183. PUMP ASSEMBLY — AUXIL- 10-185. Replacement — Pump Assembly —

IARY FUEL CELL — CRASHWORTHY. Auxiliary Fuel Cell — Crashworthy. Replace
pump assembly (50, figure 10-17) if unservice-
10-184. Removal – Pump Assembly — Auxil- able.
iary Fuel Cell — Crashworthy. 10-186. Installation — Pump Assembly —
Auxiliary Fuel Cell — Crashworthy. a. P l a c e
NOTE packing (47) in pump assembly (50) discharge
Turn battery switch to OFF. Drain all fuel port. Run nut (46) up on valve (45). Screw valve
from cell. (45) into pump assembly (50) discharge port and
secure with nut (46).
a. Remove hose assembly (35, figure 10-17)
from valve (45) on pump assembly (50). b. Place packing (51) in groove on fuel cell.
Tilt pump assembly (50), push up and in until
b. Disconnect electrical harness (34) at pump assembly is seated and bolt holes are
electrical quick disconnect (33) on existing provisions aligned.
panel (32) c. Place cover (43) over top holes and secure
pump assembly (50) and cover (44) with bolts (42)
c. Removal bolt (40), jumper (41) and washer and washers (43). Install bolts at lower left hole
(39) from pump assembly (50) Remove remaining and go clockwise.
bolts (42) and washers (43) from pump assembly.
d. Secure jumper (41) to pump assembly (50)
Remove cover (44)
with washers (39) and bolt (40). Torque bolts (40
and 42) 45 TO 55 inch pounds.
Pump assembly (50) must be removed

from fuel cell with care to avoid damage
to pump and float switch (38).
Failure to install required jumper (41) could
d. Remove pump assembly (50) by pulling out, result in a potential fire hazard.
tilting pump forward and with a down and outward
movement allow pump to clear the fuel cell opening e. Connect hose assembly (35) to valve (45) and
electrical harness (34) by electrical quick disconnect
e. Remove packing (51) from fuel cell (33) at panel (32).
f. Remove valve (45), nut (46) and packing (47)

from pump assembly (50)
1 0 - 5 5/(10-56 blank)
TM 55-1520-210-23-2
CHAPTER 11
FLIGHT CONTROLS
SECTION I. CONTROL SURFACES
(Not Applicable)
SECTION Il. FLIGHT CONTROL COMPONENTS
11-1. FLIGHT CONTROL SYSTEM.
11-2. Description– Flight Control System. The

flight control system consists of the collective pitch Use of hydraulic ground test equipment,
control system, cyclic control system (pitch and roll), with any flight control tube disconnected,
elevator control system and tail rotor (directional) may result in damage to swashplate,
control system. The flight control systems are scissors and sleeve assemblies.
mechanical linkages, actuated by conventional
controls, and are used to control flight attitude and NOTE
direction.
Before using table 11-1, ensure all normal
The flight control systems are a straight through sys- operational checks have been performed.
tem with hydraulic boost. A synchronized elevator is
linked into the fore and aft control system at the NOTE
swashplate. Electrically operated force trims,
connected to cyclic and tail rotor controls, induce Isolate potential problem areas by
artificial feel and stabilize control stick and tail rotor disconnecting the pilots stick or pedals and
control pedals. the hydraulic actuators from the
interconnecting linkage prior to
11-3. Troubleshooting - Flight Control troubleshooting.
System. Perform troubleshooting of the light control
system in accordance with Table 11-1. NOTE
When installing adjustable tubes
insure that tubes and bearings are
centered and jam nut is tightened
prior to advancing to next step of
the procedure.
Table 11-1. Troubleshooting Flight Control System
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
a. Cyclic System
1. Cyclic stick rough or binding.
STEP 1. Check for dirt or foreign material at base of stick.
Remove boot and clean as required (paragraphs 11-59 and 11-61).
Change 16 11-1
TM 55-1520-210-23-2
Table 11-1. Troubleshooting Flight Control System (Cont)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
STEP 2. Check for interference in control linkage.
Adjust or repair as necessary (paragraph 11-67).
STEP 3. Check for bent control tubes.
Replace rods as necessary (paragraph 11-67).
STEP 4. Check for dry or seized bearings.
Replace bearings as necessary (paragraph 11-185).
STEP 5. Check for binding, loose or torn boots.
Adjust or replace boot (paragraphs 11-59 and 11-61).
STEP 6. Check force gradient assemblies and magnetic brakes for binding.
Adjust or repair force gradient assemblies (paragraph 11-82 through 11-85).
Adjust or repair magnetic brakes (paragraph 11-78).
2. Helicopter drifts to right or left.
Check swashplate for proper rigging.
Rig swashplate (paragraph 11-55).
3. Uneven cyclic application force (boost off).
Check for missing or out of adjustment swashplate balance spring (right forward arm).
Adjust or replace and adjust spring (paragraph 11-55).
4. Insufficient stick travel,
STEP 1. Check for interference in stick base or control linkage.
Repair linkage as necessary (paragraph 11-67).
STEP 2. Check for proper rigging.
Rig as required (paragraph 11-55).
11-2
TM 55-1520-210-23-2
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
5. Pilot and copilot’s sticks out of synchronization.
Check for correct rigging of interconnecting linkage.
Rig adjustable tubes as necessary (paragraph 11-55).
b. Collective System
1. Collective stick light or heavy.
STEP 1. Check minimum friction adjustment of collective stick.
Adjust friction as necessary (paragraph 11-27).
STEP 2. Check for dirt, oil, or grease on friction surface.
Remove boot and check friction surfaces. Clean and adjust as necessary (paragraphs
11-27).
STEP 3. Check control linkage and supports for looseness and damage.
Replace linkage as necessary (paragraphs 11-10, 11-11).
STEP 4. Check balance spring on hydraulic actuator servo for out of adjustment or missing.
Adjust spring as required (paragraph 7-82).
2. High vertical vibration level.
STEP 1. Check minimum friction nut adjustment (causes pilot induced vibration).
STEP 2. Check control linkage and supports for looseness and damage.
3. Insufficient collective travel.
11-3
TM 55-1520-210-23-2
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
STEP 2. Check linkage for correct rigging,
Rig as necessary (paragraph 11-6).
4. Binding or rough operation.
Replace linkage as necessary (paragraphs 11-10 and 11-11).
STEP 2. Check for bent control rods.
Replace rods as necessary (paragraphs 11-10 and 11-11).
STEP 4. Check for binding, torn, or loose boot.
Align or replace boots (paragraphs 11-10 and 11-11).
STEP 5. Check for dirt or foreign matter at base of stick.
Remove boot clean as necessary (paragraphs 11-10 and 11-11).
5. Motoring collective stick (stick is driven from position by feedback from main rotor)
STEP 1. Check minimum friction adjustment.
STEP 2. Check balance spring on hydraulic actuator servo for out of adjustment or missing.
Replace or adjust spring as required (paragraph 7-82).
c. Elevator Control System
1. Elevator loose when cyclic stick is in neutral.
Check for broken or disconnected linkage.
Repair control linkage as necessary (paragraphs 11-176 and 11-177). Adjust linkage as
necessary (paragraph 11-172).
11-4
TM 55-1520-210-23-2
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
2. Elevator loose only when cyclic stick is in forward or aft position.
STEP 1. Check for loose, worn, or damaged linkage supports.
Repair linkage system as necessary (paragraph 11-176).
STEP 2. Check for worn bearings.
3. Elevator position does not correspond to cyclic stick position.
Repair control rods as necessary (paragraphs 11-176 and 11-177). Adjust linkage
as necessary (paragraph 11-172).
STEP 2. Check for correct rigging of controls.
Rig as necessary (paragraph 11-172).
4. Elevator binds or operates rough.
STEP 1. Check for seized bearings.
Replace as necessary (paragraph 11-185).
STEP 2. Check bearing preload.
Adjust as necessary (paragraph 2-293).
d. Tail Rotor Controls
1. Tail rotor pedal adjustment rough or binding.
STEP 1. Check for dirt or foreign material in pedal adjustment linkage.
Clean linkage as necessary. Adjust as required (paragraph 11-110).
2. Tail rotor controls rough or binding.
Check linkage between pedals and power cylinder (figure 11-24) for any Interference
over the full travel range. Adjust as required (paragraphs 11-109 and 11-110).
Change 6 11-5
TM 55-1520-210-23-2
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
Replace damaged tubes as required (paragraph 11-163).
Replace bearings as required (paragraph 11-185).
STEP 4. Check force gradient and magnetic brake for binding.
Adjust as required (paragraph 11-111 for magnetic brake or paragraph 11-113 for force gradient
assembly).
3. Pilots and copilots pedal out of synchronization.
Check interconnecting pushrod (adjustable) for correct rigging,
Rig control linkage as required (paragraph 11 -110).
4. Insufficient pedal travel.
Check for any interference in control linkage.
Rig as required (paragraph 11-111 for magnetic brake or paragraph 11-113 for force gradient
assembly).
5. Controls binding (hydraulic power off).
Check chain and sprocket.
Replace chain or sprocket as necessary (paragraph 11-149).
11-4. COLLECTIVE CONTROL SYSTEM. Movement of either control stick is transmitted through
linkage and hydraulic actuator to main rotor pitch
11-5. Description - Collective Control System. control mechanism, causing helicopter to ascend or
The collective control system (figure 11-1) consists of descend or to remain at constant altitude.
a jackshaft assembly with dual control sticks, push-pull
tubes and bellcranks, and a hydraulic actuator con- The collective hydraulic actuator has an irreversible
netted to a collective lever on swashplate assembly. valve to reduce feedback forces.
11-6 Change 7
TM 55–1520–210–23-2
1. Pilots collective stick 6. Control arm 12. Control tube 18. Irreversible valve
2. Boot 7. Bearing and housing 13. Bellcrank 19. Actuator tube
3. Control 8. Control assembly 14. Control tube 20. Collective sleeve lever
4. Power control (throttle) 9. Elbow 15. Support 21. Spring
interconnect tube 10. Control tube 16. Hydraulic actuator 22. Stop
5. Jackshaft assembly 11. Lever 17. Servo valve
Figure 11 – 1. Collective Control System.
Change 6 11–7
TM 55-1520-210-23-2
11-6. Rigging - Collective Control System. provides mounting for the collective stick assemblies and
a. Rig system with control sticks, jackshaft attachment of collective control tube. The jackshaft is
assembly and all nonadjustable control tubes and mounted on structural members by two housing
bellcranks installed and connected. assemblies and a support (figure 11-2).
NOTE 11-9. Adjustment - Collective Jackshaft (installed).
Check that stop (22, figure 11-1, view NOTE
B) is firmly against nut. Adjustment of collective minimum
b. Place collective control stick full UP against stop friction Is contained In paragraph 11-
and secure with friction adjustment knob. 27. 11-10. Inspection - Collective
c. Adjust control tube (14) to fit attachment point on Jackshaft (Installed).
lever of servo valve (17), with hydraulic actuator (16) a. Inspect jackshaft for free travel and excessive
bottomed full up and control valve lever at top of travel lateral looseness. Minimum chuck is 0.005 inch.
(view B). Shorten tube by one-half to five turns of rod b. Inspect jackshaft for loose, missing or improperly
end and attach to valve lever with bolt, washers and nut installed hardware.
Torque nut to 25 inch-pounds maximum (bolt must turn c. Inspect bolt and bushing installations for
freely) and install cotter pin, no clamp-up allowed. enlarged holes and looseness of bolt and bushing.
d. Inspect jackshaft for external surface corrosion.
11-11. Removal - Collective Jackshaft.
A measurement other than the Low

Pitch dimensions (view A, figure 11-1)
may cause engine RPM to build Take precautions against damage by
greater than 6600 + 40 from full Low accidental movement of linkage while
Pitch to full Power. Jackshaft is disconnected.
d. Place collective control stick full DOWN against a. Remove pilots and copilots seats (paragraph 2-
stop. Position collective sleeve lever (20) to obtain 218 or 2-249).
dimension of 2.39 TO 2.45 inches from center of cam b. Remove boot (42, figure 11-2) from pilots
roller to transmission cap plate surface (view A). collective control stick (34) (detail A, sheet 2).
e. Position control valve in neutral (view B). Use c. Disconnect electrical connector from pilots
auxiliary hydraulic power if available. Adjust clevis on collective stick.
actuator tube (19) to fit trunnion on collective sleeve lever d. Disconnect control tube (46) from gear lever on
and connect. Torque jamnut and seal area (figure 7-12). lower end of pilots collective stick by removing cotter pin
Lockwire (C155) nut. (43), nut (44), washers (45), and bolt (47). Disconnect
f. Check for free travel of collective controls with control tube (22) from both levers by removing nuts (17
hydraulic boost pressure off. Insure collective levers do and 26), washers (2 and 18), and bolts (1 and 19).
not bottom on swashplate assembly attaching bolts. If Disconnect control tube (10) by removing cotter pin (11),
levers do make contact, inspect for damage (figure 5-41) nut (12), washers (9), bolt (8). Disconnect jackshaft tube
and reran system, paragraph 11-6a thru e. (20) by removing nuts (21 and 25), washers (2 and 15),
g. Apply hydraulic boost pressure and check for tapered bushings (4 and 16), and bolts (3 and 14).
1.31 inches total travel of collective pitch sleeve (view A). e. Remove nuts (37 and 39), washers (36 and 40),
h. Check main rotor minimum pitch angle screws (41), and bolts (35) attaching housing assembly
(paragraph 5-13,0). (38) to structural intercostal. Remove pilots collective
i. Inspect complete collective control system for stick (34) and housing assembly (38) (detail B, sheet 2).
security of parts.
11-7. COLLECTIVE JACKSHAFT.
11-8. Description - Collective Jackshaft. A
collective jackshaft, mounted laterally under cabin floor,
11-8 Change 10
TM 55-1520-210-23-2
1. Bolt 16. Tapered bushing

2. Washer 17. Nut
3. Bolt 18. Washer
4. Tapered bushing 19. Bolt
5. Jackshaft tube 20. Jackshaft tube
6. Bolt 21. Nut
7. Washer 22. Tube assembly
8. Bolt 23. Support
9. Washer 24. Arm
10. Control tube 25. Nut
11. Cotter pin 26. Nut
12. Nut 27. Washer
13. Nut 28. Screw
14. Bolt 29. Downlock assembly
15. Washer
Figure 11-2. Collective Jackshaft (Sheet 1 of 3)
11-9
TM 55-1520-210-23-2
30. Switch box 40. Washer

31. Cover 41. Screw
32. Throttle friction knob 42. Boot
33. Collective friction knob 43. Cotter pin
34. Pilots collective stick 44. Nut
35. Bolt 45. Washer
36. Washer 46. Control tube
37. Nut 47. Bolt
38. Housing assembly 48. Straw
39. Nut
11-10
TM 55-1520-210-23-2
49. Co-pilots collective stick 56. Nut

50. Boot 57. Washer
51. Nut 58. Control assembly
52. Washer 59. Bolt
53. Nut 60. Bolt
54. Housing assembly 61. Screw
55. Bolt 62. Shim
f. Remove copilots collective stick (49, detail C, (3) Remove nuts (21), washers (15), four
figure 11-2) as follows: tapered bushings (16), and bolts (14) attaching
(1) Remove access panel from floor. jackshaft tubes (5 and 20) to arm (24). Identify bolts
and bushings for reinstallation in same location.
(2) Remove housing (54) from intercostal Remove jackshaft tube (20) from left side of helicopter
structure (detail C, sheet 3) by removing nuts (51 with control assembly (58).
and 53), washers (52), shim (62), and bolts (55
(4) Remove nuts (25), washers (2), tapered
and 59).
bushings (4), and bolts (3) attaching jackshaft tube (5)
(3) Remove bolts (60), washers (57) and nuts to housing assembly (38, detail A). Identify bolts and
(56). bushings for reinstallation in same location. Remove
jackshaft tube (5).
(4) Remove copilots stick (paragraph 11-28). (5) Remove nuts (13), washers (7), and bolts
g. Remove collective jackshaft tube as follows: (6) and remove support assembly (23).
11-12. Disassembly — Collective Jackshaft
(1) Disconnect control tube (10) from arm (24)
(AVIM). a. Remove control assembly (58, figure 11-2)
on jackshaft by removing cotter pin (11, nut (12),
if not previously removed by removing bolts (55 and
washers (9), and bolt (8). 59), washers (52) and nuts (51 and 53) attaching
(2) Remove nuts (51 and 53), washers (52), control assembly to jackshaft tube (20).
bolts (55 and 59), and shim (62) attaching housing b. Remove lever arm (24) (if not previously
(54) to intercostal structural member (detail C, sheet removed) from jackshaft tube (5) by removing bolts
2). (3), washers (2), bushings (4), and nuts (25) attaching
lever arm (24) to jackshaft tube (5).
Change 2 11-11
TM 55-1520-210-23-2
11-13 Inspection – Collective Jackshaft. a. 11-16. Installation – Collective Jackshaft.

Inspect jackshaft details for corrosion and me-
chanical damage. NOTE
N O T E If collective sticks and jackshaft are in
If alignment of holes in pilots collec- one assembly; remove bolts and
tive stick elbow P/N 204-001-194-3 bushings from jackshaft tubes (5 and 20,
and jackshaft tube P/N 204-001- figure 11-2).
109-1 cannot be obtained by ream- a. Apply a coat of primer (C312) or polyam-
ing to accept oversized tapered ide primer (C206) to mounting faces of housing
bushing, replace jackshaft tube. assembly (38 and 54, figure 11-2), and support
11-14. Repair or Replacement – Collective assembly (23).
Jackshaft (AVIM). a. Repair components of b. Lower pilots control stick through floor
jackshaft as follows opening and insert elbow through mounting hole of
structural intercostal. Attach housing assembly (38)
(1) Polish out scratches (maximum 0.010 to intercostal with screws (41), bolts (35), washers
inch depth) using 600 grit sandpaper (C234). (36 and 40), and nuts (37 and 39). Torque nuts 50 TO
Obtain a smooth scratch free surface 70 inch-pounds
c. Install tube (5) to housing assembly (38).
(2) Treat repaired areas using chemical
Secure with tapered bushings (4), nuts (25), washers
film (C62). (2), and bolts (3) Torque nuts 50 TO 70 inch-pounds.
(3) Apply two coats zinc chromate primer See detail B for correct tapered bushing installation.
(C312) or polyamide primer (C206) to repaired
area. d. Install arm (24) to jackshaft tube (5) with bolts,
1 1 - 1 5 . Assembly – Collective Jackshaft tapered bushings, washers, and nuts as in step c.
(AVIM). a. Assemble details as shown in figure Torque nuts 50 TO 70 Inch-pounds
11-3
e. Position support (23) on left side beam at B.L.
b. Clamp in a suitable fixture, holding 14.00. Secure with bolts (6), washers (7), and nuts
dimensions shown (13) Torque nuts 50 TO 70 Inch-pounds
f. Install jackshaft tube (20) and housing

c. Drill through tube and detail being replaced
assembly (54) from left side. Place shim (62) between
using a No. F (0.257 inch) drill
housing assembly (54) and support structure. Install
bolts (55 and 59), washers (52), and nuts (51 and 53)
d. Insert reamer, (187) so that end of pilot
to secure housing assembly (54) to support structure.
projects through parts to be reamed.
Torque nuts 50 TO 70 Inch-pounds
e. Ream one side (smooth finish) g. Install bolts (14), tapered bushings (16),
washers (15), and nuts (21) in jackshaft tube (20) and
f. Install tapered bushing in reamed hole arm (24). Torque nuts 50 TO 70 inch-pounds. See
detail B for correct tapered bushing Installation
g. Ream opposite hole using the tapered
bushing to support reamer pilot h. Check lateral alignment of universal in
housing assembly (54) and remove or add shims (62)
h. Install tapered bushings and secure with bolt, to provide minimum lateral deflection
washer and nut.
i. Repeat steps c through h for the remaining i. Align levers on axis of each housing
assembly. Install control tube (22). Install bolt (19) on
holes.
j. Disassemble, remove burrs and metal left end (copilots) with head down. Install bolt (1) on
particles. right side (pilots) with head up. Place one washer (2)
under bolt heads and one washer under nuts (17) and
k. A p p l y primer (C312) or polyamide primer 26). Torque nuts 20 TO 25 inch-pounds and install
(C206) to all bare metal. cotter pins.
11-12
TM 55-1520-210-23-2
VIEW A-A VIEW B-B

1. Drill four no. F (0.25 inch) holes in line. 2. Drill eight no. F (0.25 inch) holes in line
Taper ream (T87) holes, 125 finish. Taper ream (T87) holes, 125 finish,
Install Install
Tapered bushing (79B1-4-7 or 20-037-4-7) (4 reqd) Tapered bushing (79B1-4-5 or 20-037-4-5) (8 reqd)
Bolt (2 reqd) Bolt (4 reqd)
Washer (4 reqd) Washer (8 reqd)
Nut (2 reqd) Nut (4 reqd)
1. Pilot collective control assembly 6. Bolt

2. Tube Nut
3. Arm Assembly Washer
4. Tube Tapered bushing
5. Copilot collective control assembly 7. Bolt
Nut
Washer
Tapered bushing
Figure 11-3. Collective Jackshaft Repair
Change 4 11-13
TM 55-1520-210-23-2
j. Connect control tube (46) to pilots collective h. Slide elbow assembly (10) out of support
stick with bolt (47), washers (45) and nut (44). assembly (3).
Torque nut 7 TO 12 inch-pounds and install cotter
pin (43). i. Remove spirolox (1) securing bearing (2) to
support assembly (3) Remove bearing (2).
k. Connect electrical connector to receptacle and
lockwire (C155. Install boot (42) using screws (48). j Refer to paragraph 11-185 for removal of
bushings (4 and 22), sleeve (11) and bearings (5, 12
and 23) from support assembly (3)
l. Install copilots collective stick in control
assembly elbow (58). 1 1 - 2 1 . Inspection — Control Assembly –
Collective Jackshaft (AVIM) a. Inspect all parts
m. Install bolts (60), with bolt heads up wash-
of control assembly for wear, damage and corrosion
ers (57) and nuts (56).
n. Adjust collective friction (paragraph 11-27), b. Inspect bearings for binding and damage,
1 1 - 2 2 . Repair or Replacement — Control
o. Attach control tube (10) to arm (24). Install Jackshaft
Assembly – Collective
one washer (9) under bolt head (8) and one washer (9)
(AVIM) a. Replace all defective bearings. Refer to
under nut (12) Torque nut 30 TO 40 inch-pounds
paragraph 11-185 for bearing replacement.
and Install cotter pin (11).
b. Replace all parts that show evidence of wear,
p. Check collective rigging (paragraph 11-6)
damage and corrosion
11-17, CONTROL ASSEMBLY – 1 1 - 2 3 , Assembly – Control Assembly –
Collective Jackshaft (AVIM) a. Place bearing (2,
COLLECTIVE JACKSHAFT,
figure 11-4) in support assembly (3) and secure with
11-18. Description — Control Assembly — spirolox (1)
Collective Jackshaft. A control assembly (58, figure
b. Install sleeve (11), bushings (4 and 22) and
11-2) is mounted on left side of the collective
bearings (5, 12 and 23), in support assembly (3),
jackshaft The control assembly provides for
mounting of the copilots collective stick and transmits c. Slide elbow assembly (10) into support
copilots throttle motion to control tube (22) which is assembly (3)
Interconnected to pilots throttle control.
d. Install key (9) in slot at bottom of drive
1 1 - 1 9 , Removal — Control Assembly – assembly (8)
Collective Jackshaft. Refer to paragraph 11-11
e. Install shim (13), guide (7), and drive assembly
11-20, Disassembly — Control Assembly — (8) in elbow assembly (10)
Collective Jackshaft (AVIM). a. Remove cotter
pin (27, figure 11-4), nut (26), and washer (25) f. Slide pinion (21) on drive assembly (8) and
secure with washer (15) and nut (16).
b. Remove nut (18), washer (17), screw (14).
Slide shaft (24) from support assembly (3) and lever NOTE
(20)
If unable to adjust shim (13) to required
c. Remove lever (20) and shim (19) from support
friction, adjust shim (19) to provide re-
assembly (3)
quired friction.
d. Remove nut (16) and washer (15) attaching
pinion (21) to drive assembly (8), g. Position lever (20) and shim (19) between
bearings (5 and 23) and insert shaft (24) through bear-
e. Remove pinion (21 ) from drive assembly (8). ings (5 and 23), shim (19), and lever (20). Align hole in
lever and shaft and install screw (14), washer (17),
f. Remove shim (13), guide (7), and drive and nut (18). Install washer (25) and nut (26) on shaft.
assembly (8) from elbow assembly (10). Check for a 0.50 TO 1.50 pounds pull at end of lever
(20). to rotate lever. Add or remove shim (13), as re-
g. Remove key (9) from slot in drive assembly (8). quired, to provide for 0.50 TO 1.50 pounds friction.
Secure nut (26) with cotter pin (27).
11-14 Change 5
TM 55-1520-210-23-2
11-32. Assembly - Pilots Collective Stick a.1. Slide tube (4) onto inner tube against connec-
tor or laminated friction washer. Install friction nut (3)
NOTE and bearing (2) on tube assembly. Secure with retainer
ring (1).
If shoes (11) have been removed, assure
the hole in pin (15) has been engaged by b. Slide throttle grip (33) onto tube assembly;
pin (16) upon reassembly. Also ensure align holes in grip with hole in throttle shaft, and install
that pins (9) are secured by cotter pins pin (34).
(7).
c. Install nut (30), steel washer (29), rubber
a. If inner tube (35, figure 11-6) was replaced, washer (28), and steel washer (27), in that order.
place new tube in elbow (20), install nut (36), torque at
500 to 600 inch-pounds and lockwire with 0.032 corro- d. Position switch box (26) on tube (4). Align holes
sion-resistance wire. and install pin (24).
Change 7 11-19
TM 55-1520-210-23-2
1. Collective Stick Grip 5. Connector

2. Friction Nut 6. Washer
3. Stick Assembly 7. Washer
4. Setscrews 8. Nut
9. Friction Laminated Washer
Figure 11-5. Collective Friction Adjustment-Pilots Collective Stick
e. Install switch box cover and secure with screws

(25).
f. Connect drag link (10) to pin (6), Secure with cotter

pin (7).
g. Secure cable (5) to collective stick at bracket and in-

stall clamp.
11-33. Installation - Pilots Collective Stick. a. Position

stick assembly (34, figure 11-2) in place and secure to
airframe using bolts (35), washers (36 and 40), nuts (37
and 39), and screws (41), Refer to paragraph 11-16.
b. Deleted.
Figure 11-5.1. DELETED

11-20 Change 7
TM 55-1520-210-23-2
28. Non-metallic washer

1. Retaining Ring 10. Drag Link 19. Support
29. Washer
2. Bearing 11.Friction-Shoes 20. Elbow
30. Throttle Friction Nut
3. Collective Friction Nut 12. Nut 21. Retaining Ring
22. Washer 31. Nut
4. Tube 13. Washer 32. Washer
5. Cable Assembly 14. Housing 23. Pocking
24. Pin 33. Throttle Grip
6. Pin 15. Pin
25. Screw 34. Pin
7. Cotter Pin 16. Pin
26. Switch Box 35. Innertube
8. Jackshaft Tube 17. Bolt
27. Washer 36. Nut
9. Pin 18. Washer
Figure 11-6. Pilots Collective Stick Exploded View
11-21
TM 55-1520-210-23-2
c. Deleted. c. Inspect all parts for thread damage.
d. Deleted. d. Inspect bearings for looseness and binding.

Replace defective bearings.
e. Deleted.
NOTE
f. Deleted.
Bearings (10), (19) and bushing (11) figure 11-7,
are not required on grip assembly PN 205-001-
11-34. COPILOTS COLLECTIVE STICK. 119-1.
11-35. Description - Copilots Collective Stick. The
copilots collective stick (left side provides same collective 11-39. Assembly - Copilots Collective Stick. (AVIM) a.
and throttle control as pilots collective stick. The copilots Insert tube assembly (20, figure 11-7) into stick assembly
collective stick is mounted to an elbow on control assemb- (18). Install grip assembly (8) onto stick assembly (18).
ly attached to left side of collective jackshaft.
b. Align holes in grip assembly (8) with slot in stick as-
11-36. Removal - Copilots Collective Stick. a sembly.
Remove screws (61, figure 11-2) and remove boot (50).
c. Install screw (9) and washers (21).
b. Remove bolts (60), washers (57), and nuts (56) at-
taching stick assembly to elbow. d. Assemble switch box (5) to top of stick assembly. in-
stall nut (4).
c. Disconnect electrical plug from airframe mounted
receptacle. e. Attach conduit (7) to stick assembly, using pin (6),
switch box (5) and conduit (7).
d. Disengage stick assembly (49) from drive assemb-
ly. Remove stick assembly. f. Install cover (3) using screws (1) and washers (2).
11-37. Disassembly - Copilots Collective Stick.
(AVIM) a. Release clamps (13 and 17, figure 11-7) at bot- g. Attach cable assembly to stick using two clamps (13
tom of stick assembly by removing screw (12), washer and 17), screw (12), washer (15) and nut (16).
(15) and nut (26).
11-40. Installation - Copilots Collective Stick. a.
Install stick assembly (49 figure 11-2) to elbow and control
b. Remove four screws (1) and washers (2) securing
assembly (58), engaging stick to control guide.
switch box cover (3) to switch box (5).
b. Install two bolts (60), washers (57), and nuts (56).
c. Drive out pin (6), remove nut (4) and remove switch
box (5) from stick assembly (18).
c. Install boot assembly (50) Secure boot to cabin floor
d. Remove conduit (7) from stick assembly (18). with screws (61).
d. Connect electrical plug to airframe receptacle.

e. Remove screw (19) and washers (21). Remove grip
assembly (8).
11-41. CONTROL TUBES COLLECTIVE
f. Slide tube assembly (20) from stick assembly (18). CONTROL SYSTEM.
11-42. Description - Control Tubes Collective Con-
11-38. Inspection - Copilots Collective Stick: a. trol System. Adjustable and nonadjustable
Inspect parts for nicks, scratches and wear. Replace control tubes are used in the collective con-
damaged parts. trol system. The non-adjustable type is fitted
with
b. Inspect all detail pails for corrosion. Replace parts
that have corrosion.
11-22 Change 5
TM 55-1520-210-23-2
1. Screw 8. Grip 15. Washer

2. Washer 9. Screw 16. Nut
3. Cover 10. Bearing 17. Clamp
4. Nut 11. Bushing 18. Stick assembly
5. Switch box 12. Screw 19. Bearing
6. Pin 13. Clamp 20. Tube assembly
7. Conduit 14. Electrical plug 21. Washer
Figure 11-7. Copilots Collective Stick – Exploded View
11-23
TM 55-1520-210-23-2
bonded and riveted clevis ends. The adjustable type has 11-44. Inspection — Control Tubes — Collective
a threaded clevis end and locknut which secures clevis Control System.
end.
a. Inspect control tubes (6, 10 and 19, figure 11-8)
11-43. Removal — Control Tubes — Collective Con- for corrosion, wear, and mechanical damage. See figure
trol System. 11-9for wear and damage limits. If a crack in the support
a. Remove access doors (39, 65, 69, 70, 71, 72, 73, tubes is suspected, refer to TM 1-1520-256-23, Techni-
and 79, figure 2-18) as required. cal Manual Aviation Unit Maintenance (AVUM) and Avi-
ation Intermediate Maintenance (AVIM) manual nonde-
b. Detach end of control tube (6, figure 11-8), from structive inspection procedures for UH-1 helicopter
torque tube lever (1) by removing cotter pin (5), nut (4), series.
washers (3), and bolt (2).
c. Detach opposite end of control tube (6) from lever b. Inspect clevis end holes for wear and clevis end
(13) by removing cotter pin (5), nut (8), washer (3), and for looseness in tube.
bolt (7).
d. Detach end of control tube (10) from lever (13) by
removing cotter pin (5), and nut (11), washers (3), and 11-45. Repair or Replacement — Control Tubes —
bolt (9). Collective Control System (AVIM).
e. Loosen and slide clamp (26) forward off boot.
Detach opposite end of control tube (10) from bellcrank a. Polish out corrosion or mechanical damage to
(23) by removing cotter pin (5), nut (24), washer (3), and control tubes (repair areas only) in accordance with limits
bolt (25). in figure 11-9.
f. Detach end of control tube (19) from bellcrank
b. Any damage to swage transition area or damage
(23) by removing cotter pin (5), nut (18), washers (3), and
bolt (20). in repair areas that is in excess of limits is cause for
replacement of tube assembly.
g. Detach opposite end of control tube (19) from
collective hydraulic actuator by removing cotter pin, nut,
washers and bolt. 11-46. Installation — Control Tubes — Collective
Control System.
Premaintenance Requirements for Control Tubes a. Attach end of control tube (6, figure 11-8) to arm
Collective Control System on torque tube lever (1) and install bolt (2), washers (3),
nut (4), and cotter pin (5).
Model All b. Attach opposite control tube (6) to lever (13) and
Part No. or Serial No. All install bolt (7), washers (3), nut (8) and cotter pin (5).
Special Tools None
c. Attach opposite end of control tube through boot.
Test Equipment Eddy Current Inspection (See detail C.) Position forward end of control tube (10)
Unit to lever (13). Install bolt (9), washers (3), nut (11) and
Support Equipment None cotter pin (5).
Minimum Personnel Two d. Attach end of control tube (10) to bellcrank (23).
Required Install bolt (25), washers (3), nut (24) and cotter pin (5)
Consumable Materials None (detail C).
Conditions e. With collective stick full down, position boot con-
trol on tube (10) so that end of boot is 7.90 inches from
References TM 1-1520-256-23 bulkhead. Install clamp (26) on boot and tighten.
11-24 Change 14
TM 55-1520-210-23-2
f. Attach end of control tube (19) to bellcrank (23). cranks, levers and supports are incorporated in the col-
Install bolt (20), washers (3), nut (18) and cotter pin (5). lective control system. The supports are airframe
mounted and provide a pivot mount for levers and bell-
g. Attack control tube (19) to hydraulic actuator dur-
cranks.
ing rigging of collective control system.
h. Rig system (paragraph 11-6). 11-49. Removal — Bellcranks, Levers and Supports
i. Install access doors (39, 65, 69, 70, 71, 72, 73 and — Collective Control System.
79, figure 2-18) as required. a. Remove lever (13, figure 11-8) from bracket as
follows:
11-47. BELLCRANKS, LEVERS AND SUPPORTS —
COLLECTIVE CONTROL SYSTEM. (1) Remove access door (73, figure 2-18).
11-48. Description — Bellcranks, Levers and Sup- (2) Disconnect control tubes (6 and 10, figure
ports — Collective Control System. Various bell- 11-8) from lever (13).
Change 14 11-24.1/(11-24.2 blank)

TM 55-1520-210-23-2
1. Lever 4. Nut
2. Bolt 5. Cotter pin
3. Washers 6. Control tube
Figure 11-8. Collective Control System (Bellcranks, Levers, Supports, and Control Tubes) –
11-25
TM 55-1520-210-23-2
7. Bolt 14. Bolt 21. Bolt

8. Nut 15. Nut 22. Bolt
9. Bolt 16. Nut 23. Bellcrank
10. Control tube 17. support 24. Nut
12, Nut 19. Control tube 26. Clamp
13. Lever 20. Bolt
Figure 11-8. Collective Control System (Bellcranks, Levers, Supports, and Control Tubes) —
11-26
TM 55-1520-210-23-2
NOTES:
1. Maximum mechanical and corrosion limits for all three tubes is 0.005 inch after clean-up.
2. No damage in shaded areas.
3. No cracks allowed.
Figure 11-9. Wear and Damage Limits (Control Tubes) Collective Control System
(3) Remove cotter pin (5), nut (12), two wash- Special Tools None
ers (3) and bolt (14) from bracket and lever (13). Remove
lever (13). Test Equipment Eddy Current Inspection
b. Remove bellcrank (23) and support (17) as fol- Unit
lows: (Detail C) Support Equipment None
(1) Remove cargo hook (paragraph 14-285).
(2) Disconnect control tubes (10 and 19) (See Required
Detail C.) from bellcrank (23).
(3) Remove cotter pin (5), nut (15), two wash-
ers (3) and bolt (21) from support (17) and remove bell- Special Environmental None
crank (23). Conditions
(4) Remove four nuts (16), eight washers (3)
and four bolts (22) from support (17) and remove support
(17).
Premaintenance Requirements for Bellcranks,

Levers, and Supports Collective Control System 11-50. Inspection — Bellcranks, Levers and Sup-
ports — Collective Control System.
Model All
a. Inspect bellcranks, levers and supports for loose
Part No. or Serial No. All bearings. Refer to paragraph 11-185 for bearing limits.
Change 14 11-27
TM 55-1520-210-23-2
b. Inspect bellcranks, levers and supports for corro- 11-53. CYCLIC CONTROL SYSTEM.
sion and mechanical damage. See figure 11-10 for in-
spection limits. If a crack in the Bellcranks, Levers, or 11-54. Description — Cyclic Controls. A system of
Supports is suspected, refer to TM 1-1520-256-23, Tech- linkage (figure 11-11) transmits movement from cyclic
nical Manual Aviation Unit Maintenance (AVUM) and Avi- control sticks to swashplate which actuates rotating con-
ation Intermediate Maintenance (AVIM) manual nonde- trols to main rotor, controlling direction of helicopter.
structive inspection procedures for UH-1 helicopter Fore-aft lateral control are independent linkages from
series. control stick to an intermixing bellcrank. From this point
on the swashplate horns, linkage cannot be considered
11-51. Repair — Bellcranks, Levers and Supports — separately as to effect. Two hydraulic power cylinders
Collective Control System (AVIM). are incorporated to reduce effort required for control and
to reduce feedback forces from main rotor. Two force
a. Replace loose or damaged bearings in bell- gradient units, with magnetic brakes, are incorporated
cranks, levers and supports. Refer to paragraph 11-185 for artificial control feed and stabilization of controls.
for bearing replacement.
b. Remove minor surface corrosion or repair dam- 11-55. Rigging — Cyclic Controls.
age areas using fine grit sandpaper (C233). Observe
limits shown in figure 11-10. CAUTION
(1) Treat repaired areas with chemical film
(C62). Use of hydraulic ground test equipment,
with any flight control tube disconnected,
(2) Paint repaired area using primer (C312). may result in damage to swashplate, scis-
sors and sleeve assemblies.
11-52. Installation — Bellcranks, Levers and Sup-
ports — Collective Control System.
a. Install lever (13, figure 11-8). Position lever (13) Premaintenance Requirements for Rigging Cyclic
into bracket of cabin structure and install bolt (14), wash- Controls
ers (3), and nut (12). Install cotter pin (5).
b. Install bellcrank (23) and support (17) as follows:
Model All
CAUTION Part No. or Serial No. All
Special Tools (T32)
Ensure that bellcrank (23) and support Test Equipment None
(17) are positioned properly prior to instal-
lation. (See detail C.) Support Equipment Maintenance Work
Stands
(1) Install separation tape (C278) (overlapping
edges 1/4 inch) to support (17). Minimum Personnel Two
Required
(2) Install washers (3) on bolts (22).
Consumable Materials (C59), (C113), (C177),
(3) Apply primer (C312) to bolts (22) and install (C155), (C231), (C278),
bolts (22), support (17), washers (3) and nuts (16) (C312)
through support to cabin structure. (See detail C.)
(4) Position bellcrank (23) as shown in detail C Conditions
to support (17) and install bolt (21), washers (3) and nut
(15). Secure nut (15) with cotter pin (5). a. Rig system with control sticks, jackshaft, bell-
(5) Install control tube assemblies (10 and 19) cranks, and all nonadjustable tubes installed and con-
to bellcrank (23). nected (paragraph 11-100).
b. Place and hold both cyclic control sticks in either
(6) Install cargo hook (paragraph 14-289).
extreme right or left lateral position against stops. Adjust
(7) Install access door (73, figure 2-18). tube (6, figure 11-11) to fit and connect.
11-28 Change 14
TM 55-1520-210-23-2
TYPE OF DAMAGE
MECHANICAL DAMAGE
(AFTER CLEAN-UP) 0.015 IN. 0.010 IN. 0.005 IN.
CORROSION DAMAGE
(BEFORE CLEAN-UP) 0.0075 IN. 0.005 IN. 0.0025 IN.
MAXIMUM AREA PER

FULL DEPTH REPAIR 1 IN. SQ 0.10 IN. SQ. 0.10 IN. SQ.
NUMBER OF REPAIRS ONE PER AREA ONE PER AREA ONE PER AREA
EDGE CHAMFER 0.05 BY 0.05 0.04 BY 0.04
BORE DAMAGE 0.002 IN. FOR ONE-FOURTH CIRCUMFERENCE
NO CRACKS ALLOWED
ALL DIMENSIONS IN INCHES UNLESS OTHERWISE SPECIFIED
Figure 11-10. Wear and Damage Limits (Bellcranks, Levers, and Supports) –
Collective Control System
11-29
218-260 0 - 88 - 12
TM 55-1520-210-23-2
11. Lever
1. Control tube-Fore Aft 21. Control tube
12. Control tube
2. Cyclic Control Stick
13. Control tube 22. Servo Valve
3. Control tube-Lateral 23. Support
4. Force gradient-Lateral 14. Matched Link Set
5. Bellcrank 15. Bellcrank 24. Cylinder Assembly
6. Control tube 16. Bellcrank 25. Control tube
7. Control tube Fore Aft 26. Control tube
17. Control tube
8. Cyclic Control Stick 27. Irreversible Valve
18. Control tube
9. Force gradient-Fore Aft 28. Support
19. Bellcrank 29. Cylinder Assembly
10. Control tube 20. Bellcrank 30. Control tube
Figure 11-11. Cyclic Control System
11-30
TM 55-1520-210-23-2
c . Place and hold both cyclic control sticks in j. Remove fixture (T32).
extreme forward or extreme aft position against
stops. Adjust tube (7) to fit and connect. k. Place and hold cyclic stick against forward
stop Place arm of fore-aft magnetic brake against aft
d. Place and hold pilots cyclic stick in extreme stop. Adjust fore-aft force gradient (9) to fit. Extend
aft-left corner position, so that upper arm of bellcrank clevis fitting 3-1/2 turns and connect.
(20) is in its uppermost position. Bottom out piston up-
travel at top of cylinder (24) and set lever of servo
valve in up position (view A, figure 11-11). Adjust l. Check controls for full free travel before
tube (21) to fit, then shorten three full turns and applying hydraulic pressure. Check controls for full
attach to valve lever with bolt, nut, and washers. free travel with hydraulic pressure applied.
Install washer next to bolt head and also next to nut.
Torque nut to 25 Inch-pounds maximum (bolt must m . Check that balance spring (view D, figure 11-
turn freely) Install cotter pin. 11) is hooked over a spacer on a bolt installed through
swashplate control horn. On some swashplates a pin,
e . Place and hold pilots cyclic stick in extreme two washers, and cotter pin are used in lieu of spacer
aft-right corner position, and adjust tube (26) in same and bolt. Hook lower end of spring in proper hole of
manner. Attach tube to valve lever and torque as bracket so that spring does not go slack when
outlined in step (d). swashplate horn is at lowest position. Make final
adjustment as required by flight test
f. Install cyclic stick fixture (T32) on copilots
control stick (view B, figure 11-11). n . Inspect complete cyclic controls system for
security and safetying of parts.
g. Position swashplate according to dimen-
o. Check synchronized elevator for proper
sions with limits shown (figure 11-12). With rigging. Adjust as necessary.
servo valve levers neutral, adjust rod end clevis
on control tubes (25 and 30, figure 11-11) to fit 11-56. CYCLIC CONTROL STICK.
and connect to swashplate horns. Use auxiliary
hydraulic power if available. After final adjust-
11-57. Description - Cyclic Control Stick. Two
ment torque jam nut and seal area (figure 7-12). cyclic control sticks are installed. The grips are
Lockwire (C155) the nut. equipped with a trigger type (2 position)
communications switch, a cargo hook release switch,
and a force trim switch. The control sticks are
h. Check arm of fore-aft magnetic brake for identical except for an adjustable friction on the pilots
alignment of letter “F” opposite scribe mark on shaft stick. Linkage between cyclic control sticks and
and lateral magnetic brake arm for letter “L” opposite swashplate control horns includes push-pull tubes,
mark on shaft. bellcranks, control tubes, two force gradients with
magnetic brakes, and two hydraulic actuators.
i. Place arm of lateral magnetic brake at center
of travel. With cyclic stick in neutral, adjust link on
lateral force gradient (4) to fit and connect.
Change 2 11-31
TM 55-1520-210-23-2
N O T E
11-58. Inspectlon-Cyclic Control Stick (In-
stalled). a. Inspect for binding, full travel and synchro-
nization of pilots and copilots cyclic stick assemblies. Ensure P22J Jumper is inserted into J22 re-
ceptacle, pin E to pin F, when copilots cyclic
b. Inspect friction lock for restriction of cyclic stick stick is removed.
movement and proper release.
a. Remove pilots and copilots seats (paragraph 2-
c. Check boot for cuts, tears, deterioration and miss- 218 or 2-249).
ing, loose or improperly installed hardware.
b. Remove screws (33, figure 11-13) and washers
11-59 Removal-Cyclic Control Stick. (12) to detach boot assembly (32) from floor.
N O T E c. Remove boot assembly (32) from cyclic control

stick (2).
Use this procedure to remove complete stick
assembly, including support and lever. d. Remove access doors (65 and 69, figure 2-18).
DIMENSION A
The dimension A measurement is measured from the
machined surface where the bolts seat to the center
line of the trunion retainer bolt holes.
LEFT HORN RIGHT HORN
13.97 -13.91 1 DEG DOWN LEFT 14.19 - 14.13
13.92 - 13.86 1-1/2 DEG DOWN LEFT 14.23 - 14.18
13.86-13.80 2 DEG DOWN LEFT 14.30 - 14.24
Adjust from 1 degree to 2 degrees down left as
required for satisfactory flight.
Personnel Hoist Rescue Missions Only with Hoist lnstalled
on Right Side of Aircraft:
LEFT HORN RIGHT HORN
13.6 -13.80 2 DEG DOWN LEFT 14.30 - 14.24
13.80-13.74 2.5 DEG DOWN LEFT 14.36 - 14.30
N O T E
Adjust Ieft and right horn from 1 degree to 15
degrees down left with rescue hoist installed on left
side of aircraft.
Figure 11-12. Swashplate Setting Dimensions
11-32 Change 4
TM 55-1520-210-23-2
e. Disconnect cyclic control stick cable plug (31, c. Remove two cotter pins (11) nuts (10)
figure 11-13) from receptacle on structure. washers (12), and bolts (8) attaching support
assembly (9) to gimbal (14) and separate parts
f. Remove cotter pins and nuts (34), washers
(12) and bolts (27) attaching control tube (fore and aft) d. Remove two cotter pins (11) nuts (13).
(35) and control tube (lateral) (28) to lever assembly washers (12), and bolts (21) attaching gimbal (14) to
(26). lever assembly (26) and separate parts.
g. Remove bolts (6) and washers (7) from e. Remove two bearings (22), two bearings (16).
support assembly (9). and shims (23).
h. Remove stick assembly (2) and support

assembly (9). 11-61. Inspection — Cyclic Control Stick (Re-
moved). a. Inspect bearings, (figure 11 -13) for wear
11-60. Disassembly – Cyclic Control Stick. and damage.
a. Remove screw (20, figure 11-13), lock washer (19),
and clamp (18) attaching electric cable (31) to lever NOTE
assembly (26).
For bearing tolerances, refer to
b. Remove cotter pin (11), nut (17), washers (12), paragraph 11-185.
and bolt (24) attaching stick assembly (2) and lever
assembly (26) and separate the parts. b. Inspect bolts for thread damage.
Change 2 11-32.1/(11-32.2 blank)

TM 55-1520-210-23-2
Figure 11-13. Cyclic Control Stick Assembly (Sheet 1 of 2)
11-33
TM 55-1520-210-23-2
1. Rivet 19. Lockwasher

2. Stick assembly 20. Screw
3. Bell 21. Bolt
4. Friction material 22. Bearing
5. Collar 23. Shim
6. Bolt 24. Bolt
7. Washer 25. Bearing and sleeve
8. Bolt 26. Lever assembly
9. Support assembly 27. Bolt
10. Nut 28. Control tube (lateral)
11. Cotter pin 29. Bolt
12. Washer 30. Nut
13. Nut 31. Electrical cable
14. Gimbal 32. Boot assembly
15. Shim 33. Screw
16. Bearing 34. Nut
17. Nut 35. Control tube (fore and aft)
18. Clamp
Figure 11-13. Cyclic Control Stick Assembly (Sheet 2 of 2)
c. Inspect cyclic control stick for loose, missing or

improperly installed hardware.
d. Check boots for cuts, tears, and deterioration.
e. Inspect all components of cyclic control sticks

for nicks, scratches, dents, broken or damaged tubing Cleaning materials are flammable and
and frayed or broken cabling. toxic. Avoid skin contact and breathing of
solvent vapors.
f. Elongation of bolt holes shall not exceed 0.001
inch on the diameter. Score marks on the inside sur- (1) Scrape old sheet felt out of bell and clean
face of the holes maybe polished out for one fourth of with methyl-ethyl-ketone (C177).
the circumference of the hole, if the depth of the score
is 0.002 inch or less. (2) Apply cement (C59) to new friction material
and install in bell (3).
11-62. Repair or Replacement - Cyclic Control
Stick d. Replace all parts that do not appear suitable for
continued use.
N O T E 11-63. Assembly - Cyclic control Stick
Do not attempt to repair any damaged
components.
NOTE
Bolt heads (21, figure 11-13) must be

a. Replace bearings if worn, rough, or damaged installed inboard for step a.
(figures 11-13 and 11-14).
b. Replace electrical wires if frayed or broken. a. Attach gimbal (14) to lever assembly (26) by
installing two bearings (22), shims (23), and inserting
c. Replace sheet felt (C113), (4, figure 11-13) in bolts (21), securing with washers (12), nuts (13), and
bell (3), if worn or damaged. cotter pins (11).
11-34 Change 7
TM 55-1520-210-23-2
NOTE 11-64.3 OPERATION — TRIGGER DETENT MECH-

Bolt heads must be installed outboard for ANISM.
step b.
11-64.4 As the trigger is depressed for “first stage
b. Attach gimbal (14) to support assembly (9) by make” it applies pressure to pin 7 (figure 11-13.9). Pin 7
installing two bearings (16), shims (15), inserting bolts (8) compresses spring 6 which in turn offers resistance to
andsecuring with washers (12), nuts (10), and cotter pins the trigger through pin 7. See figure 11-13.1 for internal
(11). position of trigger detent mechanism components and
NOTE figure 11-13.5 for approximate position of trigger at “first
Insert stick assembly (2) so the fore and stage make.”
aft control tube attachment point is aft
when the assembly is installed in helicop-
ter.
c. Place stick assembly (2) through support assem-
bly (9) into lever assembly (26) and secure by inserting
bolt (24), washers (12), one under bolt head and one
under nut (17) and insert cotter pin (11).
d. Position electrical cable (31) and secure with
clamp (18) by installing screw (20) with lock washer (19).
11-64. Installation — Cyclic Control Stick.

NOTE
Use this procedure to install a stick as-
sembly complete with support and lover. Figure 11-13.1. Internal Position of Trigger Detent
a. Position cyclic control stick (2, figure 11-13) in Mechanism Components for “First Stage Make”
place. Secure support assembly (9) to structure with four
bolts (6) and washers (7).
b. Attach fore and aft (35) and lateral control tubes
(28) to control stick lever (26) with bolts (27, 29) washers After “first stage make,” “peak detent” operation is in-
(12), nuts (34). Secure with cotter pin (11). fluenced by screw 1, spring 3, and ball 4 (figure 11-13.9).
Prior to “peak detent” ball 4 is seated in ball seat of pin
c. Connect and lockwire if applicable control stick 7. See figure 11-13.2 for identification of different areas
electrical cable plug (31) to receptacle on structure below of pin 7.
floor. Check that cable support clamp allows enough
slack in cable for full stick travel only.
d. Install boot assembly (32), secured to floor with
eight screws (31) and washers (12).
e. Install access doors (66, 68, 69, 70, 77 and 78,
figure 2-18).
f. Install pilots and copilots seats (paragraph 2-223
or 2-252).
11-64.1 DESCRIPTION — TRIGGER DETENT MECH-

ANISM.
11-64.2 The trigger detent mechanism is a device con-

sisting of seven components which provides a “positive Figure 11-13.2. Pin 7 (PM 21217) Area
feel” for each of the two trigger switch positions. Identification
Change 14 11-35
TM 55-1520-210-23-2
To reach “peak detent” continue depression of trigger

and ball 4 (figure 11-13.9) will ride up radius of ball seat
depressing spring 3 (figure 11-13.9) and onto large
shank of pin 7 (figure 11-13.9). See figure 11-13.3 for
internal position of trigger detent mechanism compo-
nents and figure 11-13.5 for approximate position of trig-
ger at “peak detent.”
Figure 11-13.5. Approximate Trigger Position
11-64.5 DISASSEMBLY — TRIGGER DETENT

MECHANISM.
11-64.6 Disassembly of trigger detent mechanism may

be required for the following reasons:
Figure 11-13.3. Internal Position of Trigger Detent a. Inspection of trigger detent mechanism compo-
Mechanism Components for “Peak Detent” nents.
b. Lubrication of pin 7 and ball 4 (figure 11-13.9).
c. Replacement of trigger detent mechanism compo-
When ball 4 (figure 11-13.9) leaves ball seat of pin 7 nents.
(figure 11-13.7) and rides up onto large shank of pin 7, a
decrease in trigger pressure will be felt. At this point CAUTION
trigger pressure is from compression of spring 6 (figure
11-13.9) only. Continued depression of trigger will bring Trigger should be left in grip handle during
“second stage make.” See figure 11-13.4 for internal disassembly of trigger detent mechanism
position of trigger detent mechanism components and components to prevent loss of ball 4 (fig-
figure 11-13.5 for approximate position of trigger at “secure 11-13.9) into interior of grip.
ond stage make.”
11-64.7 Remove screw 1 and/or 1a, this will allow the
removal of spring 3 and ball 4. See figure 11-13.9 for part
identification and location. Inspect insert PM21265 (fig-
ure 11-13.9) in accordance with paragraph 11-64.10e.
11-64.8 Remove nut 5 or 5a (figure 11-13.9), this will

allow the removal of spring 6 and pin 7 (figure 11-13.9).
See figure 11-13.9 for part identification and location.
Inspect all components and insert PM21264 (figure
11-13.9) in accordance with paragraph 11-64.10 c, e, f.
NOTE
If it is determined that any component of
the trigger detent mechanism is worn or
Figure 11-13.4. Internal Position of Trigger Detent defective, replace all components of the
Mechanism Components for “Second Stage Make” trigger detent mechanism.
11-36 Change 14
TM 55-1520-210-23-2
11-64.9 INSPECTION – TRIGGER DETENT f. Check insert PM21264 to see if it is bent or

MECHANISM. deformed. If so, remove and replace grip assembly.
11-64.10 Operate the trigger to insure that there
is no binding. If binding occurs check the following:
1 1 - 6 4 . 1 1 . INSTALLATION – TRIGGER
a. Lubrication of pin 7 and ball 4 (figure 11- DETENT MECHANISM.
13.9) (see paragraphs 3-4 and 3-7).
b. Adjust trigger forces (see paragraphs 3-11 11-64.12 Trigger and switch must be installed into
through 3-16). grip handle prior to installation of trigger detent
mechanism. Follow installation instructions
c. Pin 7 (figure 11-13.9) may have a burr worn pertaining to each grip handle.
up between ball seat radius and large shank (see
figure 11-13.6). If so, replace all components of 11-64.13 Layout and identify all parts of detent
trigger detent mechanism. mechanism kit. For identification and positioning
of parts for installation see figure 11-13.9.
11-64.14 Apply a thin film of lubrication (C126)
to pin 7 (figure 11-13.9). Place pin 7 into insert
(PM21264) (figure 11-13.9) located at the top of
grip handle.
11-64.15 Place spring 6 (figure 11-13.9) (short
spring) into insert (PM21264) above pin 7. Spring
6 will seat over small shank and rest on flange of
pin 7.
11-64.16 Thread nut 5 or 5a (figure 11-13.9)
onto insert (PM21264) (figure 11-13.9) a few
Figure 11-13.6 turns to retain pin 7 and spring 6.
Burr Worn Up On Pin 7 (PM 21217)
11-64.17 Apply a thin film of lubrication (C126)
to ball 4 (figure 11-13.9). Install ball 4 into insert
d. Insert PM21265 may have corner wear (PM21265) located on side of grip handle.
from contact with ball 4 (figure 11-13.9) due to
poor adjustment (see figure 11-13.7). If so return 11-64.18 Place spring 3 (figure 11-13.9) (long
grip handle to Bendix for insert replacement. spring) into insert (PM21265) (figure 11-13.9)
Spring will be seated on top of ball 4.
11-64.19 Thread nut 2 (figure 11-13.9) onto

screw 1 about ¼ of an inch. If you are using
screw 1a, do not use nut 2.
11-64.20 Thread screw 1 or 1 a (figure 11-13.9)

into insert (PM21265) (figure 11-13.9) Thread
only a few turns initially as it is used for adjust-
ment of trigger detent force in later operation.
11-64.21 ADJUSTMENT OUTRIGGER DETENT

MECHANISM.
Figure 11-13.7
Corner Wear on Insert (PM 21265) 11-64.22 Actuate trigger several times to assure
smooth action.
e . Check inserts PM21265 and PM21264 for
1 1 - 6 4 . 2 3 Check all three trigger actuation
thread mutilation. If mutilation is present, remove
forces using a suitable spring guage. See Table 11-
and replace grip assembly.
1.1 below:
11-37
TM 55-1520-210-23-2
Table 11-1.1. Trigger Actuation Forces 11-65. TUBE AND LEVER ASSEMBLY — CYCLIC
CONTROLS.
A. First Stage Make 2.25 ± 0.50lbs.
B. Peak Detent 7.50 ± 0.50 lbs.
11-66. Description — Tube and Lever Assembly —
C. Second Stage Make 5.00 ± 1.00 lbs. Cyclic Controls. Two control tubes and lever assem-
blies are mounted under the floor and forward of the pilot
11-64.24 To adjust “first stage make”: seats. These are segments of linkage between cyclic
control sticks and swashplate control horns.
a. To increase force, tighten (clockwise) nut 5 or
5a, check force with spring gage.
b. To decrease force loosen nut 5 or 5a (figure
11-13.9) (counter-clockwise). Check force with spring
gage.
Premaintenance Requirements for Tube and Lever
11-64.25 To adjust “peak detent”:
Assembly–Cyclic Controls
a. To increase force, tighten (clockwise) screw 1 or
1a, check force with spring gage.
b. To decrease force, loosen screw 1 or 1a (figure
Model All
11-13.9) (counter-clockwise). Check force with spring
gage. Part No. or Serial No. All
Special Tools None
11-64.26 To adjust “second stage make” follow proce-
dure as described in 11-64.14a and 11-64.15b. Test Equipment Eddy Current Inspection
Unit
11-64.27 TESTING TRIGGER DETENT MECH-
ANISM.
11-64.28 After forces have been set, actuate trigger sev- Required
eral times to insure that there is no binding, recheck all Consumable Materials None
forces in accordance with Table 11-1.1., using spring
gage. Make adjustments if needed. Special Environmental None
Conditions
11-64.29 Apply sealant (C22) around nut 5 or 5a in re- References TM 1-1520-256-23
cessed area of grip handle.
11-64.30 Hold screw 1 in place and secure locknut 2 up

to grip handle.
11-67. Inspection — Tube and Lever Assembly —
11-64.31 If screw 1 and nut 2 are used apply small Cyclic Controls (Installed).
amount of glyptol around screw 1 thread at top of nut 2.
Glyptol is used as a device to determine if the detent a. Inspect tube and lever assembly (13 and 14,
adjustment has been tampered with. See figure 11-13.8. figure 11-14) for binding.
b. Inspect bearing in arm assembly (19) figure

11-14) for 0.012 inch radial and 0.030 inch axial maxi-
mum allowable wear.
c. Maximum allowable lateral play on tube and

lever assembly (13 and 14) is 0.200 inch.
d. Inspect tube and lever assembly (13 and 14) for

corrosion, cracks, nicks, and scratches. No cracks al-
lowed. If a crack in the Tube and Lever Assembly is
suspected, refer to TM 1-1520-256-23, Technical Manu-
al Aviation Unit Maintenance (AVUM) and Aviation Inter-
Figure 11-13.8. mediate Maintenance (AVIM) manual nondestructive in-
Apply Glyptol to Screw and Nut. spection procedures for UH-1 helicopter series.
11-38 Change 15
TM 55-1520-210-23-2
Part
Number Description
1 PM21220 Screw
1a PM21220-1 Screw
2 PM21639 Nut
3 PM21219 Spring
4 PM21638 Ball
5 PM21222 Screw
5a PM21222-1 Nut
6 PM21218-1 Spring
7 PM21217 Pin
Figure 11-13.9
Exploded View of Trigger Detent Mechanism Components
11-39
TM 55-1520-210-23-2
11-68. Removal –Tube and Lever Assembly – and 70, figure 2-18) from cabin floor and lower skin of
Cyclic Controls. fuselage.
N O T E
c. Remove cotter pin (8, figure 11-14), and nut
Parts of control system can be removed (23), washer (30), and bolt (32) attaching tube
separately as need occurs, or completely assembly (33) to tube and lever assembly (31),
in practical sequence. Take precaution,
against damage by accidental movement d. Remove cotter pin (6), nut (18), washer (16),
of linkage while disconnected. and bolt (15) attaching tube assembly (17) to arm
assembly (19).
a. Remove pilots and copilots seats (paragraph
2-218 or 2-249). e. Remove cotter pin (6), nut (28), washer (26),
and bolt (25) attaching tube assembly (27) to tube and
b. Remove access doors (40, 64, 65, 66, 68, 69, lever assembly (20).
11-40
TM 55-1520-210-23-2
Figure 11-14. Cyclic Control Tube and Lever Assembly (Sheet 1 of 2)
Change 15 11-41
TM 55-1520-210-23-2
1. Nut 13. Tube and lever assembly 25. Bolt

2. Washer 14. Tube and lever assembly 26. Washer
3. Tapered bushing 15. Bolt 27. Tube assembly
4. Bolt 16. Washer 28. Nut
5. Clevis assembly 17. Tube assembly 29. Nut
6. Cotter pin 18. Nut 30. Washer
7. Nut 19. Arm assembly 31. Tube and lever assembly
8. Magnetic brake 20. Tube and lever assembly 32. Bolt
9. Washer 21. Clevis assembly 33. Tube Assembly
10. Bolt 22. Lockwire 34. Nut
11. Force gradient – fore-and-aft 23. Bolt 35. Washer
12. Housing Assembly 24. Washer 36. Bolt
Figure 11-14. Cyclic Control Tube and Lever Assembly (Sheet 2 of 2)
11-42
TM 55-1520-210-23-2
f. Remove lockwire, washer (24), and bolt (23) at- c. Inspect tube and lever assembly for corrosion,
taching clevis assembly (21) to tube and lever assembly cracks, nicks and scratches. No cracks allowed. If a
(20). crack in the Tube and Lever Assembly is suspected, refer
to TM 1-1520-256-23, Technical Manual Aviation Unit
g. Remove bolts (4), washers (2), tapered bushings
Maintenance (AVUM) and Aviation Intermediate Mainte-
(3), and nuts (1) from each side of tube and lever assem-
nance (AVIM) manual nondestructive inspection proce-
bly (20). Identify bolts and tapered bushings for rein-
dures for UH-1 helicopter series.
stallation in same location.
h. Remove bolts (36), washers (35), and nuts (34) d. Inspect bearing in arm assembly (19, figure
attaching housing assemblies (12) to beam. Withdraw 11-14) for 0.012 inch radial and 0.030 inch axial maxi-
tube and lever assemblies (13 and 14) through access mum allowable wear.
openings.
11-71. Repair or Replacement — Tube and Lever As-
11-69. Disassembly — Tube and Lever Assembly — sembly — Cyclic Controls (AVIM).
Cyclic Controls. Identify parts for reassembly in same a. Replace worn or rough bearings and damaged or
locations. unserviceable parts (figure 11-14).
b. Replace all parts that do not meet inspection re-
CAUTION quirements.
Parts are match drilled and shall not be
intermixed. 11-72. Installation— Tube and Lever Assembly —
Cyclic Controls.
a. Remove bolts (4, figure 11-14) washers (2), ta-
pered bushings (3) attaching components of tube and a. Inspect structural intercostal mounting surfaces
lever assembly (13 and 14). of housing assembly (12, figure 11-14) to determine if
tape (C278) is torn or missing. Install new tape if torn or
b. Remove tube (13 and 14) from lever or arm. missing.
NOTE
Premaintenance Requirements for Tube and Level Tape (C278) shall cover the entire mating
Assembly-Cyclic surface area of one of the parts. Also, it
shall extend at least 1/4 inch beyond the
Conditions Requirements joint edges.
Model All b. Align marks previously indexed on tubes and lev-
ers. Insert tube and lever assemblies (13 and 14, figure
Part No. or Serial No. All 11-14) with housing assemblies (12) in place, through
Special Tools None access openings at sides of cabin lower skin.
Test Equipment Eddy Current Inspection c. Slip ends of tube and lever assemblies (13 and
Unit 14) on shafts of arm assembly (19).
Support Equipment None d. Align bolt holes with center arm pointing up and
Minimum Personnel Two end down. If new tube and lever assemblies (13 and 14)
Required are being installed, line ream holes for bolts (4) using
taper reamer (T87).
e. Apply primer (C312) on tapered bushings (3) and
Special Environmental None mounting surfaces on tube and lever assemblies (13 and
Conditions 14).
CAUTION
11-70. Inspection — Tube and Lever Assembly — Do not intermix parts. Parts are drilled and
Cyclic Controls (Removed). matched during assembly.
a. Maximum allowable elongation of bushing hole is
f. Install bolts (4), tapered bushings (13), washers
0.003 inch.
(2), and nuts (1). Torque bolts 50 TO 70 inch-pounds.
b. Maximum allowable wear on tube and lever as- Check 0.030 TO 0.060 clearance between tube and
sembly bearings is 0.010 inch radial. washer as noted on figure 11-14.
Change 14 11-43
TM 55-1520-210-23-2
g. Secure housing assemblies (12) to each beam 11-72.3 Removal — Support Assemblies (AVIM).
by installing bolts (36), washers (35), and nuts (34). Flat
a. Remove support assembly (18, figure 11-14.1)
or tapered shims, maximum thickness of 0.063 inch, may
as follows:
be installed between beam and housing (12) to obtain
proper chuck and to eliminate binding caused by misa- (1) Remove soundproofing blanket and left ac-
ligned beams. Check for free operation. cess doors (23 and 24, figure 2-18) from pylon area.
NOTE (2) Remove cyclic and collective control hy-
If shims are installed between housing draulic cylinder assemblies (33, figure 7-11) and (6, fig-
(12) and beam, tape (C278) shall be ure 7-23) (paragraphs 7-71 and 7-84).
installed between housing and shim and (3) Remove droop compensator jackshaft and
between shim and beam. Tape (C278) shall support from support assembly (18, figure 11-14.1)
cover the entire mating surface and shall (paragraph 4-126).
extend at least 1/4 inch beyond the joint
edges. (4) Remove wire bundle and battery cables
routed through support assembly (18).
h. Install bolt (23) washers (24) to attach clevis as-
sembly (21) to tube and lever assembly (20). Secure with (5) Remove plug button located outboard of nut
lockwire (C155). (13) on left side of cabin pylon structure.
NOTE (6) Remove nuts (13), washers (12) and bolts
If adjustable control tubes are not correct (11) attaching support assembly (18) to pylon structure.
length to be attached, leave one end free (7) Remove nuts (14), washers (10) and bolts
until controls are rigged. (9) attaching support assembly (18) to top of lift beam.
i. Install bolt (25), washer (26), and nut (28) to attach (8) Remove nuts (15), washers (16) and bolts
tube assembly (27) to tube and lever assembly (20). (17) attaching support assembly (18) to pylon structure.
Secure with cotter pin (6). Lift, rotate and remove support assembly (18) through
j. Install bolt (15) from right side, washer (16), and access opening (24, figure 2-18),
nut (18) to secure tube assembly (17) to arm assembly
b. Remove support assembly (3, figure 11-14.1) as
(19). Secure with cotter pin (6).
follows:
k. Install bolt (32), washer (30), and nut (29) to
(1) Remove soundproofing blanket and right
install tube assembly (33) to tube and lever assembly
side access doors (24 and 31, figure 2-18) from pylon
island in cabin area.
l. Install access doors (40, 64, 65, 66, 68, 69, and
70, figure 2-18) in cabin floor and lower skin of fuselage. (2) Remove cyclic hydraulic cylinder assembly
(33, figure 7-11) (paragraph 7-71).
m. Install pilots and copilots seats (paragraph 2-223
or 2-252). (3) Remove nuts (8, figure 11-14.1), washers
(7) and bolts (6) attaching support assembly (3) to top of
11-72.1 SUPPORT ASSEMBLIES. cargo lift beam.
(4) Remove nuts (19), washers (5) and bolts (4)
11-72.2 Description — Support Assemblies. Two hy-
attaching support assembly (3) to top of cargo lift beam.
draulic cylinder support assemblies (figure 11-14.1) (lo-
cated left and right side, and below transmission assem- (5) Remove nuts (1), washers (2) and bolts (20)
bly) are provided for support of two cyclic and collective attaching support assembly (3) to cabin structure. Lift
cylinder assemblies. The supports are attached to the and remove support assembly through access opening
cabin structure and top side of cargo lift beam. (24, figure 2-18).
11-44 Change 14
TM 55-1520-210-23-2
Premaintenance Requirements for Support 11-72.4 Inspection — Support Assemblies (AVIM).

Assemblies
Conditions Requirements a. Inspect support assembly (3, figure 11-14.1) in
accordance with damage limits outlined in figure 11-14.2
Model All and table 11-2. If a crack in the Support Assemblies for
Part No. or Serial No. All the Hydraulic Cylinder Assembly is suspected, refer to
TM 1-1520-256-23, Technical Manual Aviation Unit
Special Tools None Maintenance (AVUM) and Aviation Intermediate Mainte-
Test Equipment Eddy Current Inspection nance (AVIM) manual nondestructive inspection proce-
Unit dures for UH-1 helicopter series.
b. Inspect support assembly (18) in accordance
with damage limits outlined in figure 11-14.3 and table
Required
11-2. If a crack in the Support Assemblies for the Hy-
Consumable Materials None draulic Cylinder Assembly is suspected, refer to TM
Special Environmental None 1-1520-256-23, Technical Manual Aviation Unit Mainte-
Conditions nance (AVUM) and Aviation Intermediate Maintenance
References TM 1-1520-256-23 UH-1 helicopter series.
Change 14 11-44.1/(11-44.2 blank)

T M 55-1520-210-23-2
NOTE: Bore elongation does not apply to this hole.

TYPE OF DAMAGE
MECHANICAL: NICKS, 0.020 INCH 0.030 INCH
SCRATCHES, ETC.
CORROSION 0.010 INCH 0.015 INCH
MAXIMUM AREA PER 0.25 SQUARE INCH 0.50 SQUARE INCH

FULL DEPTH REPAIR
MAXIMUM NUMBER TWO PER SEGMENT

OF REPAIRS
EDGE CHAMFER 0.040 INCH 0.060 INCH
SURFACE COATING BRUSH ALODINE
BORE REPAIR 0.002 – ONE-QUARTER CIRCUMFERENCE
THREAD DAMAGE:
LENGTH: ONE-TENTH INCH
NUMBER: ONE PER THREADED SEGMENT
BORE ELONGATION: 0.0015 INCH MAXIMUM

CRACKS NONE ALLOWED
Figure 11-14.2. Support assembly (P/N 204-001-340), Hydraulic

Cylinder Assembly – Damage Limits
11-47
TM 55-1520-210-23-2
NOTE: Bore elongation does not apply to these holes

TYPE OF DAMAGE
MECHANICAL: NICKS, 0.020 INCH 0.030 INCH

SCRATCHES, ETC.

MAXIMUM AREA PER 0.24 SQUARE INCH 0.50 SQUARE INCH
FULL DEPTH REPAIR
MAXIMUM NUMBER TWO PER SEGMENT

OF REPAIRS
EDGE CHAMFER 0.040 INCH 0.060 INCH
SURFACE COATING BRUSH ALODINE
BORE REPAIR 0.002 – ONE-QUARTER CIRCUMFERENCE
THREAD DAMAGE:
LENGTH: ONE-TENTH INCH
NUMBER: ONE PER THREADED SEGMENT
BORE ELONGATION: 0.0015 INCH MAXIMUM
CRACKS NONE ALLOWED
Figure 11-14.3. Support Assembly (P/N 204-001-303). Hydraulic

Cylinder Assembly – Damage Limits
11-48
TM 55-1520-210-23-2
11-72.5. Cleaning.- Support Assemblies. (1) Position support assembly (3) be-
tween attachment supports of pylon structure
and align holes in support assembly with holes
in top of cargo lift beam. Place washer (5) on
Cleaning materials are flammable and bolts (4). Apply a light coat of primer (C312) to
toxic. Avoid skin contact and breathing bolts and install bolts through support assem-
of solvent vapors. bly (3) and cargo lift beam.
(2) Place a washer (2) on each of bolts
a. Clean support assemblies (3 and 18 fig-
(20). Apply a light coat of primer (C312) to bolts
ure 11-14.1) with solvent (C261). A nonmetal-
and install bolts through support assembly (3)
lic, soft bristle brush may be required to
and supports of pylon structure.
dislodge stubborn deposits.
(3) Place a washer (7) on each of two
b. Rinse support assemblies with clean water bolts (6). Apply a light coat of primer (C312) to
and allow to air dry. bolts and install bolts through support assem-
11-72.6. Repair — Support Assemblies bly (3) and top of lift beam.
(AVIM). a. Any damage to support assembly (3,
figure 11-14.1) exceeding limits outlined in (4) Install washers (2, 5 and 7), and nuts (1,8
figure 11-14.2 requires replacement of part. No and 19) on bolts (4, 6 and 20) and tighten nuts.
cracks allowed.
(5) Install hydraulic cylinder assembly (33,
figure 7-11) (paragraph 7-78).
(6) Install right side access doors (24 and 25,

Chemical film material and primers are figure 2-18) and soundproofing blanket to pylon
flammable and toxic. Provide adequate island in cabin area.
ventilation. Do not use near fire or open
flame. b. l n s t a l l s u p p o r t a s s e m b l y (18, fig-
b. Polish nicks, scratches or corrosion to ure 11-14.1) as follows:
original surface finish with 600 grit sandpaper
NOTE
(C232). Treat repair area with chemical film
material (C62) followed with a light application Do not tighten nuts (13, 14 and 15)
of primer (C312) or primer (C206). until all bolts (9, 11 and 17) are
c. Thread damage, bent, or corrosion, to installed with unthinned wet prim-
studs of support assemblies (3 or 18) requires er (C312) in support assembly (18).
replacement of part. Apply primer (C312) to (1) Position support assembly (18) be-
replacement stud prior to installation to sup- tween forward and aft attachment supports of
port. pylon structure and align holes in support as-
d. Any damage to support assembly (18) ex-
sembly with holes in top of lift beam. Place a
ceeding limits outlined in figure 11-14.3 re- washer (10) on each of four bolts (9). Apply a
quires replacement of part. No cracks allowed. light coat of unthinned primer (C312) to bolts
e. Polish, treat, and touchup damaged repaired and install bolts through support assembly (18)
areas of support assembly (18) as outlined in above and lift bean.
step b. (2) Place washer (12) on bolts (11). Apply
11-72.7. Installation — Support Assemblies a light coat of unthinned primer (C312) to bolts
(AVIM). a. Install support assembly (3, figure and install bolts through support assembly (18)
11-14.1) as follows: and supports of pylon structure.
N O T E (3) Place washers (16) on bolts (17). Ap-
ply a light coat of unthinned primer (C312) to
Do not tighten nuts (1, 8 and 19)
bolts and install bolts through support assem-
until all bolts (4, 6 and 20) are in-
bly (18) and supports of pylon structure.
stalled with unthinned wet primer
(C312) in support assembly (3). (4) Tighten nuts (13, 14 and 15).
11-49
TM 55-1520-210-23-2
(5) Install (lateral) hydraulic cylinder assembly (6,

figure 7-11) (paragraph 7-78, step b).
Some magnetic brakes. P/N 204-001-376-3
(6) Install (collective) hydraulic cylinder assembly have external stops. Ensure that when remov-
(6, figure 7-23) (paragraph 7-91). ing the arm from the shaft that the stop is not
accidentally removed. If the stop has been
(7) Install droop compensator bracket and jackshaft removed, reinstall the stop, attaching hardware,
to support assembly (18) (paragraph 4-132). and check for proper stop alignment as illus-
trated in figure 11-15.
(8) Route and install wire bundle and battery cables
up through support assembly (18). (1) Place arm of lateral magnetic brake at center
of travel. With cyclic stick in neutral, adjust link on
(9) Install plug button in hole, located outboard of lateral force gradient (4, figure 11-11) to fit and con-
nut (13) on left side of cabin pylon structure. nect.
(10) Service and bleed hydraulic system (paragraph (2) Place and hold cyclic stick against forward
7-6). stop. Place arm of fore-aft magnetic brake against aft
stop. Adjust fore-aft force gradient (9, figure 11-11) to
(11) Perform operational check and test of hydrau- fit. Extend clevis fitting 3-1/2 turns and connect.
lic system and hydraulic cylinder assemblies (6 and
33, figure 7-11) and (6, figure 7-23) (pararaphs 7-3 (3) Place directional control arm at center of travel
and 7-4). and with control pedals held in neutral, adjust force
gradient tube to fit and connect.
(12) Inspect hydraulic cylinder assemblies (6 and
33, figure 7-11) and (6, figure 7-23) and attaching hose b. Attach force gradient assembly to brake arm with
connections for leaks (table 7-1). nut (7) and secure with cotter pin (6). Connect electri-
cal plug to brake body and secure with Iockwire (C155).
(13) Install left access doors (23 and 24, figure 2-
18) and soundproofing to pylon island in cabin area. c. Check flight controls for unobstructed full travel.
11-73. MAGNETIC BRAKE-CYCLIC

CONTROLS. 11-76. Inspection-Magnetic Brake Cyclic Con-
trols (Installed). a. Check flight controls for
11-74. Description-Magnetic Brake Cyclic Con- unobstructed full travel.
trols. A magnetic brake used in conjunction with a
force gradient assembly is mounted in each control b. Check assembly for corrosion, unobstructed
element: the fore and aft cyclic, the lateral cyclic and travel, cannon plug safetying.
the tail rotor pitch control. All three assemblies are
identical except for the position of the arm on the c. Check for loose, missing or improperly installed
hardware.
brake. By positioning one of the letters “D”, “L”, or “F
relative to the brake shaft, the brake may be used in
11-77. Removal-Magnetic Brake--Cyclic Con-
either the D-irectional, L—ateral, or F-ore and aft
control assembly (figure 11-15). trols. a. Disconnect electrical plug from brake body.
11-75. Rigging—Magnetic Brake Cyclic Con- b. Remove cotter pin and nut (7, figure 11-14) at-
taching force gradient (11) to brake (8) arm.
trols. a. Rig the fore and aft cyclic, lateral cyclic, and
tail rotor pitch control magnetic brakes as follows:
11-50 Change 4
TM 55-1520-210-23-2
c. Remove our bolts (10) and washers (9) attaching c. Connect electrical plug to brake body and secure with
magnetic brake (8) structure. lockwire (C155).
11-78. Repair or Replacement — Magnetic Brake — d. Rig magnetic brake cyclic controls.
Cyclic Controls. a. Replace magnetic brake assemblies
having malfunction that will not allow unobstructed full 11-80. FORCE GRADIENT CYCLIC CONTROLS.
travel for cyclic controls.
11-81. Description — Force Gradient Cyclic
b. Deleted. Controls. Two force gradient assemblies are used in the
cyclic control system in conjunction with magnetic brake
c. Deleted. assemblies. The force gradient and magnetic brake assem-
blies serve to give artificial “feel” to the flight controls and
11-79. Installation — Magnetic Brake Cyclic enable the pilot to “trim” the helicopter.
Controls. a. Mount brake arm on brake (paragraph
11-73). Secure arm with retaining bolt.
b. Position brake in place on structure and install mount-

ing bolts (10, figure 11-14) and washers (9).
Change 5 11-51
TM 55-1520-210-23-2
Figure 11-15 Magnetic Brake Adjustment (Sheet 1 of 2).
11-52
TM 55-1520-210-23-2
Figure 11-15. Magnetic Brake Adjustment (Sheet 2 of 2)
11-53
TM 55-1520-210-23-2
11-82. Adjustment - Force Gradient Cyclic 11-83. Removal — Force Gradient — Cyclic
Controls. Controls. a. Remove cotter pin (6), nut (7, figure
11-14) attaching force gradient (11) to magnetic
NOTE brake (8).
Ensure that parts are not intermixed b. Disconnect other end from clevis (5).
when two or more force gradient
assemblies are disassembled at one time.
11-84. Inspection - Force Gradient — Cyclic
a. Remove force gradient assembly (paragraph Controls. a. Inspect for preloading and freedom of
11-83). operation.
b. Preload spring in force gradient assemblies b. Inspect for loose, missing or improperly
(lateral, fore and aft, and directional) as follows: installed hardware.
(1) Remove spring assembly (7, figure 11-16) c. Inspect for bottoming at all control positions.
from housing (3) by removing cap (2).
d. Inspect shaft lock nuts for security and cap for
(2) Place spring assembly, with clevis correct safetying.
installed, in a vise as shown in figure 11-16.
e. Inspect bearing for wear and damage (figure
NOTE 11-44).
Do not tighten vise on rod. Allow spring f. Inspect for wear and damage in accordance
retainer to pull evenly against both jaws with figure 11-17.
of vise.
11-85. Repair or Replacement — Force Gradient

(3) Attach spring scale (11) to bolt installed — Cyclic Controls (AVIM) a. Repair or replace
through clevis (12). Compress spring (7) with a steady force gradients in accordance with wear and damage
2.5 TO 3.5 pounds pull. limits of figure 11-17.
(4) While maintaining this tension, tighten b. Replace worn or damaged bearings (figure
adjustment nut (8) until it makes contact with spring 11-44).
retainer (6).
11-86. Installation — Force Gradient — Cy-
(5) Hold adjustment nut (8) while tightening
clic Controls.
jam nut (9).
a. Connect force gradient shaft to clevis (5,
c. Reassemble force gradient assembly as figure 11-14). Adjust in accordance with paragraph
follows: 11-75.
(1) Place spring assembly (7, figure 11-16) in

housing (3).
(2) Install cap (2) and tighten sufficiently to 11-87. MIXING LEVER ASSEMBLY –
eliminate end play.
CYCLIC CONTROLS
NOTE
A cap too tight or too loose will cause end 11-88. Description — Mixing Lever Assembly —
play, Cyclic Controls. The mixing lever assembly consists
of bellcranks, matched links, and support. It is
(3) Apply Iockwire (C155) to cap (2) to mounted on the right main beam below the cabin
prevent rotation in either direction. floor area
11-54
TM 55-1520-210-23-2
Figure 11-16. Force Gradient Assembly Adjustment (Sheet 1 of 2)
Change 5 11-55
TM 55-1520-210-23-2
1. Lockwire 8. Adjustment nut

2. Cap 9. Jam nut
3. Housing 10. Nut
4. Bearing 11. Spring scale
5. Shaft 12. Clevis
6. Spring retainer 13. Link assembly
7. Spring 14. Washer
Figure 11-16. Force Gradient Assembly Adjustment (Sheet 2 of 2)
11-56 Change 5
TM 55-1520-210-23-2
11-89. Removal — Mixing Lever Assembly — 11-90. Disassembly — Mixing Lever Assembly –
Cyclic Controls. a. Remove access door (72, Cyclic Controls. a. Remove cotter pin (16, figure
figure 2-18). 11-19), nut (20), washers (2), and bolts (1) attaching
upper matched link (3).
b. Remove cotter pin and nut (14, figure 11-18),
washers (2), and bolt (4) disconnecting end of tube
(16). b. Remove cotter pins (16), nuts (9 and 11)
aluminum washers (5), and bolts (4 and 7) attaching
c. Remove cotter pin (11), nut (12), washers (2), upper and lower matched links (6). Remove bellcrank
and bolt (6) disconnecting end of tube (15). (8).
d. Remove cotter pin (11), nut (13), washers (2),

and bolt (5) disconnecting end of tube (7). c. Remove cotter pin (16), nut (10), washers (12),
and bolt (13) attaching lower matched link (3).
e. Remove cotter pin (11), nut (10), washers (2),
and bolt (8) disconnecting end of tube (9).
d. Remove cotter pin (16), nut (15) aluminum
f. Remove bolt (3) and washer (2) attaching washers (18), and bolt (19) attaching bellcrank (17) to
support (1) to right main beam. support (14).
204-001-045-5
FORCE GRADIENT ASSEMBLY
TYPE OF DAMAGE
MECHANICAL DAMAGE
(AFTER CLEAN-UP) 0.015 IN. 0.010 IN.
CORROSION DAMAGE
(BEFORE CLEAN-UP) 0.0075 IN. 0.005 IN.
MAXIMUM AREA PER

FULL DEPTH REPAIR 1 IN. SQ. 0.10 IN. SQ.
NUMBER OF REPAIRS ONE PER AREA ONE PER AREA
EDGE CHAMFER 0.05 BY 0.05 IN. 0.04 BY 0.04 IN.
BORE DAMAGE 0.002 INCH FOR ONE-FOURTH CIRCUMFERENCE
REPLACE PARTS WITH DAMAGED THREADS
Figure 11-17. Wear and Damage Limits — Force Gradient
11-57
TM 55-1520-210-23-2
1. Support 9. Tube
2. Washer 10. Nut
4. Bolt 12. Nut
5. Bolt 13. Nut
6. Bolt 14. Nut
7. Tube 15. Tube
8. Bolt 16. Tube
Figure 11-18. Mixing Lever Assembly — Cyclic Controls — Removal and Installation
11-58
TM 55-1520-210-23-2
1. Bolt 11. Nut

2. Washer 12. Washer
3. Matched links 13. Bolt
4. Bolt 14. Support
5. Aluminum washer 15. Nut
6. Matched links 16. Cotter pin
7. Bolt 17. Bellcrank
8. Bellcrank 18. Washer
9. Nut 19. Bolt
10. Nut 20. Nut
Figure 11-19. Mixing Lever Assembly — Cyclic Controls — Disassembly and Assembly
11-59
TM 55-1520-210-23-2
Premaintenance Requirements for Tube and Lever washers (18), and nut (15). Torque nut 50 TO 70 inch-
Assembly-Cyclic Controls pounds. Secure with cotter pin (16).
Conditions Requirements b. Place lower half of matched link (3) on lower at-
tachment point of support (14). Install bolt (13), washers
Model All (12), and nut (10). Torque nut 50 TO 70 inch-pounds.
Part No. or Serial No. All Secure with cotter pin (16).
Special Tools None c. Place bellcrank (8) between both upper and low-
er matched links (6). Install bolt (7), with aluminum wash-
Test Equipment Eddy Current Inspection
er (5) through upper matched link (6) and aft attachment
Unit
point of bellcrank (8) and through lower matched link (6).
Support Equipment None Install aluminum washer (5) and tighten nut (9) slightly.
Minimum Personnel Two Install bolt (4), with aluminum washer (5) through upper
Required matched link (6) and through aft attachment point of bell-
crank (17), and through lower matched link (6). Install
Consumable Materials None aluminum washer (5) and nut (11). Torque nuts 50 TO 70
Special Environmental None inch-pounds. Secure with cotter pins.
Conditions d. Place upper matched link (3) on upper attach-
References TM 1-1520-256-23 ment point of support (14). Install bolt (1), with washers
(2), and nut (20). Torque nut 50 TO 70 inch-pounds.
Secure with cotter pin (16).
11-91. Inspection — Mixing Lever Assembly — Cy-
clic Controls.
11-94. Installation — Mixing Lever Assembly — Cy-
a. Inspect bearings for wear and roughness (para- clic Controls.
graph 11-185).
a. Inspect mounting surface on right main beam of
b. Inspect parts for wear, elongated bolt holes, support (1, figure 11-18) to determine if tape (C278) is
cracks, nicks, and surface damage (figure 11-20). No torn or missing. Install new tape if torn or missing.
cracks allowed. If a crack in the Mixing Lever Assembly
is suspected, refer to TM 1-1520-256-23, Technical NOTE
Manual Aviation Unit Maintenance (AVUM) and Aviation Tape (C278) shall cover the entire mating
Intermediate Maintenance (AVIM) manual nondestruc- surface area of one of the parts. Also, it
tive inspection procedures for UH-1 helicopter series. shall extend at least 0.25 inch beyond the
joint edges.
c. Inspect parts for corrosion.
d. Inspect for loose, missing or improperly installed b. Install bolts (3) and washers (2) to attach support
hardware. (1) to right main beam.
c. Place tube (9) on bell crank (8, figure 11-19) and
11-92. Repair or Replacement — Mixing Lever As- attach with bolt (8, figure 11-18), washers (2), and nut
sembly — Cyclic Controls. (10). Secure with cotter pin (11).
a. Repair or replace mixing lever assembly in accor-
d. Place tube (7) on bellcrank (8, figure 11-19) and
dance with wear and damage limits of figure 11-20.
attach with bolt (5, figure 11-18), washers (2), and nut
b. Replace any parts that do not meet inspection (13). Secure with cotter pin (11).
requirements.
e. Place tube (15) on bellcrank (8, figure 11-19) and
c. Refer to paragraph 11-185 for bearing replace- attach with bolt (6, figure 11-18) washers (2), and nut
ment. (12). Secure with cotter pin (11).
11-93. Assembly — Mixing Lever Assembly — Cy- f. Place tube (16) on bellcrank (17, figure 11-19) and
clic Controls. attach with bolt (4, figure 11-18) washers (2), and nut
a. Place bellcrank (17, figure 11-19) on center at-
tachment point of support (14). Install bolt (19), aluminum g. Install access door (72, figure 2-18).
11-60 Change 14
TM 55-1520-210-23-2
11-95. CONTROL TUBES — CYCLIC CONTROL SYS- a. Remove access doors (66, 68, 69, 70, 72, 73, and
TEM. 79, figure 2-18) as required for access to cyclic control
11-96. Description — Control Tubes — Cyclic Con- tubes.
trol System. Control tubes (adjustable and non-adjust- b. Detach end of control tube (6, figure 11-21) from
able) are used throughout the cyclic control system. The pilots cyclic stick by removing cotter pin (1), nut (2), two
tubes are connected to bellcranks and levers supports washers (3) and bolt (7), (detail A, sheet 1).
with standard hardware.
c. Detach opposite end of control tube (6) from arm
11-97. Removal — Controls Tubes — Cyclic Control of tube and lever assembly by removing cotter pin (1), nut
System. (4), two washers (3) and bolt (5), (detail A, sheet 1).
CAUTION
When disconnecting control tubes, main
rotor hub and blade assembly should not
be rotated. Damage to swashplate and
scissors and sleeve assembly may result.
Change 14 11-61
TM 55-1520-210-23-2
TYPE OF DAMAGE
MECHANICAL DAMAGE
(AFTER CLEAN-UP) 0.015 IN 0.010 IN. 0.005 IN.
CORROSION DAMAGE
MAXIMUM AREA PER

FULL DEPTH REPAIR 1 IN.SQ. 0.10 IN. SQ. 0.10 IN.SQ.
Figure 11-20. Wear and Damage Limits— Mixing Lever Assembly Cyclic Control System
11-62
TM 55-1520-210-23-2
d. Detach end of control tube (8) from pilots cyclic u. Detach end of control tube (38) from arm of tube
stick by removing cotter pin (1), nut (9), two washers (3) and lever assembly by removing cotter pin (33), nut (37),
and bolt (10), (detail A, sheet 1). two washers (31) and bolt (36), (detail D, sheet 3).
e. Detach opposite end of control tube (8) from bell- Premaintenance Requirements for Control
crank (11) by removing cotter pin (1), nut (18), two wash- Tubes-Cyclic Control System
ers (13), and bolt (20), detail B, sheet 2).
f. Detach end of control tube (16) from copilots cy- Conditions Requirements
clic stick by removing cotter pin (1), nut (42), two washers Model All
(31), and bolt (41), (detail D, sheet 3). Part No. or Serial No. All
g. Detach opposite end of control rube (16) from Special Tools None
bellcrank (11) by removing cotter pin (1), nut (17), two Test Equipment Eddy Current Inspection
washers (13) and bolt (19), (detail B, sheet 2). Unit
h. Detach end of control tube (14) from bellcrank
(11) by removing cotter pin (1), nut (15), two washers Minimum Personnel Two
(13), and bolt (12), (detail B, sheet 2). Required
i. Detach opposite end of control tube (14) from mix- Special Environmental None
ing levers and support (43) by removing cotter pin (50), Conditions
nut (52), two washers (45) and bolt (53), (detail E, sheet References TM 1-1520-256-23
4).
j. Detach control tube (32) from lever (35) by remov-
11-98. Inspection — Control Tubes — Cyclic Control
ing cotter pin (33), nut (34), two washers (31) and bolt
System.
(30), (detail C, sheet 3).
k. Detach opposite end of control tube (32) from a. Inspect control tubes for corrosion, wear, and me-
mixing levers and support (43) by removing cotter pin chanical damage. Refer to figure 11-22 for wear and
(50), nut (52), two washers (45) and bolt (53), (detail E, damage limits. If a crack in the Control Tubes is sus-
sheet 4). pected, refer to TM 1-1520-256-23, Technical Manual
Aviation Unit Maintenance (AVUM) and Aviation Inter-
l. Detach control tube (49) from mixing levers and mediate Maintenance (AVIM) manual nondestructive in-
support (43) by removing cotter pin (50), nut (51), two spection procedures for UH-1 helicopter series.
washers (45) and bolt (48), (detail E, sheet 4).
b. Inspect clevis end holes for wear and clevis end
m. Detach opposite end of control tube (49) from for looseness in tube.
bellcrank (72) by removing cotter pin (57), nut (73), two
washers (54) and bolt (77), (detail F, sheet 5). 11-99. Repair or Replacement — Control Tubes —
n. Detach control tube (49) from mixing levers and Cyclic Control System (AVIM).
support (43) by removing cotter pin (50), nut (51), two
washers (45) and bolt (48), (detail E, sheet 4). a. Polish out corrosion or mechanical damage to
control tubes in accordance with limits of figure 11-22.
o. Detach opposite end of control tube (49) from
bellcrank (72) by removing cotter pin (57), nut (73), two b. Any damage to control tubes in excess of limits
washers (54) and bolt (77), (detail F, sheet 5). is cause for replacement of control tube.
p. Detach control tube (59) from bellcrank (61) by 11-100. Installation — Control Tubes — Cyclic Con-
removing cotter pin (57), nut (60), two washers (54) and trol System.
bolt (58), detail F, sheet 5).
a. Install control tubes (16, 38, 59, and 70, figure
q. Detach opposite end of control tube (59) from
11-21) by the rigging procedure (paragraph 11-55).
right fore and aft, and lateral cyclic actuator (paragraph
7-77). b. Align end of control tube (6, figure 11-21) on arm
r. Detach of control tube (70) from bellcrank (72) by of tube and lever assembly. Install bolt (5) with washer (3)
removing cotter pin (57), nut (71), two washers (54), and through clevis. Install washer (3), nut (4) and cotter pin
bolt (69), (detail F, sheet 5). (1), (detail A, sheet 1).
s. Detach opposite end of control tube (71) from c. Align end of control tube (6) to lever on bottom of
hydraulic cylinder assembly (paragraph 7-77). pilots cyclic stick. Install bolt (7), two washers (3), nut (2)
and secure with cotter pin (1), (detail A, sheet 1).
t. Detach end of control tube (38) from copilots cy-
clic stick by removing cotter pin (33), nut (40), two wash- d. Align end of control tube (8) on lever on
ers (31) and bolt (39), (detail D, sheet 3). bottom of pilots cyclic stick. Install bolt (10), two
Change 14 11-63
TM 55-1520-210-23-2
1. Cotter pin 6. Control tube

2. Nut 7. Bolt
4. Nut 9. Nut
5. Bolt 10. Bolt
Figure 11-21. Cyclic Control System (Bellcranks, Levers, Supports, and Control Tubes) –
11-64
TM 55-1520-210-23-2
11. Bellcrank 21. Nut

12. Bolt 22. Clevis
13. Washer 23. Bolt
14. Control tube 24. Bolt
15. Nut 25. Bearing
17. Nut 27. Nut
18. Nut 28. Support
19. Bolt 29. Nut
20. Bolt
11-65
TM 55-1520-210-23-2
30. Bolt 37. Nut

34. Nut 41. Bolt
35. Lever 42. Nut
36. Bolt
Figure 11-21. Cyclic Control System (Bellcranks, Levers, Supports, and Control Tubes) —
11-66
TM 55-1520-210-23-2
43. Mixing levers and support 49. Control tube

45. Washer 51. Nut
46. Bolt 52. Nut
48. Bolt
Figure 11-21. Cyclic Control System (Bellcranks, Levers, Supports, and Control Tubes) —
11-67
TM 55-1520-210-23-2
54. Washer 66. Bolt

55. Bolt 67. Bolt
56. Nut 68. Nut
58. Bolt 70. Control tube
59. Control tube 71. Nut
60. Nut 72. Bellcrank
61. Bellcrank 73. Nut
62. Nut 74. Nut
63. Bolt 75. Support
64. Nut 76. Bolt
65. Support 77. Bolt
washers (3), nut (9) and secure with cotter pin (1), h. Align forward end of control tube (32) to lever
(detail A, sheet 1). (35). Install bolt (30), two washers (31), nut (34), and
secure with cotter pin (33), (detail C, sheet 3).
e. Align end of control (8) on bellank (11).
Install bolt (20) with washers (13), nut (18) and secure
with cotter pin (1), (detail B, sheet 2). i. Align rod end bearing on aft end of control tube
(32) to mixing levers and support (43). Install bolt (53),
f. Align end of control tube (14) to bellcrank (11). two washers (46), nut (52), and secure with cotter pin
install bolt (12), two washers (13), nut (15) and secure (50), (detail E, sheet 4).
with cotter pin (1), (detail B, sheet 2).
g. Align opposite end of control tube (14) to j. Align end of control tube (47) to mixing levers
mixing levers and support (43). Install bolt (44), two and support (43). Install bolt (46), two washers (45),
washers (45), nut (53), and secure with cotter pin (50), nut (53), and secure with cotter pin (50), (detail E,
(detail E, sheet 4). sheet 4).
11-68
TM 55-1520-210-23-2
TYPE OF DAMAGE
MECHANICAL DAMAGE
CORROSION DAMAGE
(BEFORE CLEAN-UP) 0.0075 IN. 0.005 IN, 0.0025 IN.
MAXIMUM AREA PER
FULL DEPTH REPAIR 1 IN.SQ 0.10 IN.SQ. 0.10 IN.SQ.
BORE DAMAGE 0.002 IN. FOR ONE-FOURTH CIRCUMFERENCE
Figure 11-22. Wear and Damage Limits (Control Tubes, Links, and Clevises)—
Cyclic Control System (Sheet 1 of 2)
11-69
TM 55-1520-210-23-2
DAMAGE REPAIR AREA SYMBOLS

TYPE OF DAMAGE
MECHANICAL DAMAGE NO DAMAGE ALLOWED MAXIMUM DAMAGE AFTER

CLEAN-UP 0.005 IN.
NO CRACKS ALLOWED
NOTE: Maximum pIay allowed in bearing — 0.010 inch axial or 0.005 inch radial.
205001-1035-2
Figure 11-22. Wear and Damage Limits (Control Tubes, Links, and Clevises) –
Cyclic Control System (Sheet 2 of 2)
11-70
TM 55-1520-210-23-2
k. Align opposite end of control tube (47) to bell- (4) Remove cotter pin (57), nut (64), two wash-
crank (61). Install bolt (63), two washers (54), nut (62), ers 55 and bolt (55) from support (65) and remove bell-
and secure with cotter pin (57), (detail F, sheet 5). crank (61) from support.
l. Align end of control tube (49) to arm of mixing (5) Remove four nuts (57), washers (54), and
levers and support (43) bellcrank. Install bolt (48), two four bolts (66) from support (65) and remove support.
washers (45), nut (51), and secure with cotter pin (50),
(detail E, sheet 4). Premaintenance Requirements for Bellcranks,
m. Align opposite end of control tube (49) to bell- Levers, and Supports-Cyclic
crank (72). Install bolt (77), two washers (54), nut (73),
and secure with cotter pin (57), (detail F, sheet 5). Conditions Requirements
11-101. BELLCRANKS, LEVERS AND SUPPORTS — Model All
CYCLIC CONTROL SYSTEM. Part No. or Serial No. All
11-102. Description — Bellcranks, Levers and Sup- Special Tools None
port — Cyclic Control System. Various bellcranks, Test Equipment Eddy Current Inspection
levers and supports are incorporated in the cyclic control Unit
system. The supports are mounted to the airframe for Support Equipment None
attachment of levers and bellcranks. Minimum Personnel Two
Required
11-103. Removal — Bellcranks, Levers and Sup- Consumable Materials None
ports — Cyclic Control System.
a. Remove bellcrank (11, figure 11-21) and support Conditions
(28) as follows: (detail B, sheet 2). References TM 1-1520-256-23
(1) Remove access doors (68 and 69, figure
2-18). 11-104. Inspection — Bellcranks, Levers and Sup-
(2) Disconnect cyclic control tubes (8, 14 and ports — Cyclic Control System.
16, figure 11-21) and lateral cyclic clevis (22) from bell-
a. Inspect bellcranks, levers and supports for corro-
crank (11), (paragraph 11-97).
(3) Remove cotter pin (1), nut (29), washers spection limits. If a crack in the Bellcranks, Levers, and
(13) and bolt (26) from support (28) and remove bellcrank Supports is suspected, refer to TM 1-1520-256-23, Tech-
(11) and bearing (25) from support. nical Manual Aviation Unit Maintenance (AVUM) and Avi-
(4) Remove four nuts (27), washers (13), and ation Intermediate Maintenance (AVIM) manual nonde-
four bolts (24) from support (28) and remove support. structive inspection procedures for UH-1 helicopter
series.
b. Remove bellcrank (72) and support (75) as fol-
lows: (detail F, sheet 5). b. Inspect bellcranks and supports for loose bear-
(1) Remove cargo hook (paragraph 14-285). ings. Refer to paragraph 11-185, for bearing limits.
(2) Remove troop seat (paragraph 2-256), c. Inspect bellcranks and levers for clearance and
soundproofing blanket, and access door (80, figure 2-18) freedoms of movements.
from pylon island in cabin area.
11-105. Repair or Replacement — Bellcranks, Lev-
(3) Disconnect control tubes (49 and 70, figure ers and Supports — Cyclic Control System (AVIM).
11-21) from bellcrank (72), (paragraph 11-97).
a. Replace loose or damaged bearings. Refer to
(4) Remove cotter pin (57), nut (71), two wash- paragraph 11-185 for replacement procedures.
ers (54) and bolt (69) from support (75) and remove
bellcrank (72). b. Remove minor surface corrosion or repair allow-
(5) Remove four nuts (68), washers (54) and able damage using fine grit sandpaper (C235). Observe
four bolts (76) from support (75) and remove support. limits shown in figure 11-23.
c. Remove bellcrank (61) and support (65) as fol- 11-106. Installation — Bellcranks, Levers and Sup-
lows: (detail F, sheet 5). ports — Cyclic Control System.
(1) Remove cargo hook (paragraph 14-285).
a. Install tape (C278) on support (28, figure 11-21).
(2) Remove troop seat, soundproofing blanket, Apply zinc chromate primer (C312) to bolts (24). Position
and access door (80, figure 2-18) from pylon island in support to forward side of bulkhead at station 37.00.
cabin area. Install four bolts (24) with aluminum washers (13) and
(3) Disconnect control tubes (47 and (59, figure install four washers (13) with nuts (27), (detail B, sheet
11-21) from bellcrank (61), (paragraph 11-97). 2).
Change 14 11-71
T M 55-1520-210-23-2

TYPE OF DAMAGE
MECHANICAL DAMAGE
CORROSION DAMAGE
MAXIMUM AREA PER
FULL DEPTH REPAIR 1 IN.SQ. 0.10 IN.SQ. 0.10 IN. SQ.
NO CRACKS ALLOWED
Figure 11-23. Wear and Damage Limits (BelIcranks and Supports)–

Cyclic Control System
11-72
TM 55-1520-210-23-2
b. Position bellcrank (11) between ears of f. Install cargo hook (paragraph 14-145).
support (28). Apply primer (C312) to outer race
of bearing (25) and install bearing in top arm of g. Install access door (68, 69 and 80,
figure 2-18) and soundproofing blanket
support (28). Install bolt (26) with washer (13)
on transmission pylon in cabin area.
through support and bellcrank pivot and install
washer (13) with nut (29) and cotter pin (1),
h. Install troop seat (paragraph 2-260)
(detail B, sheet 2).
c. Install tape (C278) on support (65 or 75).
Apply primer (C312) to bolts (66 or 76). From 11-107. TAIL ROTOR CONTROL
inside transmission pylon support area, posi- SYSTEM.
tion support (65 or 75) to aft side of bulkhead
at either right or left BL 9.70, at WL 21.00. 11-108. Description — Tail Rotor Control
Install four bolts (66 or 76) with washers (54) System. a. The tail rotor control system (figure
through bulkhead and support and install alu- 11-24) includes control pedals, pedal adjusters, a
force gradient (centering spring) assembly with an
minum washers (54) and nuts (56 or 68), (detail
electrically operated magnetic brake, hydraulic
F, sheet 5). actuator, a quadrant, cables and control chain
d. Position bellcrank (61 or 72), with stop at operating a pitch control mechanism mounted
pivot point facing up, to support (65 or 65). through the tail rotor shaft, and connecting linkage
Install bolt (55 or 68) with aluminum washer Actuation of pedals causes power-assisted pitch
(55) through support and bellcrank. Install alu- change of tail rotor blades to offset main rotor torque
minum washers (54) with nuts (64 or 74) and and control directional heading of helicopter.
cotter pins, (detail F, sheet 5).
e. Attach control tubes (47, 49, 59 or 70) as
required (paragraph 11-100). 11-109. Deleted.
11-73
TM 55-1520-210-23-2
11-74
TM 55-1520-210-23-2
Figure 11-24. Tail Rotor Control System (Sheet 2 of 2)
11-75
TM 55-1520-210-23-2
Figure 11-25. Tail Rotor Control Crosshead and Link Usage
11-76
TM 55-1520-210-23-2
Figure 11-26. Adjuster Assembly — Tail Rotor Controls —

Removal and Installation — Typical
11-120. Inspection — Adjuster Assembly e. Inspect bushings in bellcrank (1), upper plate
(AVIM). a. Inspect chain (32, figure 11-27) for (6), lower plate (8), SUPPORT (14), SUPPORT assembly
wear, damaged links, and corrosion. (34) for wear, elongation, and looseness. Maximum
allowable bushing wear is 0.002 inch over 1/4 of cir-
cumference of bore.
b. Inspect sprockets (33 and 41) for wear and
chipped or missing teeth. 11-121. Repair or Replacement — Adjuster
Assembly (AVIM). a. Replace components that do
c. Inspect keys (31 and 42) for wear. not meet inspection requirements.
d. Inspect bellcrank (1) and support (34) for b. Repair adjuster assembly within limits
corrosion and damage. specified on figure 11-28.
Change 2 11-79
TM 55-1520-210-23-2
Figure 11-27. Adjuster Assembly - Tail Rotor Controls - Disassembly and Assembly (Sheet 1 of 2)
11-80
TM 55-1520-210-23-2

31. Key 38. Cotter pin
32. Chain 39. Nut
33. Sprocket 40. Washer
34. Support 41. Sprocket
35. Washer 42. Key
36. Nut 43. Bolt
Figure 11-27. Adjuster Assembly - Tail Rotor Controls - Disassembly and Assembly (Sheet 2 of 2)
11-81
TM 55-1520-210-23-2
204-001-762-13 204-001-762-15
ADJUSTER ASSEMBLY ADJUSTER ASSEMBLY
TYPE OF DAMAGE
MECHANICAL DAMAGE
CORROSION DAMAGE
MAXIMUM AREA PER
FULL DEPTH REPAIR 1 IN. SQ. 0.10 IN. SQ. 0.10 IN. SQ.
NO CRACKS ALLOWED
Figure 11-28 Wear and Damage Limits — Adjuster Assemblies — Tail Rotor Controls
11-82
TM 55-1520-210-23-2
11-122. Assembly — Adjuster Assembly N O T E

(AVIM). a. Place retainers(17 and 19, figure 11-27)
and gear (18) on shaft (20) and place inside support Ensure tape (C278) covers entire
(14). faying surface area and extends at
least 1/4 inch beyond joint edges.
b. Slide nut (11) into support (14) and inside
shaft (20) with the 45 degree chamfer on the opposite
side of arm of bellcrank assembly (1). b. Secure adjuster assembly to structure using
bolts (11, figure 11-26), aluminum washers (2), and
nuts (10).
c. Place pin (21) to attach shaft (20) and nut(11).
c. Place tube (12) on adjuster assembly and
d. Install screw (16). attach with bolt (8), washers (2), and nut (9). Secure
with cotter pin (7).
e. Install spacer (7), and link (9).
f. Position screw (23) in link (9) and install pin d. Install tube (15) and attach bolt (17), washers
(24). Secure pin (24) with split pin (22). (2), and nut (16). Secure with cotter pin (7).
e. Install control tube (5) on adjuster assembly

g. Install nut (27), washers (3 and 4), and bolt(2) using bolt (1), washers (2), and nut (6). Secure with
to attach plates (6 and 8). Tighten nut and install cotter cotter pin (7).
pin (26).
f. Install control tube (3) using bolt (19),
washers (2), and nut (18). Secure with cotter pin (7).
h. Install nut (12), washers (10 and 25), and bolt
(5). Tighten nut and install cotter pin (13).
g. Install force gradient (4) using bolt (20),
i. Position bellcrank (1), with inner gear (29) in washers (2), and nut (13). Secure with cotter pin (7).
bellcrank (1), to support assembly (34).
h. Place knob assembly over adjuster and attach
j. Install bolt (30), with key (31) and sprocket securely to floor with bolts (14) and washers (2)
(33) through support (34), bellcrank(1) and inner gear i. Install access doors (70, figure 2-18), and door
(29). at Station 37, B.L. 22.
j. Install pilots and copilots seats (paragraph 2-
k. Install new pin (28) through inner gear (29) 223 or 2-252).
and bolt (30). Stake pin on both sides.
11-124. CABLES – TAIL ROTOR
l. Position chain (32) on aft sprocket (33). CONTROLS.
m. Assemble bolt (43), key (42), and forward 11-125. Description — Cables — Tail Rotor
sprocket (41 ). Position forward sprocket inside chain
Controls. Tail rotor control cables are connect-
and install bolt through support (34).
ed between a quadrant, mounted in front end
n. Install washer (40) and nut (39). Tighten nut of tail boom, and ends of a chain assembly
and install cotter pin (38). which actuates the tail rotor control quill and
pitch change rod. Cable diameter for this instal-
o. Install washer (35) and nut (36). Tighten nut lation is 1/8 inch. Left and right cables are
and install cotter pin (37). each in two sections, connected by turnbuckles
with speed rig type barrels which can be dis-
connected and reconnected without distur-
11-123. Installation — Adjuster Assembly bing cable tension adjustment provided the
a. Inspect structural intercostal mounting sur- threaded turnbuckle adjustment is not
faces of adjuster assembly (figure 11-26) to disturbed. Cable connectors are located
determine if tape (C278) is torn or missing. on front of tail boom, vertical fin under
Install new tape (C278) if torn or missing. drive shaft access door.
1 1 - 8 3/(11-84 blank)
TM 55-1520-210-23-2
NOTE g. Remove cotter pin (1), washer (9) attaching pin

(15).
When lockwiring turnbuckles, refer to
h. Remove cotter pin (1) nut (14), washers (9) and
figure 11-30 (sheet 2 of 2) and TM
bolt (11) attaching pulley (16).
1-1500-204-23 (Series).
i. Remove cotter pin (1), nut (13), washers (9),
11-126. Adjustment - Cables - Tail Rotor Controls. and bolt (10) attaching pulley (12).
NOTE j. Remove cotter pin (1), nuts (19), washers (20),

and bolts (17) attaching cable assemblies (7) to chain
assembly (18).
Tail rotor control cable will be adjusted
during rigging (paragraph 11-157). k. Remove cable assemblies (7).
11-127. Inspection - Cables - Tail Rotor Controls. 11-129. Repair or Replacement - Cables - Tail
Rotor Controls.
a. Open access cover (14, Figure 2-18) and
remove access covers (13, 16, 17 and 18). a. Replace cable assembly if it does not meet
inspection requirements outlined in paragraph 11-127.
b. Inspect cables for worn sections and broken
strands (refer to TM 1-1500-204-23 (Series)). b. Replace cable assembly if evidence of corro-
sion exists where end fitting is swaged on cable.
NOTE 11-130. Installation - Cables Tail Rotor Controls.
A new commercially manufactured
a. Attach cable assemblies (7, Figure 11-29) to
cable assembly may be flush with ball.
chain (18), using bolt (17), washer (20), and nut (19).
This is not cause for rejection.
Nut should be fingertight, allowing clevis to realign
itself when deflected. Secure with cotter pin (1).
c. Inspect pulleys for flat spots, damage, and tight
Ensure nut and cotter pin installation is on inboard side
or worn bearings. next to driveshaft.
d. Inspect grommets for wear and signs of mis- b. Install cable 7 into pulley 12 groove.
alignment.
c. Attach pulley (12) using bolt (10), washers (9)
e. Inspect supports for condition, security and and nut (13). Secure with cotter pin (1).
elongation of pulley pivot holes.
d. Attach pulley (16) using bolt (11), washers (9),
11-128. Removal - Cables - Tail Rotor Controls. and nut (14). Secure with cotter pin (1).
a. Open access cover (14, Figure 2-18) and NOTE
remove access covers (13, 16, 17, and 18).
If clevis pin is a loose fit in the pulley
b. Disconnect end of cable assemblies (4, figure bracket, proseal may be used on instal-
11-29) barrel assembly (5) by removing lockwire (6). lation to provide a close fit and to pre-
c. Remove cotter pin (1) and pin (2) attaching vent looseness.
opposite end of cables assemblies (4) to quadrant (3).
e. Align cable assemblies on pulleys.
c.1. To facilitate removal of bolt (28), remove four
nuts (44) washers (45), and bolts (46) attaching pulley f. Attach pin (15) to pulley mount using washer(9)
bracket assembly (43) to structure. and cotter pin (1).
d. Remove cotter pin (1), nut (32), washers (27), g. Place left cable (4) on pulley (26) and attach
and bolt (31), attaching pulley (26). pulley using bolt (28), washer (27) and nut (30). Secure
with cotter pin (1).
e. Remove cotter pin (1), nut (30), washers (27),
and bolt (28) attaching pulley (26). h. Place right cable (4) on pulley (26) and attach
pulley using bolt (31), washers (27), and nut (32).
f. Remove cable assemblies (4). Secure with cotter pin (1).
Change 7 11-85
TM 55-1520-210-23-2
h.1 Attach pulley bracket assembly (43) to 11-130.1 Pully Bracket-Tail Rotor Controls.
structure using four bolts (46), washers (45)
and nuts (44). a. Removal - Tail Rotor Control Cables.
Disconnect two tail rotor control cable quick disconnects/
i. Place cables (4) on quadrant assembly (3) and speed rigs. Refer to paragraph 11-128. Remove attaching
hardware, 3 sets of nuts (49, figure 11-29), washers
attach cables using pin (2). Secure with cotter pin (1). (48), and bolts (47).
b. Inspection - Pulley Bracket.

Inspect Pulley Bracket (8, figure 11-29) at the two
outboard attachment bolts (47) holes using a 10X
Do not use gripping type tools (i.e. slip joint, magnifying glass for cracks.
pliers, vise grip, and etc,) to connect cable
and barrel assemblies. Permanent damage c. Installation - Pulley Control Bracket.
to tail rotor controls may occur. Apply pressure sensative tape (C287) to mating
surfaces of pullye control bracket (8). Install 3
j. Attach end of cables (4) with barrel as- sets of nuts (49), washers (48), and bolts (47).
Reconnect cable quick disconnects/speedrigs.
sembly (5). Secure with lockwire (6), (C155).
11-86 Change 16
TM 55-1520-210-23-2
NOTE
SEE SHEET 3 OF 3
FOR EXPLODED VIEW
Figure 11-29. Cable Assemblies – Tail Rotor Controls —

Change 16 11-87
TM 55-1520-210-23-2
21. Screw 30. Nut 39. Screw

22. Washer 31. Bolt 40. Chain assembly
23. Fairlead 32. Nut 41. Cover
24. Spacer 33. Bolt 42. Bolt
25. Nut 34. Washer 43. Pulley bracket assembly
26. Pulley 35. Nut 44. Nut
27. Washer 36. Guard 45. Washer
28. Bolt 37. Nut 46. Bolt
29. Pin 38. Housing pan
Figure 11-29. Cable Assemblies — Tail Rotor Controls —

1 1 - 8 8 Change 16
TM 55-1520-210-23-2
47. Bolt
48. Washer
49. Nut
Figure 11-29. Cable Assemblies – Tail Rotor Controls –

Change 16 11-88.1/(11-88.2 blank)

TM 55-1520-210-23-2
NOTE upper forward section of the tail boom. The quadrant is

Speed rigs should be disconnected when utilized to interconnect the push-pull tubes and the tail
adjusting cable tension, then reconnected rotor control cables.
and lockwired (C155) after adjustment is
made. 11-139. Removal — Control Quadrant.
k. Adjust cable tension 40 TO 60 pounds by adjust- a. Remove cable assemblies (paragraph 11-128).
ing speed rigs equally. Lockwire (C155) speed rigs lower b. Disconnect control tube (14) from bellcrank (8) by
section (figure 11-30, sheet 2). removing cotter pin (1), bolt (4), washers (3), and nut (2).
l. Lubricate chain with cloth moistened with oil c. Remove link assembly (10) by removing cotter
(C166), (C168), or (C136). pins (1), bolts (15), washers (16), and nuts (17).
m. Rig cables in accordance with paragraphs d. Remove cotter pin (1), bolt (5), washers (6), and
11-109 and 11-110. nut (7), and remove bellcrank (8) from upper support
n. Install access doors (16, 17, and 18, Figure 2-18) assembly.
and close access cover (14). e. Remove cotter pin (1), bolt (18), washers (19),
and nut (20) securing quadrant in supports.
11-131. PULLEYS — TAIL ROTOR CONTROLS.
f. Remove quadrant (13) from helicopter.
11-132. Description — Pulleys — Tail Rotor Con-
trols. There are four phenolic pulleys located in the tail- g. Remove bolts (21), aluminum washers (22),
boom at fin station 35.10 and 75.33. The pulleys are washers (23), and nuts (24) securing lower support as-
identical and are attached to brackets with standard sembly (26) to bulkhead.
hardware. h. Remove lower support assembly (26) and shim
(25) from helicopter. Retain shim for reassembly.
11-133. Inspection — Pulleys — Tail Rotor Con-
trols.
a. Inspect pulleys for excessive grooving by visual Premaintenance Requirements for Control
examination of the surface, and by rotating pulley and Quadrant
observing if the cable twists, rotates, or jumps up and
down, as a result of interplay between the grooves of the Conditions Requirements
pulley and the lay of the cable.
Model All
b. Inspect pulley bearings for roughness, binding,
noise, rust, lubricant leakage, and excessive looseness. Part No. or Serial No. All
Special Tools None
11-134. Removal — Pulleys — Tail Rotor Con-
trols. Refer to paragraph 11-128 for removal. Test Equipment Eddy Current Inspection
Unit
11-135. Repair or Replacement — Pulleys — Tail Ro- Support Equipment None
tor Controls. Replace pulley if damaged or worn.
11-136. Installation — Pulleys — Tail Rotor Con- Required
trols. Refer to paragraph 11-130 for installation.
11-137. CONTROL QUADRANT. Special Environmental None
Conditions
11-138. Description — Control Quadrant. The tail ro-
tor control quadrant (13, figure 11-30) is located in the References TM 1-1520-256-23
Change 14 11-89
TM 55-1520-210-23-2
11-140. Inspection — Control Quadrant. f. Support P/N 204-001-793-5 with shims is to be

mounted on a table with pivot bolt for quadrant P/N
a. Inspect for visible nicks and scratches (figure
204-001-779-5 mounted vertically. A dial indicator is to
11-31).
be used to measure warpage of quadrant while it is ro-
b. Inspect quadrant, support, bellcrank and link as- tated before it is installed in the tailboom. The warpage
sembly for mechanical damage and corrosion (figure tolerance is to be ±.050 inch.
11-31).
c. Inspect the quadrant for cracks. No cracks al- 11-141. Repair or Replacement — Control Quad-
lowed. If a crack in the Control Quadrant is suspected, rant. Repair or replace control quadrant in accordance
refer to TM 1-1520-256-23, Technical Manual Aviation with limits specified in figure 11-31.
Unit Maintenance (AVUM) and Aviation Intermediate
Maintenance (AVIM) manual nondestructive inspection 11-142. Installation — Control Quadrant.
procedures for UH-1 helicopter series.
a. Install lower support assembly (26, figure 11-30)
d. Inspect all bolt holes for elongation (figure
and shim (25), and secure to bulkhead with bolts (21),
11-31).
aluminum washers (22), washers (23), and nuts (24).
e. Inspect bearings for wear and roughness (figure Ensure that shim contains same number of laminations
11-44). as when removed.
11-90 Change 15
TM 55-1520-210-23-2
1. Cotter pin 11. Cotter pin (2 reqd)

2. Nut 12. Pin (2 reqd)
3. Washer 13. Quadrant
4. Bolt 14. Control tube
5. Bolt 15. Bolt
6. Washer 16. Washer
7. Nut 17. Nut
8. Bellcrank 18. Bolt
9. Cable assembly (2 reqd) 19. Washer
10. Link assembly 20 Nut
Figure 11-30. Quadrant Assembly — Tail Rotor Controls — Removal and Installation (Sheet 1 of 2).
Change 14 11-90.1/(11-90.2 blank)

TM 55-1520-210-23-2
Figure 11-30. Quadrant Assembly — Tail Rotor Controls —

11-91
TM 55-1520-210-23-2
TYPE OF DAMAGE
MECHANICAL DAMAGE
CORROSION DAMAGE
(BEFORE CLEAN-UP) 0.0075 IN. 0.005 IN.
MAXIMUM AREA PER
FULL DEPTH REPAIR 1 IN.SQ. 0.10 IN. SQ.
NUMBER OF REPAIRS ONE PER AREA ONE PER AREA
Figure 11-31. Wear and Damage Limits-Quadrant Assembly—

Tail Rotor Controls
11-92
TM 55-1520-210-23-2
b. Position quadrant (13) in position between 11-143. CONTROL TUBE AND QUILL - TAIL
upper and lower support assemblies, and install bolt ROTOR.
(18), washer (19) and nut (20).
c. Check for 0.010 inch minimum end clearance
between quadrant (13) and lower support assembly 11-144. Description - Control Tube and Quill -
(26). Secure nut (20) with cotter key (1). Tail Rotor. Tail rotor blade pitch control is accom-
plished by means of a control quill assembly mounted
d. Connect bellcrank (8) to upper support assem- in right side of 90 degree gearbox, with a control tube
bly with bolt (5), washers (6), nut (7). Secure with cotter extending through hollow rotor drive shaft to a pitch
pin (1). control cross-head and links connected to tail rotor.
Control quill has a sprocket, actuated by a chain
e. Connect link assembly (10) to quadrant (13) attached to control cables, with a worm thread engage-
and to bellcrank (8) with bolts (15), washers (16) and ment to control tube. Rotation of sprocket is trans-
nuts (17). Secure with cotter pins (1). mitted through tube as linear motion at crosshead and
f. Connect control tube (14) to bellcrank (8) with pitch change links. Chain and sprocket are enclosed
bolt (4), washers (3) and nut (2). Secure with cotter pin by a metal housing pan with a removable cover for
(1). access (figure 11-32).
g. Install cable assemblies (paragraph 11-130).

h. Rig tail rotor control cables in accordance with NOTE
paragraphs 11-109 and 11-110.
i. Secure cable terminals to speed rigs (27) with The following procedures apply to tail
lockwire (29, C155). rotor control chain, PN 1560-UH-1-752-1
j. Ensure cable does not twist chain. Swivel is (roller type chain).
located between chain and cable. When adjusting ten-
sion cable can become twisted. As it works the twist
will transfer into the chain. 11-145. Inspection Tail Rotor Pitch Control.
Change 7 11-93
TM 55-1520-210-23-2
1. Bolt 10. Control Tube

3. Housing Cover 12. Control quill
4. Sprocket guard (roller type chain install) 13. Screw
5. Control chain (roller type) 14. Housing pan
6. Washer 15. Deleted
8. Nut 17. Washer
9. Gearbox Case 18. Nut
Figure 11-32. Tail Rotor Control Tube and Quill — Removal and Installation
11-94 Change 5
TM 55-1520-210-23-2
NOTE NOTE
A 5/16 inch deep well socket maybe
Apply following procedure to determine
bored out to fit over the 1/4 inch
amount of looseness between internal
stud if difficulty is experienced in
spline of tail rotor control head slider and
rotor shaft spline and looseness in pitch the removal of nuts (18).
change rod bearings and in pitch change
threads. e. Remove pan.
(1) Mount a dial indicator on tail rotor shaft
with indicator against crosshead as illustrated in f. Pull control quill (12) with packing (11)
figure 11-32.1. and control tube (10) out of gear case (9). Cover
(2) With left control pedal held full forward, open port. Detach tube from quill by turning
manually test crosshead for radial play not to exceed sprocket to disengage thread.
0.030 inch. 11-147. Disassembly — Control Tube and
(3) With full right pedal, repeat check for radial Quill — Tail Rotor
play not to exceed 0.055 inch. Premaintenance requirements for
(4) With pedals held neutral, manually test for disassembly of control quill
axial play (along shaft centerline without radial
motion) not to exceed 0.018 inch. Excessive axial Conditions Requirements
play would Indicate worn or base pitch change rod
bearings or worn pitch change threads. Model All
Special Tools (T43)

Quill housing (10, figure 11-33) is
Test Equipment None
soft metal. Improper use of tools to
remove housing may cause damage
Support Equipment Surface block,
to quill housing.
Vee block, dial
indicator, recircu-
11-146. Removal — Control Tube and Quill lating type
— Tail Rotor. a. Remove tail rotor pitch control automatic oven.
crosshead assembly (paragraph 5-92). Be sure
bearings and retaining nut are removed from Minimum Personnel One
pitch control tube. Required
b. Remove two bolts (1, figure 11-32), washers
Consumable Materials (C261), (C162),
(2 and 7), nut (8), and cover (3) from housing pan
(C277), (C246),
(14). Remove screw (13) from bracket of pan (14).
(C271)
c. Disconnect speed rigs to allow slack in
control cables. Before removing chain from Special Environmental None
sprocket, mark the sprocket with grease pencil Conditions
to ensure proper line up of teeth upon reinstalla-
tion.
a. If not previously removed, remove cotter pin
NOTE (20) and retaining nut (19, figure 11-33) while holding
Control tube (10) may be removed sprocket (18) in padded jaws of vise or other suitable
tool. Remove sprocket.
through gearbox output shaft with-
out removing control quill (12). Ro- b. Remove retainer (17) with seal (16) and press
tate sprocket to disengage. out seal with hollow end of tool (T43).
c. Remove spacer (15) and packing (14). Use tool
d. Remove three nuts (18), washers (17) and (T43) to press duplex bearings (13) from control nut
guard (4 or 16) from gear case studs. (12).
11-95
TM 55-1520-210-23-2
11-148. Cleaning — Control Tube and Quill —

Tail Rotor

toxic. Avoid skin contact and breathing
of solvent vapors.
11-96
TM 55-1520-210-23-2
Figure 11-32.1. Checking Tail Rotor Pitoh Control for Looseness
11-97
TM 55-1520-210-23-2
1. Deleted 11. Preformed packing

2. Deleted 12. Control nut
3. Nut 13. Duplex bearings
4. Washer 14. Preformed packing
5. Sprocket guard (roller type chain install) 15. Spacer
6. Control chain (roller type chain) 16. Seal
7. Control quill 17. Bearing retainer
8. Packing 18. Sprocket
9. Control tube 19. Retaining nut
10. Quill housing 20. Cotter pin
21. Washer
Figure 11-33. Control Quill – Exploded View
11-98
TM 55-1520-210-23-2
a. Clean disassembled parts with solvent (C261). ITEM NOMENCLATURE CODE

Visually inspect all parts for damage or excessive wear.
Spacer (15, figure 11-33) may be reversed when worn 2, 5 Sprocket Guard F
excessively on one side. 9 Control M
b. Dry with filtered compressed air. 10 Quill Housing F
19 Retaining Nut M
Premaintenance Requirements for Control 18 Sprocket F
Quadrant 17 Bearing Retainer F
Conditions Requirements 15 Spacer M
Model All 12 Control Nut F
e. Inspect parts dimensionally (figure 11-34). Also
Special Tools None check control tube for out-of-round condition. Mount con-
Test Equipment Fluorescent Penetrant trol tube on centers, take measurement at mid-point of
Method control tube, measurement not to exceed 0.020 T.I.R
Eddy Current Inspection (Total Indicator Reading).
Unit f. Inspect full length of chain using 16 pitches in
Magnetic Particle Method center of chain. If length exceeds 6.18 inches, replace
Support Equipment None the chain.
Minimum Personnel Two g. Inspect chain as follows:
Required
Consumable Materials None WARNING
Conditions Cleaning materials are flammable and tox-
ic. Avoid skin contact and breathing of sol-
vent vapors.
11-149. Inspection — Control Tube and Quill — Tail (1) Clean chain with solvent (C261) and stiff
Rotor. bristle brush. Air dry.
a. Visually inspect all parts for damage or excessive (2) Inspect for broken links and missing pin
wear. Spacer (15, Figure 11-33) may be reversed when heads.
worn excessively on one side.
(3) Inspect outer links for cracks using a good
b. Inspect bearings for smooth operation. light source and a ten power magnifying glass. Special
c. Inspect control nut, control tube and quill housing attention will be given the chain that travels over the
for burrs or chipping of threads and splines. Inspection of sprocket of the control quill and 6 inches either side of this
spline wear shall be done visually. If spline teeth are worn section. Any cracks or broken links on any portion of the
such that less than half (50%) of each tooth contact area chain is cause for rejection of the chain.
remains, the part should be rejected. The control tube or (4) Nicks and scratches in the link plates up to
the quill housing can be replaced independently of each .010 inch in depth are acceptable. No clean up is re-
other. quired.
d. Inspect the following parts by magnetic particle (5) Wear and pitting of the bushings is accept-
(Code M) or fluorescent penetrant (Code F) methods able provided it does not result in exposure of the pin or
(Figure 11-33) if cracks are suspected. Refer to TM affect operation of the chain, i.e., binding or climbing on
43-0103. Alternatively refer to TM 1-1520-256-23, Tech- the sprocket.
nical Manual Aviation Unit Maintenance (AVUM) and Avi-
ation Intermediate Maintenance (AVIM) manual nonde- (6) Loose bushings, i.e., those free to turn in the
structive inspection procedures for UH-1 helicopter link plates, are unacceptable and cause for chain rejec-
series. tion.
Change 14 11-99
TM 55-1520-210-23-2
(7) Any crack in either the link plates or bush- Cracks in the head are also acceptable provided they do
ings is unacceptable and cause for chain rejection. not result in loss of head material.
NOTE h. Sprocket P/N 1560-UH1-753-1:
The bushings are roll formed from flat (1) Nicks, scratches, wear and pitting are ac-
stock resulting in a lengthwise seam ceptable provided they do not affect the operation of the
which may in some cases be misinter- chain.
preted as a crack. One such indication per
bushing is therefore considered normal (2) Cracks are unacceptable and cause for
and acceptable. It is also permissible for support rejection.
this seam to be open up to a maximum of
0.020 inch. 11-150. Repair — Control Tube and Quill — Tail Ro-
tor (AVIM).
(8) Wear of pin heads is acceptable provided
sufficient material remains to ensure pin security, i.e., a. Dress splines or threads with fine India stone
wear of overlapping area to a feather edge is acceptable. (C264) if nicks, burrs or scratches are visible.
11-100 Change 14
TM 55-1520-210-23-2
b. Apply solid film lubricant (C162) on splines and c. Replaced damaged cork plug in screw-thread
threads at control screw end of control rod as follows: end of control tube. Coat cork with wet shellac (C246)
and press into place with outer face 0.30 inch deep in
(1) Mask off other areas. screw-thread end fitting.
(2) Apply 0.0001 TO 0.0002 inch film thickness d. Replace damaged cork plug in outer end of con-
of solid film lubricant (C162), on splines and threads. trol nut. Coat cork with wet shellac (C246) and press into
place with inner face 1.85 inches from inner end of con-
(3) Cure at 375° F (190°C) for 60 minutes in a
trol unit.
recirculating type automatically controlled oven.
(4) Test film adhesion by applying strip of one- 11-151. Replacement — Control Tube and Quill —
inch adhesive tape (C271) with firm finger pressure, then Tail Rotor.
removing tape with one abrupt motion. a. Replace seals and packings at reassembly.
(5) No large particles or flakes should peel off b. Replace all parts that fail inspection require-
with tape. ments.
ITEM NOMENCLATURE MIN. MAX REPLACE

1 Control Nut-Bearing Seat OD 0.9835 0.9847 0.9825
2 Duplex Bearing
3 Duplex Bearing
4 Quill Housing ID 1.6535 1.6545 1.6555
5 Retaining Nut-Torque In/Lb 100 300
Figure 11-34. Control Quill — Limits Chart
Page 11-101.1/(11-101.2 blank) has been deleted
Change 14 11-100.1/(11-100.2 blank)

TM 55-1520-1520-210-23-2
c. Replace guard, cover, or pan when cracked or c. Place spacer (15) over packing against inner
damaged. race of bearing (13).
d. Replace control tube for faulty operation or d. Apply a small amount of sealing compound
visible defects such as cracks, bending and damaged (C242) or compound, retaining (C79) around seal (16)
threads or splines. before pressing into bearing retainer (17). Press seal
e. Replace control chain when faulty operation or (16), with lip inward, into bearing retainer (17) until flush
visible indications of excessive wear occur. When chain with outer face of retainer plate, using tool (T43).
is replaced, replace sprocket on control quill as outlined e. Place retainer assembly over spacer against
in step f. outer race of bearing.
f. Sprocket PN 1560-UH1-753-1. Nicks, scathes,
wear and pitting are acceptable provided they do not NOTE
affect operation of chain. Cracks are unacceptable and If required, a washer (21) may be
cause for sprocket rejection. Installed to prevent contact and
(1) Remove cotter pin (20) and retaining nut riding up of chain (6) on the spacer,
(19) while holding sprocket (18) carefully in padded jaws PIN 204-010-766 (15) and/or to align
of suitable tool or vise. cotter pin hole of retaining nut.
(2) Remove and replace sprocket (18) without Chain (6) must be pushed sideways
separating other parts. on sprocket (18) as far as possible to
(3) Reinstall retaining nut (19) on end of control check if It will contact the spacer, PIN
nut (12). Torque 100 TO 300 inch-pounds and align 204-010-766 (15). See figure D-357,
cotter pin holes. Appendix D, for manufacture data on
(4) Install cotter pin (20) with spread ends washer (21).
parallel to face of sprocket and bent flat against hex face f. Place sprocket (18) on splines of control nut (12)
of retaining nut (19). and against spacer (15).
11-152. Assembly - Control Tube and Quill -Tall g. Install retaining nut (19) while holding sprocket
Rotor. carefully in padded jaws of vise or other suitable tool.
Torque nut 100 TO 300 inch-pounds with holes aligned
for cotter pin (20) spread and bent against the hex face
of retaining nut (19) parallel to sprocket face.
h. Place packing (11) on inner face of quill hosing
(10) and assemble housing over bearing.
When installing Duplex Bearings,
11-153. Installation - Control Tube and Quill - Tall
insure that the scribed lines on each
Rotor.
bearing half form a "V’ with the
a. Insert control tube (10, figure 11-32) through
scribed marks aligned. inner end of control quill (12) with splines meshed. Turn
sprocket to engage quill control nut on threads of tube.
Place packing (11) on quill.
b. Uncover port on right side of 90 degree gearbox
(9). Insert control tube (10) carefully through rotor shaft
Prior to installing control nut, ensure that
and seat quill flanges over mounting studs.
control tube threads fully engage control
c. Place housing pan (14) on studs and secure
nut threads. No binding should occur.
temporarily with nuts (18) and washers (17), and with
a. Press duplex bearings (13, figure 11-33) back-
screw (13) through bracket on lower comer into matching
to-back on control nut (12) using tool (T43).
nutplate of vertical fin.
b. Place packing (14) in recess between bearing
d. Check gap between flanges of quill housing and
seat and splines of control nut (12).
retainer. If gap is more that 0.025 but less than 0.040
inch, add one thin aluminum alloy washer between
housing and retainer on each stud. If gap is more than
0.040 inch, add two thin aluminum washers in the same
manner. Packing (11, figure 11-33) must be removed
when checking this gap. After proper gap is established,
install
Change 10 11-101
TM 55-1520-210-23-2
packing (11, figure 11-33), bearing retainer (17), washers (1) Nicks and scratches in the link plates up to
(17, figure 11-32), and nuts (18, figure 11-32). Apply 0.010 inch in depth are acceptable. No clean up is
sealant (C244) externally around joints at outer joints at required.
quill housing (figure 11-32). (2) Wear and pitting of the bushings is
e. Install pitch change control head assembly acceptable provided it does not result in exposure of the
(paragraph 5-97). pin or affect operation of the chain, i.e., binding or
NOTE climbing on the sprocket
Refer to Figure 16 for lubrication (3) Loose bushings, i.e., those free to turn in the
instructions. link plates, are unacceptable and cause for chain
f Install and connect control chain (5) (paragraph rejection.
11-157).The control chain should completely engage the (4) Any crack in either the link plates or
sprocket. I the control chain rides up on the sprocket bushings is unacceptable and cause for chain rejection.
teeth, the sprocket may have excessive wear or, if new,
may have been manufactured incorrectly. Replace NOTE
sprocket as necessary. The bushings are roll formed from
g. Complete rigging by installing sprocket guard (4) fiat stock resulting in a lengthwise
on mounting studs, secure with nuts (18) and washers seam which may in some cases be
(17). Torque nuts 50 TO 70 inch-pounds. misinterpreted as a crack. One such
h. Install housing cover (3) using two bolts (1), Indication per bushing is
washers (2 and 7), nut (8). Lockwire (C155) bolts (1) therefore considered normal and
together. acceptable. It is also permissible for
this seam to be open up to a
11-154. TAIL ROTOR CONTROL CHAIN (ROLLER maximum of 0.020 Inch.
TYPE) AND SPROCKET ASSEMBLY - MAINTENANCE
PROCEDURES. (5) Wear of pin heads is acceptable provided
sufficient material remains to ensure pin security, i.e.,
11-155. Deleted. wear of overlapping area to a feather edge is acceptable.
Cracks in the head are also acceptable provided they do
11-156. Deleted. not result in loss of head material.
b. Sprocket P/N 1560UH1-753-1.
11-16.1. Inspection - Tall Rotor Control Chain Part (1) Nicks, scratches, wear. and pitting are
Number 1560-UHI-752-1 (Roller Type). acceptable provided they do not affect the operation of
the chain.
a. Using a suitable light and ten power magnifying (2) Cracks are unacceptable and cause for
glass, inspect both sides of chain as follows: sprocket rejection.
11-102 Change 10
TM 55-1520-210-23-2
11-157. Installation - Tail Rotor Control Chain NOTE

Part Number 1560-UH-1-752-1 (Roller Type).
a. Bottom out control quill by turning clockwise to Nut and cotter pin to be on inboard side
end of travel. Position sprocket, part number next to driveshaft.
1560-UH-1-753-1, on control quill splines with any f. With sprocket bottomed out in a clockwise posi-
convenient tooth of sprocket in line with upper chain tion, left tail rotor control pedal held against stop, pull
guard mounting stud (figure 11-35). on bottom control cable so as to bottom out servo.
NOTE Install control chain over sprocket and connect upper
speed rig.
This sprocket position has been found
to be the best for obtaining the sprocket NOTE
movement limit called out in stop h. The
sprocket could be removed to another Move sprocket counterclockwise only
position on the splines if necessary to as necessary to engage chain.
meet the final adjustment. g. Actuate full right and left tail rotor control pedal
stopping and holding in left pedal position. Mark any
b. Using tail rotor control chain to hold sprocket,
convenient tooth of sprocket and cover pan with
hold sprocket near midposition (figure 11-35). Approxi-
grease pencil.
mately 1 1/2 turns counterclockwise from full clock-
wise will position control quill near midposition. Install h. Pull top chain along its normal downward line of
sprocket retaining nut. Torque sprocket retaining nut travel until sprocket bottoms out. Sprocket should
100 TO 300 inch-pounds. Aligning cotter pin holes, move 1 1/4 TO 2 1/4 teeth and bottom out.
install sprocket retaining nut, cotter pin with spread
ends parallel to face of sprocket, and bend flat hex face NOTE
to retaining nut.
NOTE Relocate chain as necessary on
sprocket to assure 1 1/4 TO 2 1/4 teeth
Fairleads part number 1560-UH-1-755-1 movement of sprocket from bottom out.
may require trimming to fit properly. Verify by repeating steps g and h above.
c. If removed install new fairleads part number
1560-UH-1-755-1 using previously removed attaching NOTE
hardware. For ease of fairlead installation, remove
control chain and insert retainer plate in slots of fair- Check cable tension through lower ele-
leads and press fairleads in holes of 90° gearbox vator horn access cover. Speed rigs
mount. should be disconnected when adjust-
ing cable tension, then reconnected
and lockwired (C155) after adjustment
is made.
i. Positioning pedals in neutral position, mark any

convenient tooth of sprocket and cover pan so as to
Prior to connecting control chain to clevis visually assure no movement in sprocket position. Set
of control cable, check for a figure "8" cable tension 40 TO 60 pounds. Remove grease
safety on two removable connecting links. marks.
On chains furnished without removable
links, a safety is not required. j. Place and hold right tail rotor control pedal full
NOTE forward. Mark sprocket opposite mark on cover pane.
If safety has been removed, refer to step NOTE
d. If safety has not been removed, refer If sprocket will not rotate 2 to 3 teeth
to step e. counterclockwise, refer to paragraph
11-110, Rigging Tailrotor System, and
d. Safety removable connecting links with lock-
Figure 11-24 (view A).
wire (C155) (figure 11-36).
e. Connect control chain to clevis of control cable k Pull lower chain to rotate sprocket 2 to 3 teeth
using previously removed attaching hardware (bolts, counterclockwise. At this position, check that splines
washers, and nuts). Nut should be finger tight, allowing of pitch change slider and tail rotor shaft are securely
clevis fitting to realign itself when deflected. Install cot- engaged. Check for 40 TO 60 pounds cable tension,
ter pins (figure 11-29). lock-wire turnbuckle.
Change 7 11-103
TM 55-1520-210-23-2
Figure 11-35 Sprocket Holding Procedure for Removal and Installation of Nut
NOTE NOTE
If hydraulic power is available, Roughness or ratchiness in move-
check full left pedal sprocket posi- ment of roller chain is a normal
tion with “Boost on” to be 1/4 to 1 1/4 phenomenon, when sprockets are
teeth from bottom by observing re- new. It will become less noticeable
lation of sprocket and index mark. as sprocket teeth wear into their
normal pattern.
n. Position sprocket guard P/N 1560UH1-
m. Disconnect speed rig to relieve tension on 754-1 (4, figure 11-32) on mount-studs and
chain and remove nuts and washers from chain guard secure with washers (17) and nuts (18). Torque
mounting studs. nuts 50 to 70 inch-pounds. Reconnect speed
rig.
o. Install housing cover (3) using two bolts
(1) washers (2 and 7) and nut (8) Lockwire
NOTE (C155) bolts (1) together. Apply sealant (C244)
around control quill assembly (12) and housing
Ensure sprocket guard is centered so as pan (14).
not to bind on chain and sprocket p. Install lockwire (C155) on speed rig (fig-
throughout travel. ure 11-24).
11-104
TM 55-1520-210-23-2
Figure 11-36. Chain Safety
q. Close and secure vertical fin driveshaft cover 11-160. Removal — Control Tubes — Tail Rotor
and elevator horn access cover. Control System. a. Remove control tubes (5, figure
11-37) by removing cotter pin (1), nut (2 and 6),
r. Check tail rotor blade to boom clearance in washers (3), and bolts (4 and 7) at each end of control
accordance with paragraph 5-97. tube. (See detail A — typical four places).
s. Check pedal rigging in accordance with b. Disconnect control tube (9) by removing cotter
paragraph 11-110. pin (1), nut (10), washers (3), and bolt (8) at one end of
control tube (detail B). Remove cotter pin (1), nut (16),
t. Perform maintenance test flight (TM 55- washers (3), and bolt (15) at opposite end.
1520-242 MTF).
c. Disconnect control tube (20) by removing
cotter pin (1), nut (19), washers (3) and bolt (22) (detail
11-158. CONTROL TUBES – TAIL B). See figure 11-26 for removal of opposite end,
ROTOR CONTROL SYSTEM.
d. Disconnect control tube (12) by removing
11-159. Description — Control Tubes - Tail cotter pin (1), nut (11), washers (3), and bolt (13) at
Rotor Control System. Adjustable length control each end of control (detail B).
tubes and fixed length control tubes are used in the
tail rotor control system. The fixed type are fitted with e. Disconnect control tube (28) by removing
bonded and riveted clevis ends. The adjustable type cotter pin (27), nut (26), washers (24), and bolt (29),
have a threaded clevis end and locknut which secures (detail C). See figure 11-30 for removal at opposite
clevis end. end.
11-105
TM 55-1520-210-23-2
Figure 11-37. Tail Rotor Control System (Bellcranks, Levers, Supports, and Tubes) –
11-106
TM 55-1520-210-23-2
1. Cotter Pin 9. Control lube 17. Nut

2. Nut 10. Nut 18. Lever
3. Washer 11. Nut 19. Nut
4. Bolt 12. Control tube 20. Control tube
5. Control tube 13. Bolt 21. Clevis
6. Nut 14. Lever 22. Bolt
7. Bolt 15. Bolt 23. Bolt
8. Bolt 16. Nut
Figure 11-37. Tail Rotor Control System (Bellcranks, Levers, Supports, and Tubes) —
Change 14 11-107
TM 55-1520-210-23-2
24. Washer 31. Bolt

25. Bolt 32. Nut
26. Nut 33. Nut
29. Bolt 36. Support
30. Bellcrank
Figure 11-37. Tail Rotor Control System (Bellcranks, Levers, Supports, and Tubes) —
11-108
TM 55-1520-210-23-2
Premaintenance Requirements for Control b. Any damage to swage transition area or damage
Quadrant in repair areas that is in excess of limits is cause for
replacement.
11-163. Installation — Control Tubes — Tail Rotor
Model All Control System.
Part No. or Serial No. All a. Install control tube (28, figure 11-37) by adjusting
Special Tools None to length of replaced tube and installing bolt (29), wash-
ers (24), nut (26), and cotter pin (27). Check adjustment
Test Equipment Eddy Current Inspection of control tube at quadrant end on final rigging (figure
Unit 11-24, detail C).
Support Equipment None b. Install control tube (9, figure 11-37) by installing
Minimum Personnel Two bolt (8), washers (3), nut (10), and cotter pin (1) at for-
Required ward end of control tube (detail B). Install bolt (15), wash-
ers (3), nut (16), and cotter pin (1) at opposite end.
c. Install control tube (20) by installing bolt (22),
washers (3), nut (19), and cotter pin (1) (detail B).
Conditions
References TM 1-1520-256-23 d. Install control tube (12) by installing bolt (13),
washers (3), nut (11), and cotter pin (1) at each end of
control tube (detail B).
11-161. Inspection — Control Tubes — Tail Rotor e. Install control tube (5) by installing bolts (4 and 7),
Control System. washers (3), nut (2 and 6) and cotter pin (1) at each end
of control tube (detail A — typical four places).
a. Inspect control tubes for corrosion, wear, and me-
chanical damage. See figure 11-38 for wear and damage 11-163.1 HYDRAULIC CYLINDER AND SUPPORT
limits. If a crack in the Tail Rotor Tubes is suspected, refer ASSEMBLY, TAIL ROTOR.
to TM 1-1520-256-23, Technical Manual Aviation Unit
Maintenance (AVUM) and Aviation Intermediate Mainte- 11-163.2 Description - Hydraulic Cylinder and Sup-
nance (AVIM) manual nondestructive inspection proce- port Assembly, Tail Rotor A hydraulic power cylinder
dures for UH-1 helicopter series. in tail rotor control linkage is vertically mounted in a sup-
port (figure 11-37.1) on Station 211 fuselage bulkhead,
accessible through a door on right-hand side.
for looseness in tube.
11-163.3 Adjustment - Hydraulic Cylinder and Sup-
11-162. Repair — Control Tubes — Tail Rotor Control port Assembly, Tail Rotor.
System.
a. Adjust adapter (6, figure 11-37.2) 1.80 inches from
a. Polish out corrosion or mechanical damage to centerline of hole to top surface of piston rod of power
control tubes (repair areas only) in accordance with limits cylinder as shown and tighten nut (7) prior to installation
in figure 11-38. of cylinder and support assembly to helicopter.
Change 14 11-109
TM 55-1520-210-23-2
NOTE
1. Install aluminum washers only against magnesium.
2. Apply dissimilar metal separation tape (C278) to support assembly prior to
installation.
3. Apply a light coat of unthinned zinc chromate primer (C312) to bolt prior to
installation.
1. Cotter pin 8. Washer 15. Ring

2. Nut 9. Washer 16. Preformed packing
3. Washers 10. Nut 17. Cylinder and support assembly
4. Sleeves 11. Hose assembly 18. Cotter pin
5. Link assembly 12. Hose assembly 19. Nut
6. Bolt 13. Fitting 20. Washers
22. Control tube
Figure 11-37.1. Cylinder and Support Assembly, Tail Rotor — Removal and
Installation
11-110
TM 55-1520-210-23-2
Figure 11-37.2. Cylinder and Support Assembly,

Tail Rotor — Disassembled View
11-111
TM 55-1520-210-23-2
NOTE b. Inspect hydraulic power cylinder for cleanliness,

After tail rotor control system has been damage, freedom of movement and evidence of leaks.
rigged, balance spring tension shall be ad- Allowable leakage for this cylinder is one drop per 25
justed to prevent either control pedal from cycles.
creeping forward or aft. Increasing spring c. Inspect cylinder and support assembly (17) and
tension will prevent left pedal from creep- attaching components for security.
ing forward. Decreasing spring tension
will prevent left pedal from creeping aft. d. Inspect piston rod of power cylinder for nicks,
scratches and cracks. (AVIM). If a crack in the Piston Rod
b. Rig tail rotor control system (paragraph 11-109 or
of the Power Cylinder is suspected, refer to TM
11-110). Adjust spring (15, figure 11-37.2) tension by
tightening or loosening nut (9). If motoring persists, after
adjusting the balance spring tension, check the hydraulic
hoses (11 and 12, figure 11-37.1) to ensure that there is
ample slack to permit smooth operation of the power
cylinder. Any tension on the power cylinder by the con- e. Inspect cylinder and support assembly (17) for
necting hoses (11 and 12) can cause motoring. proper installation.
f. Inspect arm assemblies (5, figure 11-37.2), bell-
crank assembly (20) and support assembly (25) for cor-
Premaintenance Requirements for Hydraulic
rosion damage, pitting or distortion, refer to table 11-3
Cylinder and Support Assembly, Tail Rotor
(figure 11-37.2). If a crack in the ARM Assemblies, Bell-
Conditions Requirements crank Assembly, or Support Assembly is suspected, re-
fer to TM 1-1520-256-23, Technical Manual Aviation Unit
Model All Maintenance (AVUM) and Aviation Intermediate Mainte-
Part No. or Serial No. All nance (AVIM) manual nondestructive inspection proce-
dures for UH-1 helicopter series.
Special Tools None
g. Inspect hydraulic fittings (13, figure 11-37.1) and
Test Equipment Magnetic Particle Method nuts (14) for corrosion, cracks and thread damage.
Eddy Current Inspection
Unit 11-163.5 Removal — Hydraulic Cylinder Assembly,
Support Equipment None Tail Rotor.
Minimum Personnel Two a. Open access door (36, figure 2-18).
Required
NOTE
A small amount of fluid seepage will occur
Special Environmental None when disconnecting hose. Ensure protec-
Conditions tive covers are installed on all open ports
References TM 1-1520-256-23 to prevent entry of foreign material.
b. Place a suitable container under hose assem-
11-163.4 Inspection, Assembled — Hydraulic Cylin- blies (11 and 12, figure 11-37.1), disconnect hoses from
der and Support Assembly, Tail Rotor. fittings (13). Cap all fittings and hose connectors.
a. Check hydraulic cylinder for tightness or binding. c. Remove cotter pin (1), nut (2), washers (3),
Valve should be free to move on shaft. Be sure hose sleeves (4) and bolt (6) attaching link assembly (5) to
assemblies (11 or 12, figure 11-37.1) do not restrict valve adapter of power cylinder. Keep attaching parts with link
movement. assembly.
11-112 Change 14
TM 55-1520-210-23-2
d. Remove cotter pin (18), nut (19), washers (20) a. Place cylinder on clean work bench and remove
and bolt (21) from control tube (22) and disconnect con- cotter pin (17), nut (16), washers (12), and bolt (13) from
trol tube from bellcrank. power cylinder (8) and bracket (11).
e. Remove cotter pin (24), nut (23), washer (22) and b. Remove nut (9), washers (10), spring (15) and
bolt (21) from support assembly (25, figure 11-37.2). bolt (14) from brackets (11).
f. Remove nuts (18), washers (4) and bolt (3) from c. Remove fittings (13, figure 11-37.1), packings
arm assembly (5). (16), rings (15) and two nuts (14) from cylinder assembly.
g. Remove nut (19), washer (2) and bolt (1) from 11-163.7 Inspection Disassembled Hydraulic Cylin-
arm assembly (5). Remove arm assemblies (5) and re- der Assembly, Tail Rotor (AVIM).
move hydraulic cylinder (8) with bellcrank (20). a. Power Cylinder and Adjuster (AVIM). Inspect
power cylinder (8, figure 11-37.2) and adapter (6) in ac-
11-163.6. Disassembly — Hydraulic Cylinder As- cordance with table 11-3, paragraph 11-163.4 and as
sembly. follows:
Change 14 11-112.1/(11-112.2 blank)

TM 55-1520-210-23-2
DAMAGE AREA REPAIR ZONES

TYPE OF DAMAGE
MECHANICAL 0.010 INCH 0.020 INCH
MAX. DEPTH MAX. DEPTH
MAX, DEPTH MAX. DEPTH
MAXIMUM AREA PER 0.10 SQUARE INCH NOT CRITICAL
FULL DEPTH REPAIR
MAXIMUM NUMBER TWO PER ZONE NOT CRITICAL
OF REPAIRS
EDGE CHAMFER 0.040 INCH MAX, 0.080 INCH MAX.
BORE HOUSING
AND BUSHING
BORE DAMAGE: 0.002 INCH FOR ONE-FOURTH CIRCUMFERENCE
CRACKS: NO CRACKS ALLOWED
Figure 11-37.3. Cylinder and Support Assembly, Tail Rotor –

Damage Limits (Sheet 1 of 2)
11-113
TM 55-1520-210-23-2
NOTE: The allowable in-service bearing wear limits prior to replacement are as follows:
BEARING DESIGNATION BEARING WEAR LIMITS
MILITARY STANDARD MANUFACTURE MAXIMUM

PART NUMBER PART NUMBER RADIAL PLAY
MS27643-4 DSP4, DSRP4 0.006 INCH
MS27643-4 DW4, MDW4, DW4K 0.005 INCH
MS27641-8 KP8A 0.006 INCH
N/A J11672-3 0.005 INCH
Figure 11-37.3. Cylinder and Support Assembly, Tail Rotor — Damage Limits (Sheet 2 of 2)
(1) Inspect power cylinder (8) for cleanliness, (1.1) Inspect support assembly (25, figure
damage, freedom of movement and evidence of leaks. 11-37.2), left and right arm assembly (5) and bellcrank
assembly (20), refer to table 11-3 (figure 11-37.3). If a
(2) Inspect adapter (6) for nicks and scratches
crack in the Tail Rotor Support Assembly is suspected,
(figure 11-37.2).
refer to TM 1-1520-256-23, Technical Manual Aviation
(3) Inspect for hole elongation to brackets (11, Unit Maintenance (AVUM) and Aviation Intermediate
figure 11-37.2), adapter (6) and lower end of power cylin- Maintenance (AVIM) manual nondestructive inspection
der (8). procedures for UH-1 helicopter series.
(4) Inspect piston rod of power cylinder (8) and (2) Inspect support assembly (25, figure
adapter (6) for stripped or crossed threads. 11-37.2), two arm assemblies (5), and bellcrank assem-
(5) Inspect spring (15) for corrosion or deformi- bly (20) using fluorescent penetrant method per
ty. MIL-I-6866 and TM 1-1500-204-23 series.
(6) (AVIM) Inspect adapter (6) for cracks using c. Attaching Hardware. Inspect attaching hardware
magnetic particle method per MIL-I-6868 and TM of hydraulic cylinder assembly as follows:
1-1500-204-23 series. If a crack in the Power Cylinder
Adapter is suspected, refer to TM 1-1520-256-23, Tech- (1) Inspect for loose or missing hardware.
(2) Inspect hardware for corrosion.
ation Intermediate Maintenance (AVIM) manual nonde-
structive inspection procedures for UH-1 helicopter (3) (AVIM) Inspect hardware for cracks using
series. magnetic particle method per MIL-I-6868 and TM
(7) Inspect all bearings for maximum radial and 1-1500-204-23 series. No cracks allowed.
axial play in accordance with limits in figure 11-44 (AVIM).
(4) Inspect hardware for security.
b. Support Assembly. (AVIM).
(5) Inspect washers for elongated holes.
(1) Remove nuts (10), washers (8 and 9), and
bolts (7) attaching cylinder and support assembly (17) to (6) Inspect all bolts and nuts for thread dam-
bulkhead and remove support assembly. age.
11-114 Change 14
TM 55-1520-210-23-2
d. Install bolt (1), washers (2), and nut (19) to

arm assemblies (5).
e. Place washer (12) and bracket (11) on bolt
When hydraulic cylinder and support
assembly is not scheduled for immediate (13), position bellcrank (20) to power cylinder (8)
installation to helicoptor, precautionary and install bolt (13), washer (12) and nut (16).
measures must be exercised at all times Secure nut (16) with cotter pin (17).
to keep component clean and to prevent f. Place spring (15) and washer (10) on bolt
corrosion. Prepare as follows: (14) and install bolt through two brackets (11).
g. Wrap hydraulic cylinder and support as- Install washer (10 and nut (9) to bolt (14).
sembly (17, figure 11-37.1) in barrier material g. Insert adapter (6, figure 11-37.2) into link
(C115), and secure with tape (C279). assembly (5, figure 11-37.1) and install bolts (6),
washers (3), sleeves (4), and nuts (2). Secure nut
11-163.10. Installation — Hydraulic Cylin- (2) with cotter pin (1).
der, Tail Rotor.
NOTE
A small amount of fluid seepage may
occur when removing protective
When hydraulic cylinder or support dust covers from power cylinder (8,
assembly is not scheduled for imme- figure 11-37.2) which will require
diate installation to helicopter, pre- placing a rag or small container
cautionary measures must be under pressure and return ports to
exercised at all times to keep compo- catch seepage.
nent clean and to prevent corrosion. h. Remove protective covers from pressure
Prepare as follows: Wrap hydraulic and return ports of power cylinder (8).
cylinder and support assembly (17, i. The following installation procedures for
figure 11-37.1) in barrier material fitting (13, figure 11-37.1) are typical for both
(C98), and secure with tape (C279). pressure and return ports of power cylinder.
(1) Install nut (14), (backup) ring (15) and
packing (16) on fitting (13) and thread fittings
into pressure and return ports of power cylinder.
Install aluminum w s h e r s ( 2 2 )
against support assembly (25). (2) Position fittings (13), approximately as
NOTE shown and secure nut (14).
j. Install hose assemblies (11 and 12) to
For assembly and installation of hy- fittings (13). Ensure that hose assemblies are not
draulic cylinder proceed as follows: twisted, kinked, and do not foul.
a. Position bellcrank assembly (20) to sup-
port assembly (25) and install bolt (21), washers k. Position control tube (22) to bellcrank (20,
(22) and nut (23) with cotter pin (24). figure 11-37.2) and install bolt (21, figure 11-
b. Install nut (7) to adapter (6). Thread 37.1), washers (20) and nut (19). Secure nut (19)
adapter into piston rod of power cylinder (8) and with cotter pin (18).
adjust adapter (6) 1.80 inches as shown. Tighten l. Remove rag or container from under
nut (7) against piston rod. power cylinder.
m. Move pedals to full left and full right and
check hose assemblies (11 and 12) during both
positions for fouling.
Aluminum washers (2 and 4, figure n. Service and bleed hydraulic system. (para-
11-37.2) will be installed only adja- graphs 7-6 and 7-8).
cent to arm assemblies (5). o. Check rigging of tail rotor flight control
c. Position arm assemblies (5) to mounting system. (paragraph 11-109 or 11-110).
bosses of power cylinder (8) and upper bearings p. Close access door (36, figure 2-18).
of support assembly (25) and install bolt (3), q. Perform operational check of tail rotor
washers (4) and nut (18), flight control system (paragraph 7-3).
11-117
TM 55-1520-210-23-2
11-164. BELLCRANKS, LEVERS, AND SUPPORTS (2) If present, remove tapered shim note orien-
— TAIL ROTOR CONTROL SYSTEM. tation, and tie to support using bolt holes.
11-165. Description — Bellcranks, Levers and Sup-

ports — Tail Rotor Control System. Various bell- Premaintenance Requirements for Bellcranks,
cranks, levers and supports are incorporated in the tail Levers, and Supports—Tail Rotor Control System
rotor control system. The supports are airframe mounted
and provide a pivot mount for levers and bellcranks. Conditions Requirements
11-166. Removal — Bellcranks, Levers and Sup- Model All

ports — Tail Rotor Control System. Part No. or Serial No. All
a. Remove lever (18, figure 11-37, detail B) as fol- Special Tools None
lows:
Test Equipment Eddy Current Inspection
(1) Remove cotter pin (1), nut (10), two wash- Unit
ers (3), and bolt (8). Support Equipment None
(2) Remove cotter pin (1), nut (17), two wash- Minimum Personnel Two
ers (3), and bolt (23). Required
(3) Remove cotter pin (1), nut (19), two wash- Consumable Materials None
ers (3), and bolt (22). Remove lever (18).
b. Remove lever (14) as follows: Conditions
(1) Remove cotter pin (1), nut (16), bolt (15), References TM 1-1520-256-23
and two washers (3).
(2) Remove cotter pin (1), nut (11), bolt (13), 11-167. Inspection — Bellcranks, Levers and Sup-
and two washers (3). ports — Tail Rotor Control System.
(3) Remove cotter pin, nut, washers, and bolt at a. Inspect bellcranks, levers and supports for loose
lower end of lever. Remove lever (14). bearings. Refer to paragraph 11-185 for bearing limits.
b. Inspect bellcranks and levers for corrosion and
c. Remove bellcrank (30, figure 11-37, detail C) as
mechanical damage. See figure 11-39 for inspection lim-
follows:
its. If a crack in the Bellcranks or Levers of the Tail Rotor
(1) Remove cotter pin (27), nut (32), washers Control System is suspected, refer to TM
(24), and bolt (31). 1-1520-256-23, Technical Manual Aviation Unit Mainte-
(2) Remove cotter pin (27), nut (26), washers (AVIM) manual nondestructive inspection procedures for
(24), and bolt (29). UH-1 helicopter series.
(3) Remove cotter pin (27), nut (33), washers
(24), and bolt (25). Remove bellcrank (30). 11-168. Repair — Bellcranks, Levers and Supports
— Tail Rotor Control System (AVIM).
d. Remove support (36, detail C) as follows:
a. Replace loose or damaged bearings in bell-
(1) Remove four bolts (35) and eight washers cranks, levers and supports. Refer to paragraph 11-185
(24), and nuts (34). Remove support. for bearing replacement.
11-118 Change 14
TM 55-1520-210-23-2
b. Remove minor surface corrosion or repair dam- (2) Connect lever (18) to control tube clevis (21)
age areas using fine grit sandpaper (C235). Observe using two washers (3), bolt (22), and nut (19). Install
limits in figure 11-39. cotter pin (1).
(3) Connect opposite end of lever to control
(1) Treat repaired areas with chemical film
tube (9) using two washers (3), bolt (8), and nut (10).
(C62).
Install cotter pin (1).
(2) Paint repaired area using zinc chromate b. Install lever (14) as follows:
primer (C312).
(1) Position lever (14) to airframe mounting
bracket. Secure using bolt, washers, nut, and cotter pin.
11-169. Installation — Bellcranks, Levers and Sup- (2) Secure control tube (9) to center of lever
ports — Tail Rotor Control System. using bolt (15), two washers (3), and nut (16). Install
cotter pin (1).
a. Install lever (18, figure 11-37, detail B) as follows:
(3) Secure control tube (12) to top end of lever
(1) Secure lever to airframe mount using two (14) using bolt (13), two washers (3), and nut (11). Install
washers (3), bolt (23), and nut (17). Install cotter pin (1). cotter pin (1).
NOTES:
1. Maximum mechanical or corrosion damage allowed is 0.005 inch after clean-up.
This applies to all tube assemblies.
2. No damage in shaded area.
3. No cracks allowed.
205001-1044
Figure 11-38. Wear and Damage Limits (Control Tubes) Tail Rotor Controls
Change 14 11-119
TM 55-1520-210-23-2
TYPE OF DAMAGE DAMAGE AREA REPAIR SYMBOLS
MECHANICAL DAMAGE
CORROSION DAMAGE
MAXIMUM AREA PER


NO CRACKS ALLOWED
Figure 11-39. Wear and Damage Limits (Bellcranks, Levers and Supports) —
Tail Rotor Control System
11-120
TM 55-1520-210-23-2
(4) At full left pedal, without hydraulic power, Premaintenance requirements for rigging of elevator
check that sprocket is 1 1/4 to 2 1/4 teeth from bottom control system (cont.)
position as shown by reference mark.
NOTE
When there is a slight inconsistency Required
in the engine deck surface, which Consumable Materials (C231, C278, C312)
prevents alignment of the support Special Environmental None
assembly, a 0.024 Inch (maximum) Conditions
tapered shim may be placed on the
appropriate side of the support base. NOTE
c. Install support (36), (figure 11-37, detail C) using The elevator control system cannot
four bolts (35), eight washers (24) and four nuts (34). be properly rigged unless the cyclic
d. Install bellcrank (30) as follows: control system is rigged. Refer to
(1) Secure bellcrank to support using bolt (25), paragraph 11- 55.
washers (24), and nut (33). Install cotter pin (27).
(2) Secure bellcrank to control tube (28) using a. Accomplish rigging after installing all bellcranks
bolt (29), washers (24), and nut (26). Install cotter pin and nonadjustable control tubes (1, 7, and 11, figure 11-
(27). 40).
(3) Secure bellcrank to link using bolt (31), b. Install rigging fixture (C32) on copilots cyclic
washers (24), and nut (32). Install cotter pin (27). control stick.
NOTE
11-170. ELEVATOR CONTROL SYSTEM.
Cyclic controls below servo valves of
11-171. Description - Elevator Control System. The hydraulic cylinder assemblies must
synchronized elevator is located near the aft end of the not move while bottoming valves.
tail boom and is connected by control tubes, bellcranks
and mechanical linkage to the fore and aft cyclic control c. With cyclic cylinder control valves in up position
system. Fore and aft movement of the cyclic control (figure 11-40, view E) and idler arm (4) parallel to
stick produces change in the synchronized elevator longitudinal axis view A adjust tube (3) to fit and connect.
attitude, thus increasing controllability of the helicopter Remove rigging fixture and move cyclic control stick full
(figure 11-40). forward and check clearance of tube (3) with
transmission fifth mount support beam. Move cyclic stick
11-172. Rigging - Elevator Control System. full aft and check clearance of tube (5) with forward
bulkhead structure of cargo hook hole. Minimum
Premaintenance requirements for rigging of elevator allowable clearance is 0.10 inch in both places with pilots
control system cyclic stick held in full forward and full aft position.
Reinstall rigging fixture.
Conditions Requirements d. Maintain position of idler arm. Position bellcrank
(8) so that center of bolt head is 2.60 inches from
Model All bulkhead as illustrated. (See view, B). Adjust tube (5) to
Part No. or Serial No. All fit and connect.
Special Tools (T32) e Check that tube (13) is disconnected from
Test Equipment None elevator horn assembly (14).
Support Equipment Maintenance and f. Set right elevator so that chord line passes
Work Stands through rigging rivet ’P" for maximum elevator nose-
down position. (See view C.) Adjust tube (13) to
minimum length that will reach bellcrank (12) and
connect. Tube will be in line with output arm and pivot of
bellcrank (view D).
g. Remove rigging fixture (T32) from copilots cyclic
stick. Place and hold pilots cyclic stick full forward.
Change 10 11-121
TM 55-1520-210-23-2
Figure 11-40. Elevator Controls

11-122 Change 2
TM 55-1520-210-23-2
h. Set right elevator chord line 0.50 TO 0.75 inch pins (2), nuts (1 and 19), washers (3), and bolts (4 and
below rivet “R” for full forward cyclic stick position (view 9), (figure 11-41, detail A, sheet 2).
C). Aft arm of bellcrank (12) must be above horizontal.
With valves centered in both cyclic cylinders, adjust tube c. Detach end of control tube (8) from bellcrank (18)
(9) to meet these conditions with stick forward and con- by removing cotter pin (2), nut (5), washers (3), and bolt
nect. (7), detail A, sheet 2).
i. Place and hold pilots cyclic full aft. Check right d. Detach opposite end of control tube (8) from idler
elevator chord line (upper surface) to pass through rivet (25) by removing cotter pin (23), nut (22), washers (24)
“S” with ±0.400 inch (view C). and bolt (31), (detail B, sheet 3).
j. Check system for freedom of operation and full e. Detach end of control tube (33) from idler (25) by
travel. removing cotter pin (23), nut (21), washers (24), and bolt
(32), detail B, sheet 3).
NOTE
Final adjustments made in paragraph f. Detach opposite end of control tube (33) from
11-172k may change or make initial adjust- bellcrank (40) by removing cotter pin (23), nut (42), wash-
ments out of tolerance that were made in ers (24), and bolt (41), (detail C, sheet 3).
paragraph 11-172h and i. g. Detach end of control tube (37) from bellcrank
k. Final rigging of the elevator must be accom- (40) by removing cotter pin (23), nut (39), washers (24),
plished with boost on as follows: bolt (38), (detail C, sheet 3).
After the elevator system has been completely rigged h. Detach opposite end of control tube (37) from
boost off, place the pilot’s cyclic stick in extreme forward bellcrank (54) by removing cotter pin (48), nut (56), wash-
position and adjust only tube (9) to align the chord line of ers (46), and bolt (55), (detail D, sheet 4).
the elevator on rivet “R”. Each time tube (9) is adjusted,
i. Detach end of control tube (51) from bellcrank
check aft arm of bellcrank (12, view D) for above horizon-
(54) by removing cotter pin (48), nut (52), washers (46),
tal position.
and bolt (53), (detail D, sheet 4).
11-173. CONTROL TUBES — ELEVATOR CONTROL j. Detach opposite end of control tube (51) from idler
SYSTEM. (64) by removing cotter pin (48), nut (58), washers (59),
and bolt (60), (detail E, sheet 4).
11-174. Description — Control Tubes — Elevator
Control System. Control tubes (adjustable and nonad- k. Detach end of control tube (62) from idler (64) by
justable) are used throughout the elevator control sys- removing cotter pin (48), nut (61), washers (59) and bolt
tem. The tubes are connected to bellcranks, levers and (63), (detail E, sheet 4).
supports with standard hardware.
l. Detach opposite end of control tube (62) from bell-
11-175. Removal — Control Tubes — Elevator Con- crank (74) by removing cotter pin (68), nut (69), washers
trol System. (70), and bolt (75), (detail F, sheet 5).
a. Remove transmission cowling (2, figure 2-18) m. Detach end of control tube (72) from bellcrank
and the following access doors (17, 18, 24, and 36), as (74) by removing cotter pin (68), nut (71), washers (70),
required to remove elevator control tubes. and bolt (73), (detail F, sheet 5).
b. Detach control tube (20, figure 11-41) from n. Detach opposite end control tube (72) from ele-
swashplate horn and bellcrank (18) by removing cotter vator horn assembly.
Change 14 11-123
TM 55-1520-210-23-2
Premaintenance Requirements for Control a. Inspect control tubes for corrosion and mechani-
Tubes—Elevator Control System cal damage. See figure 11-42 for wear and damage lim-
its. If a crack in the Control Tubes of the Elevator Control
System is suspected, refer to TM 1-1520-256-23, Tech-
Model All ation Intermediate Maintenance (AVIM) manual nonde-
structive inspection procedures for UH-1 helicopter
series.
Special Tools None
Test Equipment Eddy Current Inspection for looseness in tube.
Unit
11-177. Repair or Replacement — Control Tubes —
Support Equipment None Elevator Control System.
Minimum Personnel Two a. Polish out corrosion or mechanical damage to
Required
control tubes (repair areas only) in accordance with limits
Consumable Materials None of figure 11-42.
Special Environmental None b. Any damage in repair areas that is in excess of
Conditions limits is cause for replacement.
References TM 1-1520-256-23 11-178. Installation — Control Tubes — Elevator
Control System.
a. Position control tube (20, figure 11-41) to swash-
11-176. Inspection — Control Tubes — Elevator plate trunnion bearing and install bolt (4), washers (3),
Control System. nut (1), and cotter pin (2).
11-124 Change 14
TM 55-1520-210-23-2
Figure 11-41. Elevator Controls System (Bellcranks, Levers, Supports, and Control Tubes) —
Change 14 11-124.1/(11-124.2 blank)

TM 55-1520-210-23-2
*Install aluminum washers only adjacent to magnesium.

**Install tape (C278) to support prior to installation.
***Apply zinc chromate primer (C312) to bolts prior to installation.
205001-1030-2
1. Nut 8. Control tube 15. Bolt
2. Cotter pin 9. Bolt 16. Bolt
3. Washer 10. Nut 17. Nut
4. Bolt 11. Support 18. Bellcrank
5. Nut 12. Bolt 19. Nut
6. Clevis 13. Nut 20. Control tube
7. Bolt 14. Nut
Figure 11-41. Elevator Controls System (Bellcranks, Levers, Supports, and Control Tubes) –
11-125
218-260 0 - 88 - 15
TM 55-1520-210-23-2
29. Support 37. Control tube

21. Nut 38. Bolt
22. Nut 30. Bolt
31. Bolt 39. Nut
23. Cotter pin 40. Bellcrank
24. Washer 32. Bolt
25. Idler 42. Nut
26. Nut 34. Support
35. Bolt 43. Nut
27. Nut
28. Bolt 36. Bolt
Figure 11-41. Elevator Controls System (Bellcranks, Levers, Supports, and Control Tubes) -
11-126
TM 55-1520-210-23-2

45. Washer 53. Bolt 61. Nut
46. Washer 54. Bellcrank 62. Control tube
47. Nut 55. Bolt 63. Bolt
48. Cotter pin 56. Nut 64. Idler
49. Bolt 57. Support 65. Support
51. Control tube 59. Washer 67. Nut
11-127
TM 55-1520-210-23-2
DETAIL F

69. Nut 76. Nut
70. Washer 77. Bolt
71. Nut 78. Bolt
72. Tube 79. Supports
73. Bolt 80. Nut
74. Bellcrank
11-128
TM 55-1520-210-23-2
Figure 11-42. Wear and Damage Limits (Control Tubes Elevation Control System) (Sheet 1 of 2)
Change 2 11-129
TM 55-1520-210-23-2
TYPE OF DAMAGE
MECHANICAL AND NO DAMAGE MAXIMUM DAMAGE AFTER

CORROSION DAMAGE ALLOWED CLEAN-UP 0.005 INCH
NO CRACKS ALLOWED
Figure 11-42. Wear and Damage Limits (Control Tubes Elevation Control System) (Sheet 2 of 2)
11-130 Change 2
TM 55-1520-210-23-2
Position opposite clevis end to bellcrank (18) and o. Install transmission fairing (2, figure 2-18)
install bolt (9), washers (3), nut (19), and cotter pin (2), and access doors (17, 18 and 24).
(detail A, sheet 2).
b. Position one end of control tube (8) with clevis 11-179. BELLCRANKS, LEVERS AND
(6) to bellcrank (18) and install bolt (7), washers (3), SUPPORTS – E L E V A T O R C O N T R O L
nut (5), and cotter pin (2), (detail A, sheet 2). SYSTEM.
c. Position opposite end of control tube (8) to
idler (25) and install bolt (31), washers (24), nut (22),
and cotter pin (23), (detail B, sheet 3). 11-180. Description — Bellcranks, Levers
and Supports — Elevator Control System. Vari-
d. Position upper (nonadjustable) end of control ous bellcranks, levers and supports are in-
tube (33) to idler (25) and install bolt (32), washers corporated in the elevator control system. The
(24), nut (21), and cotter pin (23), (detail B, sheet 3). supports are airframe mounted and provide a
pivot mount for levers and bellcranks.
e. Position lower (adjustable) end of control tube
(33) to bellcrank (40) and install bolt (41), washers 11-181. Removal — Bellcranks, Levers and Sup-
(24), nut (42), and cotter pin (23). ports — Elevator Control System. a. Disconnect
control tubes (8, 20, 33, 37, 51, 62, and 72, figure
f. Position one end of control tube (37) to 11-41) from bellcranks or levers as necessary (para-
bellcrank (40) and install bolt (38), washers (24), nut graph 11-175).
(39), and cotter pin (23), (detail C, sheet 3).
b. Detach bellcrank (18, figure 11-41) from
g. Position opposite end of control tube (37) to support (11) by removing bolt (12), cotter pin (2), nut
bellcrank (54) and install bolt (55), washers (46), nut (17), and washers (3). Detach support from
(56), and cotter pin (48), (detail D, sheet 4). transmission top case by removing nuts (13) and
washers (3) from two studs, and removing two bolts
h. Position one end of control tube (51) to (15) and one bolt (16) with nuts (10 and 14) and
bellcrank (54) and install bolt (53), washers (46), nut washers (3) from mounting bracket, (detail A, sheet
(52), and cotter pin (48), (detail D, sheet 4). 2).
c. Through access door on right side of pylon

i. Position opposite end of control tube (51) to
support, detach idler (25) from support (29) by
idler (64) and install bolt (60), washers (59), nut (58),
removing bolt (30), cotter pin (23), nut (26), and
and cotter pin (48), (detail E, sheet 4).
washers (24). Detach support (29) from transmission
fifth-mount fitting by removing four bolts (28) with
j. Position one end of control tube (62) to idler nuts (27) and washers (24), (detail B. sheet 3).
(64) and install bolt (63), washers (59), nut (61), cotter
pin (48), (detail E, sheet 4). d. Detach bellcrank (40) from support (34) at
lower right side in pylon compartment, by removing
k. Position opposite end of control tube (62) to bolt (36), cotter pin (23), nut (43), and washers (24).
bellcrank (74) and install bolt (75), washers (70), nut Detach support from structure by removing four bolts
(69) and cotter pin (68), (detail F, sheet 5). (35) and washers (24), (detail C, sheet 3).
I. Position nonadjustable end of control tube (72) e. Detach bellcrank (54) from support (57), in aft-
center fuselage compartment, by removing bolt (50),
to bellcrank (74) and install bolt (73), washers (70),
nut (71), cotter pin (68), (detail F, sheet 5). cotter pin (48), nut (47), and washers (46). Detach
support from structure by removing four bolts (49)
m. Position aft (adjustable) end of control tube with nuts (44) and washers (45), (detail D, sheet 4).
(72) to elevator horn assembly.
f. Detach idler (64) from support (65) by
n. Rig elevator (synchronized) controls in removing bolt (66), cotter pin (48), nut (67), and
accordance with paragraph 11-172. washers (59). Detach support from bulkhead by
removing bolts and washers (detail E, sheet 4).
Change 2 11-131
TM 55-1520-210-23-2
g. Detach bellcrank (74) from supports (79) by re- a. Replace loose or damaged bearings in bell-
moving bolt (78), cotter pin (68), nut (80), and washers cranks, levers and supports. Refer to paragraph 11-185
(70). Detach support (79 from tailboom structure by re- for bearing replacement.
moving three bolts (77) and washers (70) and nuts (76),
(detail F, sheet 5). b. Remove minor surface corrosion or repair dam-
age areas using fine grit sandpaper (C235). Observe
limits shown in figure 11-43.
Premaintenance Requirements for Bellcranks,
Levers, and Supports—Elevator Control System 11-184. Installation — Bellcranks, Levers and Sup-
port — Elevator Control System.
a. In tailboom at Boom Station 93.84, position sup-
Model All ports (79, figure 11-41) to mounting holes on bulkhead.
Part No. or Serial No. All Install three bolts (77), nuts (76) with anodized washers,
(70), (detail F, sheet 5).
Special Tools None
Test Equipment Eddy Current Inspection b. Position bellcrank (74), with pivot pointing down
Unit in supports (79). Install bolt (78) with washer (70) under
head and under nut (80). Torque nut and install cotter pin
Support Equipment None (68), (detail F, sheet 5).
c. In center-aft compartment of forward fuselage,
Required
position support (65) to mounting holes on tailboom bulk-
Consumable Materials None head (Boom Station 45.03). Install bolts with anodized
Special Environmental None washers. Torque bolts (detail E, sheet 5).
Conditions d. Position idler (64) with tip on pivot forward in sup-
References TM 1-1520-256-23 port (65). Install bolt (66) with anodized washers (59)
under head and under nut (67). Torque nut and install
cotter pin (48), (detail E, sheet 5).
11-182. Inspection — Bellcranks, Levers and Sup-
ports — Elevator Control System. e. In aft fuselage compartment, position support
a. Inspect bellcranks, levers and supports for loose (57) for bellcrank (54) on aft right-hand side of Station
bearings. Refer to paragraph 11-185 for bearing limits. 213.87 bulkhead, with straight side of support down.
Align to mounting holes and install four bolts (49) with
b. Inspect bellcranks, levers and supports for corro- anodized washers (45) and nuts (44), (detail D, sheet 4).
spection limits. If a crack in the Bellcranks, Levers, or f. Position bellcrank (54), with tab on pivot pointing
Supports of the Elevator Control System is suspected, up and aft, in support. Install bolt (50) with anodized
refer to TM 1-1520-256-23, Technical Manual Aviation washers (46) under head and under nut (47). Torque nut
Unit Maintenance (AVUM) and Aviation Intermediate and install cotter pin (48), (detail D, sheet 4).
Maintenance (AVIM) manual nondestructive inspection
procedures for UH-1 helicopter series. g. From lower right side of fuselage in pylon
compartment, position support (34) with straight side for-
11-183. Repair or Replacement — Bellcranks, Lev- ward and align to mounting holes at Station 157:45 right-
ers and Supports — Elevator Control System hand side at water line 27:50. Install four bolts (35) with
(AVIM). anodized washers (24). Torque bolt (detail C, sheet 3).
11-132 Change 14
TM 55-1520-210-23-2
h. Position bellcrank (40), with longer arm forward, k. At aft right-hand side of transmission, position
in support (34). Install bolt (36) with anodized washers support (11) with tape (C278) between faying surface on
(24) under head and under nut (43). Torque nut and two studs on top case of transmission. Install two nuts
install cotter pin (23), (detail C, sheet 3). (13) with anodized washers (3) on studs. Torque nuts.
Align opposite end of support to bracket. Apply unre-
i. Position support (29), with ears pointing down, on duced zinc chromate primer (C312) to bolts (15 and 16)
aft right-hand side of fifth-mount fitting. Align to mounting and install two bolts (15) and one bolt (16) with anodized
holes and install four bolts (28) with anodized washers washers (3) under heads and under nuts. Torque nuts.
(24) under heads and under nuts (27). Torque nuts (detail
l. Position bellcrank (18), with both arms aft and
B, sheet 3).
center stop lug up, in support (11). Install bolt (12) from
inboard, with washers (3) under head and under nut (17).
j. Position idler (25) in support (29). Install bolt (30)
Torque nut and install cotter pin (2), (detail A, sheet 2).
with anodized washers (24) under heads and under nuts
(26). Torque nuts and install cotter pin (23), (detail B, m. Attach control tubes (8, 20, 33, 37, 51, 62, or 72)
sheet 3). to bellcranks or levers as required (paragraph 11-178).
Change 14 11-132.1/(11-132.2 blank)

TM 55-1520-210-23-2
Figure 11-43. Wear and Damage Limits (Bellcranks, Levers, and Supports) —
Elevator Control System (Sheet 1 of 3)
11-133
TM 55-1520-210-23-2
Figure 11-43. Wear and Damage Limits (Bellcranks, Levers, and Supports) —
11-134
TM 55-1520-210-23-2
TYPE OF DAMAGE
MECHANICAL DAMAGE
CORROSION DAMAGE
MAXIMUM AREA PER

NO CRACKS ALLOWED

NOTE
Cable guard brackets and pulley
brackets are not shown in this figure,
all repair or replace criteria of this
figure and table apply to the brackets
as well as to the parts shown.
Figure 11-43. Wear and Damage Limits (Bellcranks, Levers, and Supports –
11-135
TM 55-1520-210-23-2
n. Rig synchronized elevator control system (para- requirements. Each detail is coded to footnotes located on
graph 11-172). the last page of the illustration. The footnotes provide
specific information on each assembly and must be used
11-185. BEARINGS. in conjunction with the following instructions.
11-186. Inspection-Bearings. a. Inspect bearings of
bellcrank-to-servo-tube assembly (14, figure 11-1) for a. Remove bearing as follows:
0.005 inch radial and 0.030 inch axial maximum allowable
wear. Any wear in excess of these limits is cause for re- (1) Place bearing on a suitable support having
placement. clearance for bearing. Support the bearing housing.
b. Maximum allowable elongation to a bushing or (2) Apply pressure to outer race of bearing and
clevis hole in control system is 0.003 inch. remove bearing from housing.
c. Maximum allowable lateral chuck or play for collec- b. Inspect housing by method specified in note 1, fig-
tive pitch jackshaft is 0.060 inch. ure 11-44.
d. Check pilots collective stick friction after installation

(paragraph 11-27).
e. Inspect jackshaft-to-mixing-lever tube assembly

(12, figure 11 -11) bearing for 0.005 inch radial and 0.030
inch axial maximum allowable wear. Cleaning materials are flammable and toxic.
f. Inspect bellcrank to servo valve tube assemblies (21 vapors.
and 26) bearings for 0.005 inch radial and 0.030 axial
maximum allowable wear. c. Clean aged primer from housing bore. Clean bore
with aliphatic naphtha (C178).
g. Maximum allowable elongation of bushing or clevis
hole in control system is 0.003 inch. d. Inspect chamfered edge of bearing bore hole each
side to depth and degree specified in figure 11-44.
h. Maximum allowable lateral play on jackshaft (10) is
0.200 inch. e. Remove any visible burrs on replacement sleeve
with 320 grit or finer sandpaper (C235). Chamfer sleeve
i. Maximum allowable wear of jackshaft bearings is both ends, 0.005 inch x 45 degrees maximum.
0.010 inch radial.
j. Mechanical damage limits for exposed surfaces of

clevis and rod end bearings is 0.010 inch in depth before
and after repair. Corrosion damage limit is 0.010 inch after
repair. Cleaning materials are flammable and toxic.
k. Bellcrank (Figure 11-39), P/N 205-001-728-1,
cracks and debonding of the elastomer, surrounding the vapors.
bearing, may be repaired (provided that total circumferen- f. If required, ream sleeve to dimension shown on fig-
tial separation has not occured around bearing). Use ad- ure 11-44, with a surface finish of 63 microinches. Clean
hesive/sealant (C317) for repair. Keep adhesive/sealant sleeve thoroughly with aliphatic naphtha (C178).
from the uni-ball area. Bearing, P/N J11672-3, will be un-
serviceable when radial play exceeds 0.012 inch and/or
axial play exceeds 0.030 inch.
11-187. Repair or Replacement-Bearings. The fol-

lowing instructions contain bearing replacement informa-
tion on the bellcranks, levers and supports of the flight Refer to step g. for applications requiring zinc
control system (figure 11-44). Replacement is limited to chromate primer and to step h. and i. for sealant
bearings that are retained by a ring staked sleeve and application. Do not allow primer or sealant to con-
bearings that do not require staking. Figure 11-44 il- taminate bearings.
lustrates each assembly and provides sleeve diameter
11-136 Change 5
TM 55-1520-210-23-2
KP4 Bearing Radial 0.006 Axial 0.030

KP5 Bearing Radial 0.006 Axial 0.030
KP4A Bearing Radial 0.006 Axial 0.030
DW4 Bearing Radial 0.006 Axial 0.030
DSP4 Bearing Radial 0.006 Axial 0.030
Figure 11-44. Bearing Replacement (Sheet 2 of 7)
Change 2 11-139
TM 55-1520-210-23-2

11-140
TM 55-1520-210-23-2

KSP4 Bearing Radial 0.012 Axial 0.045
11-141
TM 55-1520-210-23-2

BR-4R Bearing Radial 0.012 Axial 0.030
DSRP4 Bearing Radial 0.012 Axial 0.030
11-142 Change 2
TM 55-1520-210-23-2
DSP4 Bearing Radial 0.012 Axial 0.030 KP5A Bearing Radial 0.005 Axial 0.030
DW5 Bearing Radial 0.005 Axial 0.030 RSST-4 Bearing Radial 0.012 Axial 0.030
RALT 5-4 Bearing Radial 0.012 Axial 0.030
11-143
TM 55-1520-210-23-2
NOTE
1. Use the Eddy Current Method to inspection housing (reference
TM 1-1520-256-23) after bearing removal.
2. Ring stake sleeves on both sides using special tool kit (T99.1)
in accordance with TM 55-1500-335-23.
3. Chamfer 0.030 inch depth x 45 degrees each side of hole in housing.
6. Coat sleeve ID and OD, bearing OD, and housing bore with wet zinc
chromate primer (C253) during assembly.
7. Retain sleeve and bearing with retaining compound mil-5-22473,
grade CV, (C79).
8. Retain sleeve and bearing with anaerobic sealant, grade AA and
locquic primer, grade Q, (C79).
9. All radial and axial tolerance are the maximum.
11-144 Change 14
TM 55-1520-210-23-2
CHAPTER 12
UTILITY SYSTEMS
SECTION 1. FIRE DETECTOR SYSTEM
12-1. FIRE DETECTION SYSTEM – the detector element at one end opposite from
ENGINE. the control. This checks operation of the control
and continuity through the element. In the OFF
position, the switch connects the ends of the
12-2. Description — Fire Detection System —
element together enabling the element to re-
Engine. The engine fire detection system (figure
main active to sense a fire anywhere along its
12-1) consists of a fire detector unit, fire detec-
end. If the element is broken, it will still sense a
tor control, FIRE warning light and FIRE DETEC-
fire from either end to the first break.
TOR TEST pushbutton switch. The fire detector
unit consists of two heat sensitive elements in-
side a protective shield and mounted in spring
support brackets (3) inside each engine cowl. As
an element is heated, the resistance between
the center conductor and electrically grounded 12-3. Troubleshooting — Fire Detection System
outer shield decreases. This resistance is com- – Engine. The following Table 12-1 is a list of
pared to resistor R11 (6) mounted on the detec- conditions, test or inspection and corrective action.
tor control (5) and when the element resistance
NOTE
is less than R11 the FIRE warning light on the
instrument panel is illuminated. The FIRE DETEC- Before using this table, ensure all normal
TION TEST switch located on the instrument operational checks have been
performed.
panel simulates a fire by electrically grounding
Table 12-1. Troubleshooting Fire Detector
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. Indicator light inoperative.
STEP 1. Check for burned out bulb.
Replace bulb (paragraph 9-6).
STEP 2. Check for defective test switch.
STEP 3. Check for loose electrical connections.
Repair faulty connections (paragraph 12-7).
STEP 4. Check for broken or disconnected detector wire.
Replace or connect detector wire (paragraph 12-7).
12-1
TM 55-1520-210-23-2
Table 12-1. Troubleshooting Fire Detector (Cont)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
STEP 5. Perform test in accordance with paragraph 12-4
Replace fire detector control box if test and control circuit does not work (paragraph 12-7).
Replace fire detector wire if test or alarm circuit shows malfunction (paragraph 12-7).
2. Indicator light stays on.
STEP 1. Check for defective switch.
STEP 2. Perform test in accordance with paragraph 12-4.
Replace fire detector wire if alarm circuit does not work (paragraph 12-7).
Replace control box if test of control circuit indicates malfunction (paragraph 12-7).
3. Warning Iight stays on.
STEP 1. Check for inoperative switch.
Replace switch.
STEP 2. Check for fire detector wire shorted to ground.
Replace fire detector wire.
STEP 3. Check for inoperative control alarm
Replace control.
STEP 4. Check for 1000 OHM resistor open condition.
Replace 1k resistor.
12-2
TM 55-1520-210-23-2
12-4. Testing - Fire Detection System – NOTE

Engine.
Maximum resistance should not exceed
N O T E 20 ohms. If higher value registers, check
all connectors for tightness.
If grounding wires have already been
installed, procedures of steps a thru a3 f. Use a multimeter to check either pin “C” or “F”
are not required. However, they should ground at plug side of harness.
be inspected and replaced if needed.
NOTE
a. Locate one of the two mount clamps nearest Variable factors such as total length of
connector on top side of both engine cowlings and detector cable in the circuit, number of
remove the screw, one on each cowling. cables and interconnections, condition
a1. Locate the last wire bundle standoff (both of aircraft wiring and connector plugs
sides) on engine firewall and remove the screw on and environmental conditions such as
each side. temperature and presence of moisture in
connectors or wiring from rain, humidity
a2. Locally fabricate two 12 inch long or aircraft washing make it virtually
grounding jumpers per TM 55-1500-204-25/1 impossible to establish a standard
(use 12 gauge wire such as M22759-2-12-9 NSN minimum resistance value to fit all
6145-00-990-4856 and crimping terminal lugs such installations. While a clean dry
as MS25036-112 NSN 5940-00-143-4794 on each installation may approach the megohm
end appropriate to accommodate the removed range in some instances, individual
screw shank size). circumstances of a particular installation
as mentioned above may result in circuit
a3. Attach grounding jumper to cowling fire resistance readings considerably lower.
detector loop mount clamps and firewall wire bundle In effect, this lower circuit resistance
standoffs using removed screws (both sides). should not normally be of concern
unless malfunction of the system has
a4. Disconnect electrical plug located on main been previously reported. Because of
firewall on left side of engine area at station 166.06. the customary low resistance alarm
settings of the Edison system (30 to
NOTE 2000 ohms) experience has shown that
Do not depress push-to-test switch in cold engine resistance readings as low
excess of 15 seconds. as 20 K to 50 K ohms have no
detrimental effect on satisfactory
b. Locate plug P93 and disconnect. Short operations of the fire detection system
receptacle pins “C” and “F” together, turn battery on, and do not necessarily indicate a
depress the push-to-test switch. Fire warning malfunction situation.
should come on.
g. In cases where a positive malfunction has
N O T E been reported (usually due to grounding of the
center conductor circuit) a careful check should be
This test assures the warning test circuit made by breaking the system down to sections or
is operational except for the fire individual components to isolate the cause. In such
detection loops. instances trouble shooting individual cable
assemblies having center conductor resistance to
c. Remove the jumper wire from pins “C” and
ground readings of less than 250,000 ohms should
use it to short receptacle pin “C” to fire detector
be replaced. Edison connectors indicating
outer shield conductor ground. Find a bare spot on insulation breakdown (dry) under 600 volts DC
the outer conductor harness. Perform this check for
hi-pot test should be replaced and, of course,
both left and right engine cowl fire detection
defective connectors or aircraft wiring should be
harness. Repeat this procedure using pin “F”.
corrected. Generally, a circuit resistance level,
d. Fire warning light should come ON for both characteristic to a particular aircraft installation, will
sided. If not, clean and retighten harness ground, be established by field experience and only in
(4, figure 12-1). Recheck system for proper ground. positive cases of malfunction will it be necessary to
conduct a sectional system check. A routine system
e. Use an multimeter to check conductivity resistance check at the 100 or 250 hour inspection
between pins “C” and “F” at plug side of harness. period is recommended.
Change 6 12-3
TM 55-1520-210-23-2
Figure 12-1. Engine Fire Detector
12-4
TM 55-1520-210-23-2
h. Reconnect main firewall plug. 12-5. Removal - Fire Detection on System Engine.
i. Depress Push to-Test switch to assure that a. Make sure battery switch is in OFF position.
system is properly assembled.
j. Remove test equipment and lockwire (C154) all
electrical connectors and cannon plugs.
Change 10 12-4.1/(12-4.2 blank)

TM 55-1520-210-23-2
b. Remove lockwire between detector retaining nut b. Replace dips if broken, cracked, or
and electrical connector. Disconnect electrical wiring unserviceable.
from detector wire receptacles and cover wire ends with c. Replace fire detector control box if
insulating tape (C275). unserviceable.
c. Remove bolts, washers, and nuts attaching 12-8. Installation -- Fire Detection System -Engine.
detector wire receptacles to engine cowl.
d. Apply pressure on each side of detector wire a. Ensure battery switch is in "OFF" position.
retaining clips and remove detector wire from cowl. b. Insert detector wire ends into receptacle and
e. Remove safety wire from retaining nuts on each tighten retaining nuts. Lockwire (CI54) top and bottom
end of detector wire receptacles. Remove top nut on retaining nuts together, on each receptacle.
each receptacle and remove detector wire ends. c. Position detector wire receptacles on engine
f. Remove fire detector control box located in cowl and install attaching nuts, washers, and bolts.
electrical and radio compartment, station 178.00 on left d. Position and route detector wire through spring
hand side of helicopter, as follows (figure 12-1): retention dips.
(1) Disconnect cable connector from the fire e. Remove insulating tape from wire ends and
detector control box (5). connect electrical wiring into the detector receptacles.
(2) Remove screw (13), two washers (12), and f. Lockwire (C154) retaining nuts on receptacles to
nut (11) securing ground cable to bulkhead. electrical plugs (figure 12-1).
(3) Remove four screws (10), four washers (8), g. Install fire detector control box in electrical and
and four nuts (7), securing fire detector control box (5) to radio compartment, station 178.00 on left side of
shelf of electrical and radio compartment. helicopter as follows (figure 12-1):
(4) Remove fire detector control box (5).
12-6. Inspection - Fire Detection System - Engine. NOTE
a. Inspect wires for damage and wear.
b. Inspect wire retention dips for cracks and Before Installation, check resistor (6)
serviceability. for continuity and security on face of
c. Inspect fire detector control box for security of fire detector control box and check
mounting. that only the special pert shown in
the parts manual Is installed.
12-7. Repair or Replacement - Fire Detection
System - Engine. (1) Secure fire detector control box (5) to shelf
a. Replace wires if damaged or worn. of electrical and radio compartment using four screws
(10), four washer (8), and four nuts (7).
(2) Attach ground cable to bulkhead with screw
(13), two washers (12), and nut (11).
(3) Connect electrical connector to fire detector
control box (5).
h. Test fire detector system (paragraph 12-4).
SECTION II. WINDSHILD WIPER SYSTEM
12-9. WINDSHIELD WIPER. breakers in the overhead console panel protect these
installations in case of malfunction. A five position rotary
12-10. Description - Windshield Wiper. The switch on the miscellaneous panel of the overhead
windshield wiper assembly consist of the arm and wiper, console permits operation of the wipers at low, medium
motor converter, and motor. Helicopters are equipped or high
with a windshield wiper for both pilot and copilot Circuit
Change 10 12-5
TM 55-1520-210-23-2
speed. A selector switch permits operation of pilot and 12-11. Troubleshooting -Windshield Wiper. Table
copilot windshield wipers separately or simultaneously. 12-2 and Table 12-3 provides a guide to aid in isolating
The left and right assemblies are identical and all troubles which may be encountered during testing of the
maintenance procedures are applicable to each. units.
Table 12-2. Troubleshooting - Electric Motor Assembly
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. Motor fails to start.
STEP 1. Check for defective power source.
Repair or replace power source (paragraph 9-280).
STEP 2. Check for defective thermoprotector.

Replace thermoprotector (paragraph 12-13 and 12-17).
STEP 3. Check for defective field or armature circuit.

Repair motor assembly (paragraph 12-13 thru 12-19).
2. Motor assembly has excessive vibration/noise.

Check for defective motor assembly components.
Repair motor assembly (paragraph 12-13 thru 12-19).
3. Thermoprotector fails to deenergize motor assembly.

Check for defective thermoprotector.
Replace defective thermoprotector (paragraph 12-13 and 12-17).
4. Thermoprotector deenergizes motor assembly but fails to complete cycle.

Check for defective thermoprotector.
Replace defective thermoprotector (paragraph 12-13 and 12-17).
5. Excessive current consumption when motor operates under load and fails to reach minimum speed.
STEP 1. Check for good brush contact.
Replace brush holder if spring tension is below tolerance (paragraph 12-13 and 12-17).
12-6 Change 10
TM 55-1520-210-23-2
Table 12-2. Troubleshooting – Electric Motor Assembly (Cont)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
STEP 2. Check for worn brushes.
Replace brush and clip assemblies (paragraph 12-13 and 12-17).
STEP 3. Check for dirty commutator.
Clean commutator (paragraph 12-14).
STEP 4. Check for field strength below normal.
See Corrective Action Steps for 1, 2, 3.
STEP 5. Check for shorted commutator segments.
Repair motor (paragraph 12-13 thru 12-19).
STEP 6. Check for shorts in rotor windings.
Repair motor (paragraph 12-13 thru 12-19).
6. Motor fails to stop in PARK position.

STEP 1. Check for defective parking switch.
Replace parking switch (paragraph 12-13 and 12-17).
STEP 2. Check for defective cam assembly.
Replace cam assembly (paragraph 12-13 and 12-17).
STEP 3. Check for idler gear assemblies not secure on pinions.
Replace gear assemblies (paragraph 12-13 and 12-17).
Table 12-3. Troubleshooting — Converter Assembly
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1 Apparent grease leakage after run-in.

STEP 1. Check for proper sealing of cover plates.
Reseal plates to worm and housing assembly (paragraph 12-17).
12-7
TM 55-1520-210-23-2
Table 12-3. Troubleshooting – Converter Assembly (Cont)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
STEP 2. Check for crack in housing assembly.
Replace worm gear and housing assembly (paragraph 12-13 thru 12-19).
STEP 3. Check for defective preformed packing.
Replace preformed packing at wiper shaft (paragraph 12-13 and 12-17).
2. Wiper stroke not within limits.
Check for defective eccentric.
Replace linkage assembly (paragraph 12-13 thru 12-19).
3. Wiper does not stop at PARK position.
STEP 1. Check for defective parking switch.
Refer to table 12-2, item 6.
STEP 2. Check for proper motor and motor converter alignment.
Align or replace as required (paragraph 12-18).
STEP 3. Check for defective or worn parts in converter assembly.
Replace worn parts as required (paragraph 12-13 thru 12-19).
12-12. Removal — Windshield Wiper. c. Disconnect electrical connector and re-

move bolts attaching head guard bracket and
windshield wiper support to cabin. Lift brackets
and motor converter from cabin.
d. Remove four nuts, washers, and bolts which
attach motor-converter to bracket support.
Do not operate wiper on dry windshields.
Install 3/32 inch cotter key in standoff
12-13. Disassembly — Windshield Wiper.
holes at base of arm before operating or
a. Separate motor and converter (detail A, figure 12-
performing maintenance.
2).
a. Disconnect battery.
b. Remove windshield wiper blade and univer- (1) Cut Iockwire and remove three screws (14
sal arm from motor shaft (26), figure 12-2, by and 16) and Iockwashers (15). Remove bracket (17).
removing bolt (1), washer (2) and allen head
screw (25). (2) Remove screw (19) to free lock plate (18).
12-8 Change 2
TM 55-1520-210-23-2
1. Bolt 8. Washer 15. Washer 22. Coupling

2. Washer 9. Screw 16. Screw 23. Motor assembly
3. Wiper arm 10. Washer 17. Bracket 24. Converter assembly
4. Motor and 11. Headguard 18. Lock plate 25. Allen Head
converter assembly 12. Spacer 19. Screw 26. Motor shaft
5. Washer 13. Wiper blade 20. Lock insert 27. Sleeve serrated
6. Bolt 14. Screw 21. Nipple 28. Adjustment screw
7. Screw
Figure 12-2. Windshield Wiper Installation
12-9
TM 55-1520-210-23-2
(3) Remove three gear case mounting screws b. Converter Assembly.

(10, figure 12-4).
(4) Separate converter (24, figure 12-2) from (1) Remove retaining ring (17) from linkage
electric motor (23). shaft.
(5) Unscrew motor gear case (11, figure 12-4)

from converter assembly (24, figure 12-2).
(6) Remove and separate nipple (21) and

Coupling (22). Insert screwdriver in slots to separate
cover plate from housing.
1. Washer 11. Converter linkage assembly

2. Annular ball bearing 12. Cover plate
3. Nameplate 13. Nut
4. Screw 14. Sleeve
5. Screw 15. Preformed packing
6. Idler cover plate 16. Sleeve
7. Washer 17. Retaining ring
8. Screw 18. Bolt
9. Worm gear and housing assembly 19. Screw
10. Worm end cap 20. Washer
Figure 12-3. Converter Assembly
12-10 Change 16
TM 55-1520-210-23-2
(2) Remove four nuts (13) and screws (8). (5) Remove three screws (5); remove idler
Separate cover plate (12) from worm gear and cover plate (6) and washer (7).
housing assembly (9).
N O T E
(3) Remove sleeve (16) and packing (15) from
inside of sleeve (14) Washer (7) may be struck to cover plate
by sealing compound. Remove washer
NOTE by carefully separating with a sharp
Do not remove sleeve (14) from cover knife.
plate (12) unless sleeve is damaged and
must be replaced. The sleeve is staked in (6) Remove four screws (4); remove converter
place and damage may result during nameplate (3).
removal.
c. EIectric Motor Assembly.
(4) Using bearing puller, if necessary, remove
bearings (2) and washers (1) from linkage assembly (1) Cut Iockwire and remove end cap (31,
(11). figure 12-4).
NOTE (2) Cut Iockwire and remove three screws (10)

Do not attempt to remove worm gear securing gear case (11) to end bell and idler shaft
from housing. assembly (18).
1. Barrel assembly 10. Screw

2. Washer 11. Gear case
3. Parking switch 12. Washer
4. Filter 13. Idler gear assembly
5. Lockwasher 14. Idler gear assembly
6. Screw 15. Idler gear assembly
7. Retaining ring 16. Tie bolt
8. Cam assembly 17. Lock washer
9. Insulator 18. End bell and idler shaft assembly
Figure 12-4. Motor Assembly (Sheet 1 of 2)
12-11
TM 55-1520-210-23-2
19. Base 32. Brush holder end bell assembly

20. Screw 33. Screw
21. Sub-base 34. Lockwasher
22. Screw 35. Brush holder ring
23. Thermoprotector 36. Screw
24. Filter connector 37. Spring washer
25. Screw 38. Annular ball bearing
26. Retaining ring 39. Rotor assembly
27. Screw 40. Driveshaft gear
28. Brush and clip assembly 41. Cover and nameplate assembly
29. Brush holder assembly 42. Screw
30. Lockwasher 43. Lockwasher
31. End cap 44. Brush cover insulation
Figure 12-4. Motor Assembly (Sheet 2 of 2)
(3) Remove insulator (9) and washer (12) if (7) Remove three screws (42) and lockwash-
installed, only if worn or damaged. The insulator is se- ers (43); remove cover and nameplate assembly (41).
cured with sealing compound and the washer is staked Remove insulation (44) and retaining ring (26).
in place.
(4) Remove cam assembly (8), idler gear as- (8) Lift brushes out of brush holder assemblies
semblies (13 and 14). (29).
(5) Remove retaining ring (7), idler gear assem- (9) Remove two tie bolts (16) and lockwashers
bly (15), and washer (2). (17).
(6) Remove two screws (6) and lockwashers
(5); remove filter (4) and parking switch (3). (10) Remove end bell and idler shaft assembly
(18).
NOTE
When removing electrical components, (11) Remove rotor assembly (39), bearings (38)
unsolder electrical leads when necessary. and driveshaft gear (40) as an assembly. Disassemble
Identify leads to ensure proper connec- only if parts are damaged or worn. Remove spring wash-
tion during reassembly. er (37).
12-12 Change 14
TM 55-1520-210-23-2
(12) Cut lockwire and remove four screws (25) b. Converter Assembly.
securing filter-connector (24) in base assembly.
Remove two screws (22); remove sub-base (21).
Unsolder wires and remove filter-connector.
(13) R e m o v e t w o screws (27) and

Iockwashers (30); remove brush and clip assemblies Do not clean bearings with cleaning
solvent.
(28).
(1) Wash all metal parts, with the exception
(14) Unsolder wires and remove brush holder of bearings (2, figure 12-3), with cleaning solvent
end bell assembly items (29, 32, 33, 34, 35, 36). (C261).
(15) R e m o v e t wo screws (36) and (2) Dry with compressed air or clean lint-free
Iockwashers (34); remove end bell assembly (32). cloth.
12-15. Inspection — Windshield Wiper. a.

(16) Remove four screws (33); remove two
brush holder assemblies (29). General Inspection. Make a careful visual inspection
of all parts to determine obvious defects or damage.
Pay particular attention to the condition of threads on
(17) Remove thermoprotector (23). all bolts and nuts. Check for nicks, burrs, dents, and
other deformations which may interfere with proper
(18) Remove two screws (20); remove base operation. Minimum or maximum measurement
limits which determine replacement requirements
(19).
are given in table 12-4.
b. Converter Assembly. Perform inspection of

12-14. Cleaning – Windshield Wiper Assembly. the converter assembly parts as follows (figure 12-3):
(1) Visually inspect all parts for obvious

defects or excessive wear.
(2) Check worm gear and housing assembly

(9) and cover plate (12) for cracks.
(3) Check condition of all parts of the
of solvent vapors.
converter linkage assembly (11). Replace assembly if
any of the following conditions are apparent;
a. Electric Motor Assembly. serrations on wiper shaft are stripped; gear teeth are
chipped, broken, or show signs of excessive wear;
(1) Clean all metal parts with the exception linkage is distorted; bearings are rough. (Table 12-4.)
of the rotor assembly (39, figure 12-4), brush and
clip assemblies (28) and barrel assembly (1) with (4) Check that bearings are free running.
cleaning solvent (C261).
(5) Check worm gear in worm and housing
assembly (9) for free movement.
(2) Carefully dry with compressed air or clean
lint-free cloth. N O T E
(3) Rotor assembly (39), particularly the If worm gear is found to be defective or
commutator, should be cleaned with a dry brush. The worn, replace worm gear and housing
commutator should be wiped clean to remove any assembly (9) which will contain new
film deposit. worm gear.
218-260 0 - 88 - 16
12-13
TM 55-1520-210-23-2
Table 12-4. Inspection Limits — Windshield Wiper
ITEM FIGURE
NO. NO. DESCRIPTION MAX MIN REMEDY
18 12-4 Bearing bore 0.8665 — Replace end bell and idler

inch shaft assembly if bearing
bore exceeds dimension.
32 12-4 Bearing bore 0.8665 – Replace end bell assembly

inch if bearing bore exceeds
dimension.
39 12-4 Shaft diameter — 0.2754 Replace rotor assembly if

inch shaft diameter is less
than dimension.
39 12-4 Commutator diameter 0.869 Replace rotor assembly if

(Make sure surfaces inch commutator diameter is
are smooth and clean. ) less than indicated.
28 12-4 Brush length — 5/32 Replace brush and clip

inch assembly if worn beyond
dimension.
29 12-4 Brush spring compression 1 in. -lb. Replace brush holder

assembly if spring pressure
is less than indicated.
24 12-2 Converter-backlash 5 — Replace converter linkage

(At wiper shaft) degrees assembly (11, figure 12-3),
if backlash is greater
than indicated.
c. E l e c t r i c M o t o r A s s e m b l y . P e r f o r m (4) Check commutator for excess wear and

inspection of the electric motor assembly parts as make sure surfaces are smooth and clean. (Table 12-
follows: (Figure 12-4.) 4.)
(5) C h e c k b r u s h e s o n b r u s h a n d c l i p
assemblies (28) and discard if excessively worn.
(1) Visually inspect all parts for obvious
defects or excessive wear. Particular attention should Check brush holder assembly (29) spring pressure
be given to gear and pinion teeth, gear posts and which should be adequate for positive contact. (Table
12-4.)
bores.
(6) Check parking switch (3) by pressing in and
(2) Check that bearings are free running. releasing the switch actuating plunger. Switch action
Bearing fits should be snug but not tight at room should be positive acting and a distinct “click” should
temperature. (Table 12-4.) be audible each time the plunger is pressed in or
released. Reject switch if switch action is slow or
(3) Check windings on rotor assembly and terminals are loose, or if switch plunger is sufficiently
stator windings of barrel assembly (1) for broken worn to prevent positive contact with cam assembly
leads and frayed insulation. (8).
12-14
TM 55-1520-210-23-2
(15) If removed during disassembly, reinstall (19) Install end cap (31). Secure with lockwire
washer (12) in gear case (11) and stake in place. Install (C155).
insulator (9) in gear case and secure with sealing com- (20) Test electric motor assembly in accordance
pound (C240). with paragraph 12-19.
(16) Install gear case (11) and secure with three 12-18. Final Assembly — Windshield Wiper. The
screws (10). Do not lockwire screws until final assembly. motor and converter assembly may be assembled in
either the left or right configuration. Figure 12-7 illustrates
both configurations and depicts the proper angular orien-
(17) Position brush and clip assemblies (28) in tation of the electric motor assembly in respect to the
brush holders and secure with two screws (27) and lock- converter assembly. Determine the desired configura-
washers (30). tion, then proceed as follows:
a. Install nipple (21) in converter assembly (24,
(18) Position insulation (44) and cover and figure 12-2).
nameplate assembly (41) on barrel assembly. Secure
with three screws (42) and lockwashers (43).
Figure 12-7. Motor and Converter Assembly — Left & Right Configuration
Change 16 12-17
TM 55-1520-210-23-2
b. Install coupling (22) on converter driveshaft. k. Test final assembly in accordance with para-
graph 12-19.
c. Remove three screws (10, figure 12-4) secur-
ing gear case (11) to electric motor assembly, remove 12-19. Testing - Windshield Wiper. To test the
gear case. complete motor and converter assembly, proceed as
follows.
d. Position lock plate (18, figure 12-2) on gear
case (11, figure 12-4) flange. Screw gear case onto
a. Install the motor and converter assembly on the
nipple (21, figure 12-2)
helicopter (paragraph 12-20, and figure 12-2).
e. Install bracket (17) and secure with screws (14
b. Install wiper blade.
and 16) and washers (15).
f. Remove worn end cap (10, figure 12-3) from

converter assembly. Rotate converter driveshaft coun-
terclockwise until the output shaft stops in the park
position. After output shaft has stopped, continue
rotating driveshaft counterclockwise and count the
number of turns necessary before the output shaft Do not operate wiper on dry windshields.
reverses its direction of rotation. Divide this number of Install 3/32 inch cotter key in standoff
turns by two, and backup (rotate clockwise) converter holes at base of arm before operating or
driveshaft by that number of turns (i.e., four turns, back performing maintenance.
up two turns).
Testing of the wiper with blade raised clear
of windshield should be done in small
NOTE increments. Do not allow blade to operate
When setting converter for park there fast enough to cause whipping; this can
are two (2) places the outputs shaft bend wiper arm.
reverses direction of rotation. These are
64° apart, and park can be set at either c. Turn rotary switch to any “on” position.
location. This depends on whether the
electric motor and converter assembly d. Turn rotary switch through OFF to park position
is to be installed on pilot or co-pilot’s long enough for the wiper to travel to the park position
side. and then to off.
e. Repeat three times and observe that wiper

g. Slide cam assembly (8, figure 12-4) and idler blade returns to park position in the same place each
gear assembly (13) just far enough to rotate cam time. (Figure 12-8.)
assembly to a position so its flat segment opens park-
ing switch (3). The flat segment of the cam assembly f. Check 5.0 to 5.5 inch distance from top of wind-
should be placed in a position approximately parallel to shield.
the side of the parking switch. Then slide cam assem-
bly (8) and idler gear assembly (13) back to their fully g. Check pressure for 4.50 to 5.0 Ibs.
installed position.
h. Check travel arc for 64 degree movement.
h. Position motor assembly on gear case (11).
Ensure rotor shaft engages coupling (22, figure 12-2). i. Remove 3/32 inch cotter pin from standoff and
Install three screws (10, figure 12-4) and secure with carefully lower blade onto windshield.
Iockwire (C155). 12-20. Installation - Windshield Wiper Assembly
i. Position converter assembly and electric motor (figure 12-2).
assembly at 45 degree angle as shown in figure 12-7.
Install screw (19, figure 12-2) to tighten Iock place (18). a. Position motor-converter in support and install
Secure screws (19, 14, and 16) with lockwire (C155). mounting bolts and washers.
j. Apply light coat of sealing compound (C242) to b. Place converter shaft through hole in cabin and
threads only of worm end cap (10, figure 12-3). Care- position head guard, assembly over motorconverter.
fully install worm end cap in converter assembly. Seal- Align holes in head guard and windshield wiper support
ing compound must not enter bearing in converter with holes in cabin, and install mounting screws, con-
assembly. Secure and cap with Iockwire (C155). nect electrical connection and Iockwire (C154).
12-18 Change 7
TM 55-1520-210-23-2
Figure 12-8. Testing Windshield Wiper
c. Operate the motor-converter so that wiper

shaft is stopped in the PARK position.
d. Install wiper arm and blade assembly on
serrated shaft so that blade will be parallel to and 5.0
to 5.5 inches below the windshield wiper stop, with a Testing of the windshield wiper with
slight upward pressure being applied to arm. blade raised clear of windshield should
be done in small increments. Do not
e. Tighten allen head screw clamping wiper arm
to shaft, install washer and mounting bolt end torque allow blade to operate fast enough to
bolt 30 to 40 inch-pounds. Safety wire allen head cause whipping; this can bend wiper
screw to the mounting bolt. arm.
f. Adjust pressure of blade on windshield to 4.5 to

5.0 pounds measured at intersection of wiper blade
and wiper arm using wrench (T64) to adjust screw g. Place BAT SWITCH TO ON position. Close
(28) figure 12-2. PILOT WINDSHIELD WIPER circuit breaker. Operate
the wiper through all speeds, and return to the PARK
position.
h. Remove 3/32 inch cotter pin from standoff

Do not operate wiper on dry windshields. holes and carefully lower blade onto windshield.
Install 3/32 inch cotter pin in standoff
holes at base of arm before operating or
performing maintenance.
12-19
TM 55-1520-210-23-2
SECTION Ill. REAR VIEW MIRROR
12-21. REAR VIEW MIRROR. d. Inspect all pip pins for positive locking.
2-22. Description — Rear View Mirror. T h e 12-25. Replacement — Rear View Mirror. If
helicopter is equipped with an adjustable rear view mirror exceeds inspection requirements, replace
mirror located outside the forward cabin below the mirror assembly.
pilots lower window. This mirror, when properly
adjusted, enables the pilot to visually check the 12-26. Installation — Rear View Mirror. a. Install
operation of the external cargo suspension hook. braces and supports to structure, using previously
When the helicopter is employed on missions which removed bolts, washers, nuts and/or quick-release
do not require use of the external cargo suspension, pins.
the rear view mirror may be covered or removed and
stowed. b. Position rear view mirror and align mounting
holes.
12-23. Removal — Rear View Mirror. a. Remove
bolts, washers, nuts and/or quick-release pins, c. Screw adjustment handles through mounting
which attach braces and supports to structure and holes. Adjust mirror to desired angle, tighten
remove mirror assembly from helicopter. adjustment handles, and insert spring pins in
threaded ends of handles.
b. To remove mirror from brace assembly,
remove mirror cover and spring pins from adjustment
d. Slide protective cover over mirror and fasten
handles. holding snap.
12-24. Inspection — Rear View Mirror. a. Inspect
mirror for cracks, crazing or hazy (clouded) areas on 12-27. Adjustment — Rear View Mirror. a.
mirror glass. Remove spring pin and loosen adjustment handles.
b. Inspect mirror frame for security and damage. b. Manually adjust mirror to desired angle.
c. Inspect braces for damage, dents, cracks, and c. Tighten adjustment handles and insert spring
loose or missing hardware. pins.
12-20
TM 55-1520-210-23-2
CHAPTER 13
ENVIRONMENTAL CONTROL SYSTEM
SECTION 1. HEATING SYSTEM
13-1. BLEED AIR HEATER AND type valve located in the distribution duct which
DEFROSTER INSTALLATION. pneumatically governs the ratio of the quantity of
bleed air to ambient air. The thermostat control is
located on the right hand door post and linked to
13-2. Description - Bleed Air Heater and De- the thermostat by a flexible cable.
froster Installation. On helicopters prior to serial For cold weather operations, on helicopters serial
no. 65-9565, the basic helicopter is equipped with no. prior to 65-9565, an auxiliary combustion-type
a heater-defroster system which uses engine com- heater may be installed in the right hand side of
pressor bleed air mixed with ambient air and the fuselage, aft of the cargo area. Fuel is pumped
routed through a distribution system to cabin out- from the helicopter fuel tanks through a fuel train
lets (figure 13-1, sheet 1 of 3). Temperature of the assembly installed under the left side of the cabin
heated air is controlled to a set temperature auto- floor.
matically by the mixing valve, while the quantity
of heated air is pilot controlled by an electrically On helicopters serial no. subsequent to 65-9565,
operated valve in the bleed air line which regu- an exhaust muff heater may be installed, re-
lates the amount of bleed air reaching the mixing placing the existing bleed air heater (figures 13-3
valve. The distribution system carries heated air and 13-4).
from the mixing valve, under the cabin floor on 13-3. Troubleshooting — Bleed Air Heater and
the left hand side to a heat/defog selector valve Defroster Installation.
which enables the pilot to direct air to either heat
outlet at the pedestal on the windshield defog
nozzles. Two additional outlet positions are pro-
vided under the cockpit seats. Air for these outlets
is diverted from the main duct by a pilot con-
trolled selector valve which provides control over N O T E
the quantity of air diverted.
Troubleshoot the applicable bleed air
heat system in accordance with the
On helicopters serial no. 65-9565 through 66- following charts.
16867, heating and defrosting is basically the
same except the distribution system is under the
cabin floor on the right hand side, and the two
additional outlet positions are in the door posts N O T E
(figure 13-1, sheet 2 of 3).
Before using this table be sure all normal
On helicopters subsequent to serial no. 66-16868,
heating and defrosting is basically the same ex- operational checks have been
cept manner in which temperature and quantity of performed. If a malfunction, which is not
heated air is controlled (figure 13-1, sheet 3 of 3). listed in this table, is found notify depot
Control is accomplished by means of a thermostat maintenance.
Change 2 13-1
TM 55-1520-210-23-2
Table 13-1. Troubleshooting — Air Distribution System

Helicopter serial Nos. 62-12351 through 64-13901
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. No voltage with circuit breakers closed.
Check for faulty circuit breaker.
2. Circuit breaker trips.
STEP 1. Check for faulty electrical circuits.
Repair damaged circuit (Appendix F).
STEP 2. Check for faulty circuit breaker.
3. H/DEFOG valve does not operate.
STEP 1. Check for faulty switch.
STEP 2. Check for faulty heat/defog valve.
Replace valve if defective (paragraph 13-7).
STEP 3. Check for faulty circuit.
4. Unable to turn heater on or off.
STEP 1. Check for faulty circuits.
STEP 2. Check for faulty bleed air valve.
Replace bleed air valve if defective (paragraph 13-7).
5. No control of amount of bleed air. Inadvertent shutoff of air.
STEP 1. Check for faulty switch.
13-2
TM 55-1520-210-23-2
Table 13-1. Troubleshooting — Air Distribution System (Cont)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
STEP 3. Deleted.
STEP 4. Check for faulty butterfly valve.
Replace butterfly valve if defective (paragraph 13-7).
6. Defog selector valve does not operate.
Check for bent or broken selector lever.
Repair or replace selector lever (paragraph 13-7).
7. Selector valve does not close when selector lever is in DEFOG position.
STEP 1. Check for faulty microswitch on selector linkage.
Replace microswitch if defective (paragraph 9-5).
STEP 2. Check for faulty selector valve.
Replace selector valve if defective (paragraph 13-7).
STEP 3. Check for faulty outlet valve.
Replace outlet valve if defective (paragraph 13-7).
STEP 4. Check for damaged or unadjusted linkage.
Repair or adjust linkage (paragraph 13-7).
8. Doorpost and aft outlet valves do not turn off when selector is in COMB HTR DEFOG position (applicable
only when auxiliary combustion heater is installed).
STEP 1. Check for faulty microswitch on selector linkage.
STEP 2. Check for faulty door post air valve.
Replace door post air valve if defective (paragraph 13-7).
Change 14 13-3
TM 55-1520-210-23-2
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
STEP 3. Check for faulty outlet valve.
Replace outlet valve if defective (paragraph 13-7).
STEP 4. Check for damaged or unadjusted linkage.
Repair or adjust linkage (paragraph 13-7).

9. No air flow.
Repair damaged electrical circuit (Appendix F).
STEP 2. Check for obstructed bleed air line.
Clean or replace bleed air line (paragraph 13-7).
STEP 3. Check for faulty bleed air switch.
Replace bleed air switch if defective (paragraph 9-5).
STEP 5. Check for faulty mixing valve.
Replace mixing valve if defective (paragraph 13-7).
Helicopters Serial No. 65-9811 and subsequent
1. No voltage with circuit breakers closed.
Check for faulty circuit breaker.
2. Circuit breaker trips.
Repair electrical circuit if defective (Appendix F).
13-4
TM 55-1520-210-23-2
Table 13-1. Troubleshooting – Air Distribution System (Cont)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
STEP 2. Check for faulty circuit breaker.
3. Heater will not turn on.
Repair electrical circuit if defective (Appendix F).
STEP 3. Check for faulty overheat relay.
Replace overheat relay if defective (paragraph 9-5).
STEP 4. Check for faulty overheat switch.
Replace overheat switch if defective (paragraph 9-5).
4. Bleed air valve opens when switch is in OFF position and closes when switch is in ON position.
Check for faulty circuit.
Repair circuit if defective (Appendix F).
5. No air flow.
STEP 1. Check for faulty bleed air valve motor.
Replace bleed air valve motor if defective (paragraph 13-7).
13-5
TM 55-1520-210-23-2
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
STEP 4. Check for faulty overheat relay.
Replace overheat relay if defective (paragraph 9-5).
6. Bleed air valve will not close.
STEP 2. Check for faulty bleed air valve motor.
STEP 4. Check for jammed bleed air valve.
Replace valve if defective (paragraph 13-7).
7. Cannot control air flow at door post outlet.
STEP 1. Check for faulty electrical circuit.
STEP 2. Check for faulty doorpost outlet switch.
Replace doorpost outlet switch if defective (paragraph 9-5).
STEP 3. Check for faulty doorpost outlet valve.
Replace doorpost outlet valve if defective (paragraph 13-7).
STEP 4. Check for jammed or broken flapper valve.
Repair or replace flapper valve if defective (paragraph 13-7).
STEP 5. Check for faulty actuator valve.
Replace actuator valve if defective (paragraph 13-7).
13-6
TM 55-1520-210-23-2
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
8. Doorpost outlets do not turn OFF when HEAT/DEFOG selector is in DEFOG position.
STEP 1. Check for faulty actuator.
Replace actuator if defective (paragraph 13-7).
STEP 2. Check for faulty microswitch.
9. HEAT/DEFOG selector does not operate.
STEP 1. Check for faulty linkage.
Repair or replace faulty linkage as necessary (paragraph 13-7).
STEP 2. Check for faulty flapper valve.
Replace flapper valve if defective (paragraph 13-7).
10. No air flow with heater turned ON.
Replace bleed air valve (paragraph 13-7).
Repair defective circuits (Appendix F).
STEP 4. Check for loose or obstructed thermostat pneumatic tube.
Repair or replace tube as required (paragraph 13-7).
STEP 5. Check for faulty thermostat.
Replace thermostat if defective (paragraph 13-7).
11. Air to outlets too hot.
13-7
TM 55-1520-210-23-2
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
STEP 2. Check for faulty thermostat.
Replace thermostat if defective (paragraph 13-7).
12. Air to outlets too cool.
STEP 1. Check for restricted bleed air line.
Repair bleed air line (paragraph 13-7).
13. No air from outlets.
STEP 1. Check for obstructed bleed air line.
Repair line as necessary (paragraph 13-7).
14. No heated air at outlets.
Check for disconnected or broken pneumatic line between mixing valve and thermostat.
Repair or replace line as required (paragraph 13-7).
15. Air at outlets not hot with thermostat set above midpoint.
STEP 1. Check for leaking line from mixing valve sensor,
Repair or replace line (paragraph 13-7).
STEP 2. Check for loose thermostat knob.
Tighten knob as required (paragraph 13-7).
STEP 3. Check for faulty thermostat element.
Replace thermostat element if defective (paragraph 13-7).
13-8
TM 55-1520-210-23-2
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
STEP 4. Check for faulty limit switch.
Replace limit switch if defective (paragraph 9-5).
16. Air at outlets full hot with thermostat set below midpoint.
STEP 1. Check for loose thermostat knob.
Tighten knob as required.
STEP 2. Check for faulty thermostat element.
Replace thermostat element if defective (paragraph 13-7).
STEP 3. Check for crimped or obstructed line from mixing valve.
Repair or replace line as necessary (paragraph 13-7).
17. Heater shuts off after a short period.
STEP 1. Check for faulty temperature limit switch.
Replace temperature limit switch if defective (paragraph 9-5).
STEP 2. Check for crimped or obstructed line from mixing valve to sensor.
Repair or replace line (paragraph 13-4).
18. Heater oscillates on and off.
Check for faulty temperature limit switch.
19. Heater will not shut off in overheated condition.
Check for faulty temperature limit switch.
13-9
TM 55-1520-210-23-2
13-10
TM 55-1520-210-23-2
Figure 13-1. Heating and Defrosting System (Serial Numbers 65-9565 through 66-16867 (Sheet 2 of 3) 13-11
TM 55-1520-210-23-2
1. Windshield Nozzles 6. Bleed Air Mixing Valve 10. Heat Outlet

2. Thermostat Dial with shut off solenoid 11. Defrost Valve
3. Door Post Outlets 7. Cabin Heating Panel 12. Lower Window Nozzle
4. Distribution Valve 8. Defrost Lever 13. Engine Compartment
5. Noise Suppressor 9. Center Pedestal Outlets Floor
Figure 13-1. Heating and Defrosting System (Serial Numbers 66-16868 and Subsequent) (Sheet 3 of 3)
13-12
TM 55-1520-210-23-2
BLEED AIR HEAT SYSTEM:
1. Engine Bleed Air Hose 6. Under-Seat Registers

2. Bleed Air Control Hose 7. Windshield Nozzles
3. Air Mixing Valve 8. Heat Selector Valve
4. Noise Suppressors 9. Lower Window Nozzle
5. Bleed Air Heat Distribution Valve 10. Heat Selector Control
AUXILIARY HEATING SYSTEM:

11. Lower Right Outlet Control 19. Heater Fuel Train Assembly
12. Lower Left Outlet Control 20. Fuel Filter
13. Iris Valves 21. Fuel Pump
14. Auxiliary Heat Duct 22. Fuel Solenoid Valve
15. Thermostat Dial 23. Aft Heat Outlets
16. Door Post Outlets 24. Spot Heating Connection
17. Distribution Valve 25. Aft Outlets Valve
18. Thermostat 26. Auxiliary Combustion Heater
Figure 13-1.1. Heat-Defrost Air System with Auxilliary Heater (Serial Number 62-12351 thru 64-13901)
13-13
TM 55-1520-210-23-2
Figure 13-2 Deleted
13-4. DUCTS, NOZZLES, REGISTERS, (8) Install new flapper valves with thin aluminum
GASKETS AND MISCELLANEOUS washer on each side of valves.
VALVES. (9) Hand rotate shaft to insure proper 360° rota-
tion.
13-5. Removal-Ducts, Nozzles, Registers, Gas-
kets and Miscellaneous Valves. Remove attaching (10) If binding, use red grease pencil to mark
hardware and/or clamps and remove component. flapper where it rubs distribution box.
(11) Remove and file flappers until proper 360°
13-6. Inspection—Ducts, Nozzles, Registers,
rotation is achieved.
Gaskets and Miscellaneous Valves. a. Inspect hoses
for cracks, corrosion, wear and deterioration. (12) Reinstall flappers with both flappers in same
position.
b. Inspect nozzles, registers and valves for dam-
age and serviceability. (13) Before connecting shaft to motor, apply power
with switch in OFF position to insure motor is in off
c. Inspect gaskets or damage. position.
d. Inspect duct screens for obstructions, cuts and (14) Connect shaft to motor with flappers in off
cleanliness. position. Install cotter pins and distribution box.
(15) Apply power and run switch thru OFF, 1, 2,
e. Inspect flexible air ducts as follows. and 3 positions to insure proper operation.
(1) Silicone damage not in excess of 3.00 inches
in length and 1.50 inches wide. (16) If binding, repeat steps 10-15.
(2) Maximum of two repairs per foot of duct. (17) Disconnect cannon plug and install box in
(3) No more than 3 percent of surface area may proper position.
be repaired.
(18) Reconnect three heater hoses and cannon
13-7. Repair or Replacement-Ducts, Nozzles, plug. Plug must be safety wired.
Registers, Gaskets and Miscellaneous Valves and (19) Slide rubber coupling forward and secure with
Linkages. a. Replace damaged or unserviceable tape (C273.1) to prevent leakage.
hoses.
(20) Reinstall floor panel above heater selector
b. Replace nozzles, registers, valves, gaskets and valve assembly.
linkages which do not meet inspection requirements.
c. If necessary, clean and remove obstructions from
b.1 Remove and install flapper valve assembly as duct screens. Replace screens if cut or damaged.
follows:
(1) Remove floor panel above heater selector d. Repair flexible air ducts as follows:
valve assembly.
(2) Disconnect clamps on three forward heater
hoses and remove hoses.
(3) Disconnect cannon plug at flapper valve mo- Cleaning materials are flammable and toxic.
tor. Avoid skin contact and breathing of solvent
(4) Remove the tape at the aft heat distribution v a p o r s .
box and slide the rubber coupling back.
(1) Clean damaged area with Acetone (C12). Al-
(5) Remove distribution box carefully to avoid
breakage. low cleaned area to air dry a minimum of 30 minutes.
NOTE (2) Apply a brush coat of adhesive (C22) on dam-

Look into forward heater hoses for old flapper aged area with a 0.500 inch overlap from edge of
parts. damaged area.
(6) Remove cotter pins on each end of flapper
valve shaft and remove shaft. (3) Smooth and cure by air drying a minimum of
two hours at room temperature or until it is dry to the
(7) File flapper valves so that edge of flapper valve touch.
is even with shaft housing.
13-14 Change 4
TM 55-1520-210-23-2
(4) Clean the complete circumference of (7) Wrap fiberglass cloth around duct and
the air duct in the vicinity of damaged area with smooth out.
Xylene (C311) or Toluene (C281). Allow cleaned
area to air dry a minimum of 30 m i n u t e s . (8) Allow to air dry a minimum of two hours or
until dry to touch before handling.
(5) Use brush to apply a thin coat of adhe-
sive (22) to the complete circumference of the 13-8. Installation — Ducts, Nozzles, Registers,
duct in the damaged area and smooth out adhe- Gaskets and Miscellaneous Valves. Install
sive. component and secure with attaching hardware
and/or clamps. Before installing the P/N 205-070-
492-3 Duct Assembly, install MS21075L3 Anchor Nuts
(6) Cut a piece of fiberglass cloth (C69) of
sufficient size to cover the complete circumfer- (4 required) using MS20470AD3 rivets on the outboard
surface of the flange. Upon assembly, install the screws
ence of the duct, with a one inch overlap of the
damaged area. MS35207-264 from the inboard side.
NOTE
Coat threads of nozzle on bleed air

mixing valve (3, figure 13-1.1) with
anti seize compound (C47) prior to
installing engine bleed air here.
SECTION Il. AIR COOLING SYSTEM
Not Applicable
Change 16 13-15
Figure 13-3. Exhaust Heater
TM 55-1520-210-23-2
1. Circuit Breakers 8. Overheat Switch

2. Bleed Air Switch 9. Aft Outlet Distribution Valve
3. Heater Aft Outlet Switch 10. Door Post Outlet Distribution Valve
4. Bleed Air Motorized Valve 11. Remote Temperature Sensor
5. Bleed Air Turbine Driven Turbine 12. Tube From Sensor To Mixing Valve
Blower 13. Tube From Bleed Air Line To
6. Tail Pipe Heat Exchanger Mixing Valve
7. Variable Mixing Valve 14. Defrost Valve Micro Switch
Figure 13-4. Auxiliary Exhaust Heater System Schematic
13-17
TM 55-1520-210-23-2
13-9. AUXILIARY EXHAUST HEATER. 13-16. Inspection - Heat Exchanger - Auxiliary

Exhaust Heater - Functional (Uninstalled).
13-10. Description - Auxiliary Exhaust Heater.
The auxiliary exhaust heater (muff heater) system a. Perform leakage test on heat exchanger as
(figures 13-3 and 13-4) consists of a heat exchanger follows:
on the exhaust tailpipe, a blower for circulating air
(1) Cap off ventilating air ports on exchanger.
through the heat exchanger, a mixing valve to control
the air to maintain the desired temperature, a plenum
assembly which controls the aft cabin outlet ducts, and
connecting ducts.
13-11. Inspection - Auxiliary Exhaust Heater.
a. Check heater ducts for cracks, fraying and Do not exceed 2.5 psig in performing leak-
wear. age test.
b. Check clamps for security and condition. (2) Attach regulated air supply and pressurize
to 2 psig. Close off air supply and monitor pressure
c. Check hot air mixing valve for security of guage for two minutes. A drop in pressure indicates a
mounting. leak.
d. Check temperature control valve for security of
mounting. b. Inspect heat exchanger for leakage. There
shall be no leakage allowed into the exhaust side of the
e. Check plenum for damage and security of heat exchanger.
mounting.
13-17. inspection - Heat Exchanger.
13-12. HEAT EXCHANGER - AUXILIARY
EXHAUST HEATER. a. Heat exchangers with through cracks or holes
that allow exhaust gases to impinge on structures shall
13-13. Description - Heat Exchanger- Auxiliary be replaced.
Exhaust Heater. The heat exchanger (1, figure
13-3) is mounted on the tail pipe of the engine and b. Heat exchangers with cracks exceeding the
serves to heat the air as it is distributed through the limits defined in c., d. below shall be replaced:
heat-defrost system. Air is circulated through heat
c. Forward flange area - acceptable limits.
exchanger by the blower fan (4).
(1) Maximum single crack lengths -2 inches.
13-14. Removal - Heat Exchanger - Auxiliary
Exhaust Heater. (2) Total accumulated length of all cracks in
forward tailpipe flange shall not exceed 6 inches.
a. Disconnect joints between heat exchanger (1),
elbow (9) and duct (2). (3) Cracks shall be separated by not less than
6 inches.
b. Disconnect drain line from port on underside of
heat exchanger (1).
d. Aft tailpipe flange - acceptable limits.
c. Remove clamp (23) at connection between
(1) Maximum single crack length - 6 inches.
engine exhaust flange and heat exchanger mounting
flange.
(2) Total accumulated Iength of all cracks in aft
d. Remove heat exchanger from helicopter. tailpipe flange shall not exceed 12 inches.
13-15. inspection - Heat Exchanger - Auxiliary (3) Cracks shall be separated by not less than
Exhaust Heater (Visual) (Installed). the length of the longest adjacent crack in question.
a. Inspect tailpipe heat exchanger for cracks or
holes. N O T E
b. Ensure that heat exchanger is securely All cracks in flanges should be stop
mounted and connections are tight. drilled with a No. 40 drill.
13-18 Change 7
TM 55-1520-210-23-2
Figure 13-5. Air Blower-Exhaust Heater (Sheet 1 of 2)
Change 2 13-19
TM 55-1520-210-23-2
Key to Figure 13-5
1. Bolt 15. Insert

2. Washer 16. Liner
3. Inlet Assembly 17. Bearing
4. Elbow 18. Washer
5. Nut 19. Nut
6. Washer 20. Butterfly
7. Fan and Turbine 21. Washer
8. Screw 22. Screw
9. Retainer 23. Washer
10. Bearing 24. Nut
11. Key 25. Stop
12. Shaft 26. Nut Plate
13. Liner 27. Housing Assembly
14. Inlet 28. Identification Plate
29. Bracket
Figure 13-5 (Sheet 2 of 2)
13-20
TM 55-1520-210-23-2
13-18. Installation - Heat Exchanger. b. Remove clamp securing duct (2) to vertical port
of tee (3) and detach duct from tee.
a. Remove protective cover from engine exhaust
diffuser. c. Remove clamp securing duct (8) to horizontal
port of tee (3). Detach duct from tee.
b. Remove clamp and remove engine exhaust
tailpipe from helicopter. d. Remove bolts securing blower (7), two gaskets
and tee (3) to fan (4). Remove blower from helicopter.
c. Position tailpipe heat exchanger on outer flange
of diffuser, with drain fitting down. e. Remove screws attaching fan (4) to deck.
Remove fan from helicopter.
NOTE
13-22. Disassembly - Air Blower - Exhaust
Ensure dowels in flange in tailpipe heat Heater.
exchanger engage with holes in engine
exhaust diffuser. a. Remove bolt (1, figure 13-5), washer (2), and
inlet assembly (3) from housing (27).
d. Secure tailpipe heat exchanger to exhaust tail-
pipe with “V” band clamp (14) around flanged joint. Put a1. Remove butterfly (20) and washers (21) by
the split in the “V” band at the 6 o’clock position. loosening screws (22) and nuts (24) from bracket (29).
e. Connect drain hose from tailpipe to coupling b. Remove nut (19) and washer (18) from end of
on fuselage. shaft (12).
f. Install tailpipe fairing, antenna and anti-collision c. Remove nut (5) and washer (6) from shaft (12).
light wiring at deck connectors and close driveshaft Remove fan and turbine assembly (7) and key (11)
access door. Place protective cover on tailpipe. from shaft (12).
13-19. AIR BLOWER - EXHAUST HEATER. d. Cut Iockwire, if installed, and remove four
screws or bolts (8) and retainer (9), from housing (27).
13-20. Description - Air Blower - Exhaust
Heater. A blower assembly, driven by bleed air from e. Carefully pull shaft (12) with bearings (10 and
the engine, is mounted on the inlet port of heat 17) from housing (27) as a unit.
exchanger.
NOTE
13-21. Removal - Air Blower - Exhaust Heater.
Do not remove identification plate (28)
a. Disconnect bleed air line (5, figure 13-3) from or rotational directional arrows from
blower beneath deck. housing unless damaged.
Change 7 13-21
TM 55-1520-210-23-2
Table 13-2. Dimension Tolerance - Air Blower - Exhaust Heater
Figure Number Index Number Nomenclature Remarks

13-5 12 Shaft Replace if front end journal
is not within 0.6691 inch to
0.6695 inch diameter or if
rear journal is not within
0.4722 inch to 0.4726 inch
diameter. Replace if TIR is
greater than 0.002 inch.
13-5 27 Housing Replace Iinears if front

bearing liner is not within
1.3780 inches to 1.3791
inches diameter or if rear
bearing liner is not within
1.1024 inches to 1.1034
inches diameter.
13-22 Change 7
TM 55-1520-210-23-2
f. Using a suitable bearing puller, remove bearings CAUTION

(10 and 17) from shaft (12).
Do not force bearings into housing. If
13-23. Cleaning — Air Blower — Exhaust Heater. bearings do not slip in place with slight
a. Clean all parts with lint-free cloths saturated with hand pressure, check bearing liners for
dry cleaning solvent (C261). A soft bristle brush may burrs or corrosion.
be used to dislodge stubborn deposits. Wipe clean
and dry with filtered compressed air. b. Carefully insert shaft (12) with bearings, as a
unit, into shaft bore of housing (27).
b. Remove corrosion deposits on shaft (12) and
housing (27) bearing liners (13 and 16) using fine c. Position retainer (9) in housing with four bolt
Crocus Cloth (C68) with corrosion preventive oil (8). Tighten bolt and secure bolt with safety wire.
(C89). Clean parts after removing corrosion.
d. Install key (11) in shaft (12) and install fan and
13-24. Inspection — Air Blower — Exhaust turbine assembly (7) on shaft, align keyway in fan with
Heater. a. Visually inspect all parts for nicks, burrs, key in shaft.
scratches, dents and weldment cracks and for
evidence of excessive wear. e. Install washer (6) and nut (5) on shaft and hold-
ing fan and turbine assembly to prevent rotation,
b. Inspect ball bearings (10 and 17) for wear tighten nut (5) 115 TO 140 inch-pounds torque.
damage, roughness or binding. Check that axial play
does not exceed 0.010 inch. f. Install washer (18) and nut (19) on shaft and
tighten nut 48 TO 55 inch-pounds torque.
c. Inspect fan and turbine assembly (7) for cracks,
nicks and scratches and for bent or cracked fan g. Position inlet assembly (3) on housing (27) and
blades. secure with bolts (1) and washers (2).
d. Inspect parts for dimensional tolerances. (See h. Install butterfly (20) with washers (21). Washers
table 13-2.) (21) must be installed to prevent end play in butterfly
(20).
13-25. Repair or Replacement — Air Blower —
Exhaust Heater. a. Remove burrs and blend minor 13-27. Installation — Air Blower —Exhaust Heater.
nicks and scratches with a fine India or Carborundum a. Replace packing on nipple tube and install nipple in
Stone (C264). blower and torque. Position new gasket on blower
flange.
CAUTION
b. Position blower inside support fan (4) and line
Do not attempt to remove nicks or up holes in blower flange with holes in fan (4) and tee
scratches exceeding 0.025 inch from tur- (3).
bine blades. If the turbine blades are
damaged beyond the above limit, replace c. Install fasteners through flange of blower outlet
fan and turbine assembly. tee (3).
b. Refinish all exposed aluminum surfaces after d. Connect bleed line hose assembly (5) to blower
repair, with alodine (C62) and repaint with one coat of inlet port.
zinc chromate primer (C312) as required.
c. Replace bearings (10 and 17) if they do not 13-28. TEMPERATURE CONTROL VALVE.
meet inspection criteria.
13-29. Description — Temperature Control Valve.
d. Replace components which do not meet the The temperature control valve (24, figure 13-3) senses
dimensional tolerances in table 13-2. the air temperature in the distribution ducts and con-
trols the hot air mixing valve by increasing or decreas-
e. Replace nuts (5 and 19) regardless of condi- ing bleed air pressure by positioning the flapper valve
tion. to maintain the selected temperature.
13-26. Assembly—Air Blower—Exhaust Heater. 13-30. Removal — Temperature Control Valve. a.

a. Press bearings (10 and 17) on shaft (12) to seat Disconnect tube (17, figure 13-3) from distribution
firmly against shoulder on shaft. valve (19).
Change 2 13-23
TM 55-1520-210-23-2
b. Remove brackets that attach tubing (11) to h. Remove plug from deck and install bulkhead
lower end of bulkhead fitting. Disconnect tubing (11) fitting and jamnut.
from reducing adapter between bleed air tubes (6 and
XX). i. Install tubing (11) from bulkhead fitting to fitting
on temperature control valve (24).
c. Disconnect tubing (11, figure 13-3) from tem-
j. Attach tubing (11) to lower end of bulkhead
perature control valve (24).
fitting, previously installed and route and attach to
d. Remove tubing (17) from bulkhead fitting and reducing adapter between bleed air tubes (6 and 10)
disconnect from temperature control valve (24). on left side of fuselage. Secure tubing of bulkhead with
brackets, screws, washers, and nuts.
e. Remove clamp that secures duct (25) to elbow
(26). k Remove cap from tube (17) and attach tube to
distribution valve (19).
f. Remove elbow (26) and gasket from tempera-
ture control valve (24). l. Unstow electrical plug near hot air mixing valve
(24, figure 13-3) and attach sensor on aft side of tem-
g. Remove clamp that secures duct (8) to temper- perature control valve.
ature control valve (24).
13-34. OVERHEAT SWITCH.
h. Remove clamp that secures duct (22) to tem- 13-34.1. Description - Overheat Switch. The
perature control valve (24). overheat switch is temperature sensitive and serves to
i. Remove bolts that secure temperature control actuate the overheat relay thus turning heater off
valve (24) to cabin deck and remove temperature should an overheat condition occur.
control valve. 13-35. Removal - Overheat Switch.
a. Disconnect electrical connector.
13-31. Inspection - Temperature Control Valve.
Inspect temperature control valve for corrosion, dam- b. Remove switch.
age, and general condition.
13-36. Inspection - Overheat Switch.
13-32. Replacement - Temperature Control Valve. a. Visually inspect switch for loose wires, corro-
Replace temperature control valve if damage exceeds
sion and any damage to case that could impair normal
inspection requirements. operation.
13-33. Installation - Temperature Control Valve.
b. Inspect for proper switch actuation points as
a. Remove cover on right side of deck.
follows:
b. Position temperature control valve (24, figure (1) To verify that switch contacts close at 260°
13-3) through hole in cabin deck and secure with bolts. F plus 9° For -7° F (1 27.6° ± 3° C), submerge switch
c. Position duct (8) on aft port of temperature up to the threaded portion of the sensor probe in a well
control valve (24) and secure duct to temperature con- agitated high boiling point liquid, such as lubricating oil,
trol valve with clamp, screw, washer, and nut. MIL-L-23699 NSN9150-00-180-6266. See figure 13-6
for a suggested setup. Heat container on an electric
d. Position gasket on top flange of temperature hot plate such as P/N W-H-636, NSN 7310-
control valve (24). Position elbow (26) on temperature 00-782-0005 or other suitable heat source. Use a
control valve (24) and secure with screws. thermometer, such as P/N 15-167A, NSN 6685-01-
148-2584 or P/N 3234, NSN 6685-00-566-8667.
e. Position duct (25) on elbow (26) and secure Slowly increase temperature of the liquid no more than
with damp, screw, washer, and nut. 1° F per minute when approaching switch trip point to
f. Position duct (22) on temperature control valve insure stabilization.
(24) and secure with clamp.
(2) Allow switch to cool and verify that switch
g. Remove cap from existing bulkhead fitting at contacts open at 225° F plus or minus 9° F (107° C).
right hand forward side of deck. Install tubing (17) from
bulkhead fitting to inboard connection of temperature (3) The average of 3 readings must be taken as
control valve (24). the operating value of the switch.
13-24 Change 7
TM 55-1520-23-2
Figure 13-6. Setup For Heat Sensor Test
13-25
218-260 0 - 88 - 17
TM 55-1520-210-23-2
13-37. Replacement—Overheat Switch. R e - b. Connect and tighten electrical connector

place switch if it fails to meet inspection require-
ments. 13-39. Operational Check—Auxiliary Ex-
haust Heater. Refer to Chapter 9 for electrical
13-38. Installation—Overheat Switch. a. Po- operational check with engine off. Refer to table
sition switch on mounting and secure attaching 13-3 for operational performance test with en
hardware. gine operating.
Table 13-3. Exhaust Heater performance Test (With Engine Operating)
TURN HEATER ON CLOSE CABIN HEATER CIRCUIT BREAKERS.

PLACE HEATER SWITCH TO ON
A AIR CHECK OR VERIFY THAT BLOWER IS

DISTRIBUTION OPERATING. CHECK OR VERIFY OPERATION
SYSTEM OF DOOR POST AND AFT CABIN OUTLETS.
B TEMPERATURE CHECK OR VERIFY OPERATION OF VARIABLE

CONTROL MIXING VALVE AND TEMPERATURE SENSOR
BY VARYING TEMPERATURE SETTlNG.
C PROTECTION NO PERFORMANCE TEST APPLICABLE.

SYSTEM
13-40. Troubleshooting—Auxiliary Exhaust NOTE

Heater. Refer to heater system schematic dia-
gram, figure 13-4, electrical diagram, Appendix F, The auxiliary exhaust heater is made up
and table 13-4 as necessary to isolate trouble. of three basic subsystems.
a. Air Distribution System
b. Temperature Control System
c. Protection System
Table 13-4. Troubleshooting—Auxiliary Exhaust Heater
Part A Air Distribution System
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. Bleed air valve fails to operate, open or closed.
STEP 1 Check for voltage at load side of circuit breaker
If no voltage, replace circuit breaker (paragraph 9-12).
13-26
TM 55-1520-210-23-2
Table 13-4. Troubleshooting—Auxiliary Exhaust Heater (Cont)
Part A – Air Distribution System (Cont)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
STEP 2 Check for defective bleed air OFF-ON switch, faulty wiring, or defective bleed air valve
STEP 3 Check for 28 Vdc from pin A to pin C of P146 (bleed air valve disconnect) with bleed air switch ON. If
no voltage, replace defective switch or repair wiring as necessary If voltage exists, and valve fails to open,
replace valve (Appendix F and paragraph 13-5.)
STEP 4 Check for 28 Vdc from pin C to pin B of P146 (bleed air valve disconnect) with bleed air switch in OFF
position. If voltage exists and valve fails to operate (with bleed air valve connected), replace valve (paragraph
13-5).
2. No position control of aft outlet valves.
STEP 1 Check defective aft outlet switch, faulty wiring, or defective aft outlet valve (paragraph 13-5).
STEP 2 Check for 28 Vdc at Aft Outlet switch (S85) in the following positions
OFF 23 to GRD
1 24 to GRD
2 25 to GRD
3 26 to GRD
Replace switch if any of above conditions are not satisfied.
STEP 3 Check for 28 Vdc at P166 (Aft Outlet valve) with switch (S85) in the following positions.
OFF Pin E to A
1 Pin D to A
2 Pin C to A
3 Pin B to A
No voltage reading in any of the above positions indicates faulty wiring, repair as necessary. If
voltage exists in the above positions and outlet valve fails to operate, replace valve (paragraph 13-
5).
3. Ventilation blower does not operate
STEP 1 Check for clogged bleed air line (paragraph 13-21).
Clear line, check for ice in line (paragraph 13-21).
STEP 2 Check for defective bleed air turbine blower
Replace blower if defective (paragraph 13-21).

13-27
TM 55-1520-210-23-2
Table 13-4. Troubleshooting—Auxiliary Exhaust Heater (Cont)
Part A — Air Distribution System (Cont)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
4. No airflow control thru door post outlets.
STEP 1. Check for defective Aft Outlet switch, faulty wiring or defective door post outlet valve (paragraph 9-
5, or 13-6).
STEP 2. Check for 28 Vdc at Aft Outlet switch (S85) in the following positions.
OFF 13 to GRD
1 14 to GRD
2 15 to GRD
3 16 to GRD
Replace switch if any of the above conditions are not satisfied.
STEP 3. Check for 28 Vdc at P138 (door post outlet valve) with switch (S85) in the following positions.
OFF Pin B to A
1 Pin C to A
2 Pin D to A
3 Pin E to A
No voltage reading in any of the above positions indicates faulty wiring, repair as necessary. If
voltage exists in the above positions and door post outlet valve fails to operate, replace valve
(paragraph 13-5).
5. No air delivered to aft outlets with air directing lever positioned to HEAT.
Check for defective defrost valve microswitch.
6. No air delivered to defrost nozzle with air directing lever positioned to defrost.
Check for defective defrost valve microswitch.
1 3- 2 8
TM 55-1520-210-23-2
CHAPTER 14
HOIST AND WINCHES
SECTION I. PERSONNEL RESCUE HOIST
WARNING
Use of a Breeze BL 8300 series Internal Rescue Hoist is prohibited.
Paragraphs 14-1 through 14-148, 14-150 through 14-156, and 14-158 through 14-259 have been deleted. Figures 14-1
through 14-16, 14-17 through 14-19, 14-22 through 14-26 and figures 14-28 through 14-30 have been deleted.

TM 55-1520-210-23-2
14-149. Removal From Aircraft - High Perfor- b. Disconnect electrical connector from cable
mance Rescue Hoist. cutter and install shorting connector.
C. Open cabin ceiling soundproofing and discon-

nect input power cable.
d. Remove hoist power cable, close cabin ceiling

soundproofing.
Prior to removing the hoist from the air-
craft, first power the hoist so as to rotate e. Disconnect quick disconnect adapters (43.1
the boom approximately midway between and 45.1, figure 14-16) from retaining anchors located
the full in-board and full out-board posi- on aircraft floor.
tions.
f. Remove pin (30, figure 14-27) and rotate reac-
tion arm (9) 180 degrees, install pin (30) and attach
reaction arm (9) to stud (8).
g. Disconnect quick disconnect adapter (23, fig-

ure 14-27) and pull plunger (4) and rotate 90 degrees.
Recommend two or more persons handle Rotate vertical adjustment shaft to clear ceiling
hoist during removal and installation. anchor.
a. Disconnect battery. NOTE
Hoist must be laid on winch drive side

opposite of chain cover to prevent dam-
age of the limit switch and drive assem-
bly.
Install shorting connector to cable cutter
connector. h. Remove hoist assembly from aircraft.
Paragraphs 14-150 through 14-152 have been deleted.

Page 14-46, including Figure 14-16, has been deleted.
Change 7 14-45/(14-46 blank)

TM 55-1520-210-23-2
Figure 14-16 Hoist AssembLy, Parts Location (Sheet 2 of 3)
14-47
TM 55-1520-210-23-2
1. Control Connector Cable 42. Washer

2. Control Pendant Assembly 43. Reaction Arm Assembly
3. Clam 43.1. Quick Disconnect Adapter
4, Hook 44. Release Pin Assembly
5. Control Panel Assembly 45. Release Pin Assembly
6. Screw 45.1. Quick Disconnect Adapter
7. Clamp 46. Retainer Anchor Stud
8. Cable Hook Assembly 47. Boom Head Assembly
9< Deleted 48. Cable Cutter
10 Limit Switch Cable (J4) 49. Bolt
11 Bolt 50. Deleted
12 Washer 51. Screw
13 Nut 52. Deleted
14. Clamp 53. Deleted
15. Bolt 54. Deleted
17. Nut 56. Deleted
18. Clamp 57. Preformed Packing
19. Bolt 58. Flexible Drive Cable (Lockwire C155)
20. Washer 59. Screw
21. Upper Support Assembly 60. Washer
22. Bolt 61. Chain Guard
23. Thermal Switch Connector 62. Roller Chain
24. Washer- 63. Screw
24.1. Handle 64. Washer
25. Assembly Bracket 65. Bolt
26. Spacer 66. Clamp
27. Winch Assembly 67. Air Duct Boot
28. Vertical Adjustment Detent 68. Backing Ring
28.1 Quick Disconnect Adapter 69. Preformed Packing
29. Input Power Cable Connector 70. Shaft
30 . Cable Cutter Harness 71. Spacer
31. Winch Motor Cable (J3) 72. Spring
32. Bolt 73. Spacer
33. Washer 74. Motor
34. Boom Position Actuator and 75. V-Ring Clamp (Lockwire C155)
Structure Support 76. Drive Assy, Limit Switch
77. Housing Assy, Pump
35. Boom Head Cable (J6) 78. Brake Assy, Automatic
36. Pendant Control Cable (J2) 79. Bolt
37. Boom Motor Cable (J5) 80. Air Duct Adapter
38. Input Power Cable (J1) 81. Seal
39. Bolt 82. Packing
40. Washer 83. Interia Dump
41. Bolt 84. Cable Assembly
Figure 14-16 Hoist Assembly, Parts Location (Sheet 3 of 3)
14-48
TM 55-1520-210-23-2
b. Inspect all pulleys and rollers for damage and shall be installed on the UH-1H/V air-
freedom of movement. craft and one or more lifts with full
cable length shall be made using a
c. Inspect winch (27, figure 14-16) for condition and
dummy load of 250 to 300 Ibs.
security.
d. Inspect cable cutter (48) for condition and securi- a. Check oil level in hoist and boom head.
ty.
e. Inspect rescue hoist power cables (38, 31, 35, 36,
37, and 10) for condition and security.
f. Inspect control panel (5) and control pendant (2)
for the following:
Insure pilots cable cut switch on the
(1) Check security of mounting to hoist stanchion. pedestal and hoist operator cable cut
(2) Check security of switches. switch on the hoist control box are in
the OFF postion.
(3) Check security of cable connectors.
(4) Inspect cables for fraying and wear. b . Connect GPU to helicopter.
(5) Inspect air duct boot (67) for security and con- c . Position AIRCRAFT POSITION switch on control
dition. panel to the desired position.
(6) Check indicator lights on pendant for opera- d. Close RESCUE HOIST CONT and RESCUE HOIST
tion (press to test and dim capability). POWER circuit breakers on Pilots overhead console.
Blue POWER ON light should be ON, and fan should be
g. Check oil level in boom head and winch with operating.
hoist in normal operating position. See figure 14-17.
e. Using pendant BOOM switch, rotate boom out
h. Inspect stanchion (34, figure 14-16) for damage. and in, and then out to test boom operation.
Check electrical cable connector at control panel for
condition and security.
i. Inspect rescue hoist for correct installation and
security of all components, hardware, cotter pins, NOTE
Iockwire.
When hoist is installed on left side of
14-153. Lubrication — High Performance aircraft, pilots boom switch operates in
Rescue Hoist. The lubrication instructions are reverse.
contained on a lubrication plate located on the
side of housing assembly. The lubrication plate f. Using Pilot’s BOOM control switch, rotate boom
requirements and oil servicing of the winch, and in, and then out.
boom head is mounted on the winch case. (See
figure 14-17.) Service with Dexron II automatic
transmission fluid (C133).
14-154. Assembly - High Performance Rescue
Hoist Refer to applicable component installation
paragraph for assembly instructions. Reel cable out from the boom head in
line with the boom axis during the
14-155. Operational Check - High Performance following test procedures. Care must
Rescue Hoist. See figures 14-17 through 14-19. be taken not to pull the cable taut
around the cable guide/roller since
kinking of the cable might result.
Avoid damaging cable on rough sur-
Prior to actual Live hoisting of person- faces including the ground. It is recom-
nel after a rescue hoist has had a new mended that the cable from the hoist
or used hoist cable installed and/or be fed onto an improvised drum of at
hook assembly maintenance, the hoist least 9" diameter.
14-49
TM 55-1520-210-23-2
Figure 14-17. Oil Level Indicators and Drain Plugs
g. Position SPEED MODE SWITCH on control panel to maximum when entire 250 foot length is reeled in with
HIGH. 600 pounds maximum load. Readjust limit switch cam
number 4 if required to meet the minimum/maximum
h. Using pilots HOIST CONTROL switch lower cable length dimensions (paragraph 14-242).
hook until all the cable is out. Note caution light out
when 10 feet of cable is unreeled and ensure cable I. Repeat steps f thru i using the pendant hoist con-
speed decelerates to approximately 75 feet per minute trol. Check that cable speed can be regulated by pen-
when cable is within 10 feet of all out (250 feet). dant hoist control from 0 to 250 fpm when cable is reel-
ed out beyond 10 foot caution limit (amber light) is out.
i. Using pilots HOIST CONTROL switch, reel in cable
and observe that cable speed slows when caution light m. Place SPEED MODE switch to LOW SPEED and
comes ON. repeat steps g thru j (maximum speed is 125 fpm).
n. Reel cable all the way up and rotate boom in to
stowed position.
GPU must be used or deceleration may o. Open RESCUE HOIST CONT and RESCUE HOIST
not occur. POWER circuit breakers.
j. Push up on boom up-limit switch actuator arm 14-156. Troubleshooting - High Performance
during reeling in to check that hoist stops running when Rescue Hoist. Troubleshoot the high performance
up-limit switches are actuated. rescue hoist in accordance with Table 14-2.
k. Using pilots HOIST CONTROL switch, continue to NOTE
reel in and observe that cable speed decelerates as
hook approaches the boom head. Deceleration should Before you use this table, be sure you
take place at 12 inches minimum from boom head have performed all normal operational
when cable is reeled in with no load and 48 inches checks.
14-50
TM 55-1520-210-23-2
Figure 14-18. Control Pendant Assembly Controls and Indicators
14-51
TM 55-1520-210-23-2
Figure 14-19. Control Panel Assembly, Controls and Indicators (Sheet 1 of 5)
14-52
TM 55-1520-210-23-2
Figure 14-19. Control Panel Assembly, Controls and Indicators (Sheet 2 of 5)
14-53
TM 55-1520-210-23-2
Figure 14-19. Control Panel Assembly, Controls, and Indicators (Sheet 3 of 5)
14-54
TM 55-1520-210-23-2
Figure 14-19. Control Panel Assembly, Controls, and Indicators (Sheet 4 of 5)
14-55
TM 55-1520-210-23-2
1. Terminal
2. Terminal
3. Terminal
4. Screw
5. Bracket
6. Motor
7. Screw
8. Plenum
9. Bracket
10. Screw
11. Screw
12. Washer
13. Cover
14. Screw
15. Screw
16. Time Meter
17. Cover
18. Chassis
FIGURE 14-19 Control Panel Assembly, Controls, and Indicator
(Sheet 5 of 5)
14-56
TM 55-1520-210-23-2
Table 14-2 Troubleshooting-High Performance Rescue Hoist
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. Boom assembly electric motor inoperative.
Ensure reaction plate (52, figure 14-27) and aircraft position switch S1 (figure 14-19) are positioned properly.
Remove all electric power. Disconnect boom motor cable connector J5 (37, figure 14-16) from control panel.
Step 1. Ensure continuity is present between pins K and M of J5 connector.
Step 2. Ensure continuity is present between pins L and M of J5 connector.
If continuity is present, check boom limit and/or boom over torque limit switches.
If continuity is not present, replace boom motor, refer to paragraph 14-197.
2. Hoist boom does not swing full 205 degrees.
Remove all electric power. Disconnect boom motor cable connector J5 from control panel.
Step 1. Ensure continuity is present between pins B and F of J5 connector for counterclockwise limit
switch with boom in clockwise position. If boom is in counterclockwise position no continuity
should be present.
Step 2. Ensure continuity is present between pins A and G of J5 connector when boom is in counterclock-
wise position. If boom is in clockwise position no continuity should be present.
If continuity is present, adjust boom actuator limit switches, refer to paragraph 14-248.
Replace boom position actuator and structure support, refer to paragraph 14-197.
3. Boom overtorque cw limit switch inoperative.
Disconnect connector J5 from control panel.
Continuity should be present between pins C and H of connector J5.
If continuity is present, adjust boom overtorque cw limit switch, refer to paragraph 14-251.
4. Boom overtorque ccw limit switch inoperative.
Continuity should be present between pins D and E of connector J5.
If continuity is present, adjust boom overtorque ccw limit switch (paragraph 14-251).
14-57
TM 55-1520-210-23-2
Table 14-2 Troubleshooting-High Performance Rescue Hoist
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
5. Pendant BOOM OUT-IN switch inoperative.
Remove all electrical power from the hoist before disconnecting pendant
cable from pendant assembly.
Disconnect connector from pendant.
Step 1. With ohmmeter connected to pins A and B of pendant connector, place pendant BOOM OUT-IN switch
to OUT, continuity should be present.
If continuity is not present, replace pendant.
Step 2. With ohmmeter connected to pins A and C of pendant connector, place pendant BOOM OUT-IN switch
to IN, continuity should be present.
If continuity is not present, replace pendant.
6. Winch electric motor inoperative.
Disconnect winch motor cable connector J3 from control panel.
Step 1. Ensure continuity is present between pins A and G of connector J3.
Step 2. Ensure continuity is present between pins D and B of connector J3.
If continuity is present, replace the Control Panel assembly, refer to paragraph 14-191.
If continuity is not present, replace winch motor, refer to paragraph 14-254.
7. Winch motor temperature sensor inoperative.
Disconnect plug J3 from control panel.
Step 1. Ensure continuity is present between pins C and F of connector J3.
Step 2. Ensure continuity is present between pins H and E of connector J3
If continuity is present, replace winch motor, refer to paragraph 14-254.
8. Winch oil temperature sensor inoperative.
Disconnect boom head cable connector J6 from control panel.
Ensure continuity is present between pins E and F of connector J6.
If continuity is not present, replace over temperature sensor.
14-58
TM 55-1520-210-23-2
Table 14-2 Troubleshooting - High Performance Rescue Hoist
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
9. Hoist up limit switch inoperative,
Disconnect Plug J6 from control panel. Ensure hook is not against boom head actuator.
Ensure continuity is present between pins A and B of connector J6.
If continuity is not present, adjust up limit switch, refer to paragraph 14-245.
10. Hoist inoperative - POWER ON light not on.
Step 1. Ensure 28 vdc power is available through circuit breaker.
If multimeter does not indicate 28 vdc, replace faulty circuit breaker.
Step 2. Hoist input power check.
Ensure 28 vdc is present between pins A (+) and B (–) of connector J1.
Ensure 28 vdc is present between pins G (+) and B (–) of connector J1.
Replace input power cable
Replace bulb and press-to-test light.
Replace defective control panel, refer to paragraph 14-191.
11. Hoist control switch inoperative.
Remove all power. Disconnect connector J2 from control panel assembly.
Ensure ohmmeter indicates 0 ohms in OFF position to 500 ohms in FAST DOWN position between pins J and H of
connector J2. Ensure ohmmeter indicates 0 to 500 ohms in FAST UP position.
Replace control pendant.
12. 10 foot caution light inoperative.
Step 1. Apply power and push press to test light to check bulb.
Step 2. Reel cable out until hook is 10 feet from boom head (caution light OUT).
Step 3. Ensure continuity is present between pins E and F in connector J4 at control panel end of cable.
Step 4. Reel cable IN until continuity is not present between pins E and F of connector J4 (8 to 10 feet of
cable OUT). Adjust 10 foot caution light switch (paragraph 14-239). Replace caution light switch,
refer to paragraph 14-213.
14-59
TM 55-1520-210-23-2
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
13. One foot up deceleration limit switch inoperative.
Apply power and reel out cable until hook is more than 18 inches from boom head. Disconnect power. Remove
limit switch drive assembly cover.
Step 1. Disconnect J4 connector from control panel and assure continuity is present between pins G and H of
connector J4.
Step 2. Reel in cable using pendant switch.
No continuity should be present when hook approaches 12 to 18 inches of boom head actuator.
Remove limit switch drive assembly cover, locate one foot up deceleration limit switch cam. Reel out cable un-
til hook is 12 to 18 inches from boom head Using ohmmeter between pins G and H of connector J4 adjust one
foot up-deceleration limit switch cam until ohmmeter indicates open circuit. Install limit switch drive cover.
Connect limit switch drive connector.
Adjust one foot limit switch, refer to paragraph 14-242.
Replace one foot up-limit switch, refer to paragraph 14-213.
14. Down limit switch inoperative.
Ensure cable is not reeled out beyond 250 feet.
Disconnect limit switch drive cable connector J4 from control panel.
Assure continuity is present between pins C and D of connector J4.
Connect J4 connector to control panel.
Reel out 247 feet of cable and ohmmeter should indicate open circuit.
Adjust limit switch drive assembly down limit switch (paragraph 14-235).
Replace limit switch (paragraph 14-213).
15. Down all-stop limit switch inoperative.
Reel out cable until three wraps of cable remain on drum.
Disconnect connector J4 from control panel. Ensure no continuity is present between pins A and B of connector
J4.
Adjust down-all stop limit switch cam, refer to paragraph 14-231. Replace limit switch, refer
to paragraph 14-213.
14-60
TM 55-1520-210-23-2
Deleted
14-157. Installation — High Performance c. Move reaction plate (52) until lower base
Hoist. a. Release reaction arm from shipping plate numbered holes align with release pin
stud. Remove pin (30, figure 14-27) and rotate holes. Plate (52) must not be rotated more than
reaction arm (9) 180 degrees and reinstall pin 180 degrees.
(30). d. Lock reaction plate (52) in selected posi-
tion by replacing release pins (31) through holes
N O T E in bottom of base plate.
e. Assure reaction plate and base plate (33)
The rescue hoist assembly should be are positioned for desired installation location,
placed in position 1 or 3 in the cabin refer to figures 14-20 and 14-21.
(figure 14-2). Helicopters equipped
with personnel rescue hoist provi-
sions and subject to frequent instal-
lations of the rescue hoist kit should Recommend two or more persons
be rigged to provide maximum cyclic handle hoist during installation.
control capability for the side oppo- f. Lift hoist into aircraft.
site the hoist (desirable, but not man-
g. Release quick disconnector adapters (23,
datory). Refer to Chapter 5, Section
32, figure 14-27) at both ends of hoist.
II for swashplate setting. If only one
auxiliary fuel cell is used, it should
be opposite the hoist.
Boom will not clear door frame when
b. Select desired location and remove two hoist is installed in the number 2 or 3
release pins (31) from bottom of base plate (33). position, unless quick disconnect
adapter (23, figure 14-27) mates
with the rear stud on the aircraft
ceiling.
If reaction arm is moved and hits
h. Position hoist so quick disconnect adapt-
mechanical stops before holes align,
ers on bottom and top of hoist mate with anchor
move reaction arm in other direction
studs located on helicopter ceiling and floor.
until holes align.
14-62 Change 2
TM 55-1520-210-23-2
(1) Remove quick disconnect (1, figure

14-20.1 ) from left rear leg of troop seat.
(2) Shorten left rear leg so that the seat will sit
level in the aircraft with the hoist installed. This will
Assure reaction arm and hoist base con- require approximately 3.375 inches to be removed
nect to anchor studs on floor, do not over- from the leg. However, this length may vary from air-
tighten vertical adjustment to prevent craft to aircraft.
hoist binding and damage to helicopter
structure. (3) Locate and drill a 0.249 to 0.255 inch hole
completely through the shortened leg with center of the
i. Adjust vertical adjustment shaft (17) until quick hole 0.373 to 0.383 from bottom of leg.
disconnect adapter (23) is firmly connected to anchor
stud on ceiling.
(4) Install previously removed quick disconnect
(1) using bolt (3), washer (4), and nut (5) on shortened
N O T E leg.
If an aft facing troop seat is desired to be
located in the number one position, the (5) Install troop seat with shortened leg
following modification to troop seat is attached to stud located on top of reaction arm assem-
required. bly (43, figure 14-16).
Change 7 14-63
TM 55-1520-210-23-2
Figure 14-20, Hoist Baseplate Settings

14-64
TM 55-1520-210-23-2
Figure 14-20.1 Hoist/Troop Seat Modification

Change 3 14-64.1/(14-64.2 blank)
TM 55-1520-210-23-2
Figure 14-21. Hoist installation Positions
14-65
TM 55-1520-210-23-2
j. Remove shorting connector from cable m. Open cabin ceiling soundproofing and
cutter cartridge (48) (figure 14-16). connect input power cable (38).
k. Install cable cutter harness (30) connector n. Reinstall cabin ceiling soundproofing.
by threading into cable cutter receptacle.
o. D e l e t e d .
l. Set aircraft position switch located on
hoist control panel assembly to position corre- p. Perform operational checks, refer to TM 55-
sponding with hoist installation in helicopter. 1680-320-23 & P.
Paragraph 14-158 through 14-196 have been deleted.

Pages 14-67 through 14-81, including Figures 14-22 through 14-26 have been deleted.
14-66 Change 16
TM 55-1520-210-23-2
14-197. BOOM POSITION ACTUATOR AND 14-200. Disassembly — Boom Position Ac-
STRUCTURE SUPPORT. tuator and Structure Support Assembly
(AVIM). Refer to figure 14-27.
14-198. Description — Boom Position Actu-
ator and Structure Support (figure 14-27). a. Remove reaction arm assembly (9) from
The boom position actuator is a rotary actuator reaction plate (52), by removing quick release
with a maximum operating load of 8500 inch- pin (30).
pounds. Circuitry protection prevents operation
when the maximum operating load is exceed- b. Remove height adjuster assembly (1)
ed. The structural support assembly consists of from upper support assembly (3). Remove
an upper and lower stanchion assembly, and plunger (4) by loosening set screw (26).
post assembly.
c. Disassembly of height adjuster assembly
14-199. Removal — Boom Position Actua- (1). Remove retaining ring (20), remove ceiling
tor and Structure Support. adapter (23), remove retaining rings (19 and
22), and press out bearings (18 and 21) if
a. Remove high performance hoist assem- required.
bly from aircraft. Refer to paragraph 14-149.
d. Remove four screws (16) and cover (15)
b. Remove control panel assembly, refer to from upper support assembly (3).
paragraph 14-191.
c. During removal of the upper support as-

sembly (21) lay winch assembly and boom
head on workbench. Remove bolts (22, figure Do not disassemble the reaction
14-16), washers (24), carrying handles (24.1), arm any further than step e. Other-
sleeve spacers (26), bracket assembly (25), and wise, damage and personal injury
upper support assembly (21). could result.
d. Remove boom head assembly, refer to e. Disassembly of reaction arm assembly

paragraph 14-158. (9). Remove roll pin (27) and slide extension
arm (28) off pivot arm (55). Remove extension
e. During removal of the lower support as- cap (29), remove stud (56), remove roll pin (57),
sembly (34), lay winch assembly and boom remove quick disconnect adapter (32), and re-
head on workbench. Remove four bolts (32) move extension lanyard.
and washers (33).
f. Remove stanchion plate (6) from stan-
NOTE chion tube assembly (43). Remove grommet (5)
Make sure electrical cables are dis- from cover plate (6).
connected and tied off to prevent
interference during removaI of g. If required, remove bolt (13) and pendant
winch assembly. hook (14).
f. Remove winch assembly (27). h. If required, remove socket cap screws

(10), retainer hook (11), and retaining clip (12)
from stanchion tube assembly (43).
i . If required, loosen nut (7) and remove

stud (8) from stanchion tube assembly (43).
(14-81 blank)/14-82 Change 16

TM 55-1520-210-23-2
j. Remove two screws (40) from switch This stop screw will prevent the rotary actuator
cover assembly (41). Remove anti scuff ring assembly from coming apart.
(39) and slide switch cover (41) up to gain
access to microswitches. q. Remove nuts (35), screws (38), and
motor (37) from inertia dump assembly (36).
k. Remove nuts (60), quick release pins (31)
and heel plate (61). Remove quick release pin 14-201. Inspection, Disassembled — Boom
(30). Remove screws (58), washers (59), and Position Actuator and Structure Support
overload bracket (48). (AVIM).
NOTE a. Inspect for corrosion, dents, scratches,

cracks, loose and missing hardware and securi-
Before removing lower base plate
ty.
(33), ensure that the timing marks
are on both the base plate (33) and
b. Inspect switches and receptacles for se-
rotary actuator (45). Ensure that a
curity, damage and general condition.
timing mark is on the upper base
plate (51) after removing base plate
14-202. Repair and Replacement — Boom
(33) and reaction plate (52). If tim-
Position Actuator. a. Repair of the boom posi-
ing marks are not on either of the
tion actuator consists of replacing the boom
parts, mark them as required.
position actuator and structure support assem-
bly.
b. Replace all parts with excessive corro-

l. Remove cotter pin (53), quick disconnect
sion, dents, scratches and cracks.
(32), and thrust washer (54).
14-203. Assembly — Boom Position Actua-
m. Remove lower base plate (33), reaction
tor and Structure Support (AVIM). Refer to
plate (52) and switch lever assembly (29). Re-
figure 14-27.
move screws (64), upper base plate (51),
screws (63), and remove mounting flange (65)
a. Install motor (37) on inertia dump assem-
from support assembly (66).
bly (36), screws (38), and nuts (35).
n. Remove six bolts (42) from stanchion
b. Install rotary actuator (45), mechanical
tube assembly (43).
stop (44), inertia dump assembly (36), and mo-
tor (37) into stanchion tube assembly (43) and
NOTE
rotate assemblies 30 degrees to right or left to
While pulling assemblies out of complete installation in stanchion tube assem-
stanchion tube (43), rotate slightly bly.
to aid in disassembly.
c. Install six bolts (42) in stanchion tube
o. Remove rotary actuator (45), mechanical assembly (43) and lock wire bolts with .020
stop (44), and inertia dump assembly (36) and safety wire.
motor (37) from stanchion tube assembly (43).
d. Install mounting flange (65) on upper
p. Before completely removing these as- base plate (51) using screws (63). Install upper
semblies, back each assembly out one inch base plate (51) and mounting flange (65) on
from stanchion tube (43), insert bolt (42) into rotary actuator (45) and screws (64). Install
one of the six holes and screw approximately reaction plate (52) with switch lever assembly
halfway with rotary actuator assembly (53). (29) and lower base plate (33).
14-83
TM 55-1520-210-23-2
Figure 14-27. Boom Position Actuator and Structure Support (Sheet 1 of 3)
14-84
TM 55-1520-210-23-2
14-85
TM 55-1520-210-23-2
1. Height Adjuster 35. Nut

2 Packing 36. Inertia Dump Assembly
3% Upper Support Assembly 37. Motor
4. Quick Plunger 38. Screw
5. Nonmetallic Grommet 39. Anti Scuff Ring
6. Stanchion Plate 40. Socket Cap Screw
7. Nut 41. Switch Cover
8. Stud 42. Bolt
9. Reaction Arm Assembly 43. Stanchion Tube Assembly
10. Socket Cap Screw 44. Mechanical Stop
11. Retainer Hook 45. Rotary Actuator
12. Retaining Clip 46. Socket Cap Screws
13. Bolt 47. Switches and Adapters
14. Pendant Hook 48. Overload Bracket and Switches
15. Cover Plate 49. Control Cams
16. Screw 50. Terminal Strip Cover
17. Shaft 51. Base Plate (Upper)
18. Bearing 52. Reaction Plate
19. Retaining Ring 53. Cotter Pin
20. Retaining Ring 54. Washer Thrust
21. Bearing 55. Pivot Arm
22. Retaining Ring 56. Stud
23. Ceiling Adapter 57 Roll Pin
24. Extension Lanyard 58. Screw
25. Extension Cap 59. Washer
26. Setscrew 60. Nut
27. Roll Pin 61. Heel plate
28. Extension Arm 62. Washer
29. Switch Lever Assembly 63. Screw
30. Quick Release Pin 44. Screw
31. Quick Release Pin 65. Mount Flange
32. Adapter 66. Support Assembly
33. Base Plate (Lower) 67. Socket Cap Screw
34. Screw 68. Washer
14-86
TM 55-1520-210-23-2
NOTE l. If removed, install pendant hook (14) and bolt

(13).
During installation of the upper and
lower base plates, make sure the m. If removed, install retaining clip (12), retainer
timing marks are aligned with shaft hook (11), and socket cap screws (10) on stanchion tube
of rotary actuator. assembly (43).
n. If removed, install stud (8) and screw in until ap-
e. Install thrust washer (54) with beveled edge proximately 1/2” from stanchion tube assembly (43)
down on quick disconnect (32). Install quick disconnect and tighten nut (7).
in rotary actuator (45). Align holes and install cotter pin
(53).
f. Install overload bracket (48), quick release pin
(30), screws (58) and washers (59) on top side of reaction
plate assembly (52). Install heel plate (61), quick
release pins (31) and nuts (60).
g. Slide switch cover (41) down Install anti scuff
ring (39) and screws (40).
NOTE
Refer to paragraph 14-248 for ad-
justment of Limit Switches.
h. Install grommet (5) on stanchion plate (6) and in-

stall stanchion plate (6) into stanchion tube (43).
i. Assemble height adjuster per steps below:
(1) Press bearing (21) into top of shaft (17) hous-
ing and secure with retaining ring (22).
(2) Press bearing (18) into lower end of shaft (17)
housing and secure with retaining ring (19).
(3) Install ceiling adapter (23) in shaft (17) hous-
ing and secure with retaining ring (20).
(4) Install packing (2) and assembled height ad-
juster (1) in upper support assembly (3).
j. Install plunger (4) and set screw (26) in upper sup-
port assembly (3). Install cover plate (15) with four
screws (16).
k. Adjustment of plunger (4):
(1) Loosen set screw (26) in upper support

assembly (3).
(2) With plunger (4) in the locked position

turn plunger clockwise or counterclockwise to
obtain locking if the height adjuster groves.
(3) Pull Plunger (4) and and turn 90° clock-

wise or counterclockwise to obtain releasing of
plunger from height adjuster. If plunger does not
release, repeat steps 1 and 2.
(4) Tighten set screw (26) in upper sup-

port assembly (3).
Change 15 14-87
TM 55-1520-210-23-2
14-243. Description — Up Deceleration (1

Foot Limit) Cam. The up-deceleration cam
controls the one foot limit (12 fpm maximum
cable speed) during reel-in.
14-244. Adjustment — Up Deceleration (1

Foot Limit) Cam.
Do not rely on limit switch functions

when operating hoist to make ad-
justments.
14-239. Caution Light (10 Foot Limit) Cam.
14-240. Description — Caution Light (10 a. Remove limit switch drive assembly cover
Foot Limit) Cam. Controls the pendant CAU- plate (14, figure 14-29).
TION light and 10 foot deceleration (75 fpm b. Operate winch until one foot of cable is
maximum cable speed). extended from boom head (measure from top of
hook assembly bumper).
14-241. Adjustment — UP DECELERATION
and Caution Light (10 Foot Limit) Cam. NOTE
If winch motor stops check settings
of DOWN and DOWN ALL stop limit
switches.
Do not rely on limit switch functions c. Loosen switch 4 cam adjusting screw.
d. Rotate cam in UP direction (as shown on
justments.
instruction plate) until switch 4 is heard to actu-
a. Remove limit switch drive assembly cover ate on high section of cam.
plate (14, figure 14-29). e. Tighten cam adjusting screw.
b. Operate winch until ten feet of cable is f. Perform operational check, refer to para-
extended out from boom head (measured from graph 14-155.
top of hook assembly bumper). g. Install limit switch drive assembly cover
NOTE plate when cam adjustment is complete.
If winch motor stops, check settings 14-245. Up Limit Switches.
of the DOWN and DOWN ALL stop
limit switches. 14-246. Description — Up Limit Switch. T h e
up limit switch is actuated by the hook striker
c. If the control pendant CAUTION LIGHT is
disc (3, figure 14-26) to shut off the winch
not illuminated, adjust switch 3 CAUTION
motor.
LIGHT, Cam 3B to just actuate the switch, then
tighten cam screw (figure 14-30). 14-246.1 Inspection — Up Limit Switch(es).
d. Check the cam adjustment by reeling a. Inspect electrical wires for frayed, chafed
hoist cable out, then in; CAUTION LIGHT must or damaged wires.
illuminate when hook and bumper are within 10 b. Inspect switches and components for
feet of the full up position. damage.
e. Tighten cam adjusting screw.
14-247. Adjustment — Up Limit Switch.
f. Perform operational check, refer to para-
graph 14-155.
g. Install limit switch drive assembly cover
plate when switch adjustment is complete.
1 4 - 2 4 2 . U P — Deceleration (1 Foot Limit) when operating hoist to make ad-
Cam. justments.
14-88 Change 15
TM 55-1520-210-23-2
14-243. Description — Up Deceleration (1

Foot Limit) Cam. The up-deceleration cam
controls the one foot limit (12 fpm maximum
cable speed) during reel-in.
14-244. Adjustment — Up Deceleration (1

Foot Limit) Cam.

justments.
14-239. Caution Light (10 Foot Limit) Cam.
14-240. Description — Caution Light (10 a. Remove limit switch drive assembly cover
Foot Limit) Cam. Controls the pendant CAU- plate (14, figure 14-29).
TION light and 10 foot deceleration (75 fpm b. Operate winch until one foot of cable is
maximum cable speed). extended from boom head (measure from top of
hook assembly bumper).
14-241. Adjustment — UP DECELERATION
and Caution Light (10 Foot Limit) Cam. NOTE
If winch motor stops check settings
of DOWN and DOWN ALL stop limit
switches.
Do not rely on limit switch functions c. Loosen switch 4 cam adjusting screw.
d. Rotate cam in UP direction (as shown on
justments.
instruction plate) until switch 4 is heard to actu-
a. Remove limit switch drive assembly cover ate on high section of cam.
plate (14, figure 14-29). e. Tighten cam adjusting screw.
b. Operate winch until ten feet of cable is f. Perform operational check, refer to para-
extended out from boom head (measured from graph 14-155.
top of hook assembly bumper). g. Install limit switch drive assembly cover
NOTE plate when cam adjustment is complete.
If winch motor stops, check settings 14-245. Up Limit Switches.
of the DOWN and DOWN ALL stop
limit switches. 14-246. Description — Up Limit Switch. T h e
up limit switch is actuated by the hook striker
c. If the control pendant CAUTION LIGHT is
disc (3, figure 14-26) to shut off the winch
not illuminated, adjust switch 3 CAUTION
motor.
LIGHT, Cam 3B to just actuate the switch, then
tighten cam screw (figure 14-30). 14-246.1 Inspection — Up Limit Switch(es).
d. Check the cam adjustment by reeling a. Inspect electrical wires for frayed, chafed
hoist cable out, then in; CAUTION LIGHT must or damaged wires.
illuminate when hook and bumper are within 10 b. Inspect switches and components for
feet of the full up position. damage.
e. Tighten cam adjusting screw.
14-247. Adjustment — Up Limit Switch.
f. Perform operational check, refer to para-
graph 14-155.
g. Install limit switch drive assembly cover
plate when switch adjustment is complete.
1 4 - 2 4 2 . U P — Deceleration (1 Foot Limit) when operating hoist to make ad-
Cam. justments.
14-95 blank/(14-96) Change 15

TM 55-1520-210-23-2
Section II. CARGO SUSPENSION ASSEMBLY
14-260. CARGO SUSPENSION AS- released by use of a button, located on pilots

SEMBLY. control stick. The two position toggle switch
(cargo release), located on overhead console,
14-261. Description — Cargo Suspension must be moved from OFF to ARM before press-
Assembly. On Serial No. 62-12351 thru 72- ing button. When the switch is in ARM position
21649, a suspension assembly for carrying the amber light on the instrumental panel illu-
external cargo loads hangs at approximate cen- minates. The pilot may accomplish manual
ter of gravity from a structural cross beam release of external cargo, regardless of the
under transmission pylon. Cargo release hook, position of the ARM switch, by depression of a
on lower end of suspension assembly, extends foot pedal, which is connected by a cable
through a padded opening in lower skin of assembly to cargo hook release mechanism
fuselage. Hook unit is a horizontal loading type (figure 14-31).
with an automatic pickup latch, and has both 14-262. Lubrication — Cargo Suspension
electrical and mechanical load release provi- Assembly. When cargo hook is in daily use,
sions. Cargo hook has a guard over its hand apply a small amount of grease (C129) each
lever. The suspension has no swiveling action, day to end of load beam (29, figure 14-32)
being for use with a load connector which has where it engages latch; lubricate link (19) at
a swivel or other device to relieve torsion ef- suspension bracket (14), wipe off excess
fects due to a load twisting or turning. Cargo
grease.
hook assembly is guarded by a bumper ring
with nylon outer surface. Beginning with Serial 14-263. Operational Check — Cargo Sus-
No. 63-8739, suspension shaft is secured to pension Assembly. a. Check that upper control
lower yoke by a shear pin (instead of four bolts) cable (10, figure 14-32) and electrical cable
and by a failsafe retaining collar, two washer- (21) have enough slack to allow full swing of
type thrust bearings, and a nut threaded and suspension assembly. Cables should not allow
bonded into shaft end (figure 14-31). Cargo is release of load beam (29) during swing text.
14-97 blank/(14-98) Change 15

TM 55-1520-210-23-2
1. Manual cargo release pedal 5. Restraint springs (3)

2. External cargo electrical release switch 6. Mechanical release cable assembly
3. Cargo release off/arm switch -- 7. Cargo rear view mirror
miscellaneous panel 8. Floor access door
4. Cargo suspension assembly 9. Pylon access door
Figure 14-31. Cargo Suspension System.
14-99
TM 55-1520-210-23-2
b Check operation of mechanical release system d. Check electrical operation of cargo hook, with
as follows: minimum test load of 125 pounds suspended on load
beam (29). Check for release with switch in ARM and
(1) Ensure that cable lever (23) is approximate- release button on cyclic depressed. Check for reten-
ly parallel to plane of bolts (26) retaining cargo hook tion with switch in OFF and release button on cyclic
(27), depressed (figure 14-31).
(2) Attach a test load of 25 pounds to load NOTE

beam (29).
Ensure that BAT SWITCH is positioned
(3) Press pedal (2) against stop (1) and check to ON, or external power source is con-
the following: nected. NON-ESSENTIAL BUS switch
shall be set to MANUAL, and CARGO
HOOK circuit breaker shall be closed.
(a) Check that spring and spacer (8) in
bracket (7) are not bottomed out internally.
14-264. Troubleshooting — Cargo Suspension
Assembly. Troubleshooting the cargo suspension
(b) Check that cable lever (23) is up, but not
assembly in accordance with Table 14-3.
in contact with conduit of upper control cable (10) just
below clamp (25), and that load beam (29) released
test load. NOTE
(c) Release pedal (2) and check that upper Before you use this table, be sure you
control cable (10) and cable lever (23) returns to lock- have performed all normal operational
ed position and that load beam (29) is latched. checks.
c. If system fails any of the preceding checks,

adjust cargo suspension (paragraph 14-269).
14-100 Change 3
TM 55-1520-210-23-2
1. Stop 11. Cotter pin 21. Electrical cable 31. Sleeve Spacer
2.Pedal 12. Support clamp 22. Restraint spring 32. Shaft
3. Actuating cable 13. Screw 23. Cable lever 33. Washer
4. Turnbuckle 14.Suspension bracket 24. Yoke 34. Machine threaded bushing
5. Actuating cable 15. Bolt 25. Clamp 35. Pin
6. Cargo release relay 16.Washer 26. Bolt
7. Bracket 17. Nut 27. Cargo hook
8. Spacer 18. Cotter pin 28. Stop screw
9. Connector 19. Link 29. Load beam
10. Control cable 20. Clamp 30. Bumper ring
Figure 14-32. Cargo Suspension Installation — Typical
Change 6 14-101
TM 55-1520-210-23-2
Table 14-3 Troubleshooting - Cargo Suspension Assembly
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. Electrical cargo release inoperative.
STEP 1. Ensure that 28 Vdc is present at receptacle (1, figure 14-33) when CARGO RELEASE switch is depressed.
If 28 Vdc is not present, replace faulty solenoid (paragraph 9-5).
STEP 2. Depress CARGO RELEASE switch on pilots cyclic stick and check for 28 Vdc at receptacle.
If 28 Vdc is not present at receptacle with switch depressed, replace faulty switch (paragraph 9-5).
STEP 3. Depress CARGO RELEASE switch on co-pilots cyclic stick and check for 28 Vdc at receptacle.
If 28 Vdc is not present at receptacle with switch depressed, replace faulty switch (paragraph 9-5).
STEP 4. Depress CARGO RELEASE switch (pilots or co-pilots) and check for 28 Vdc at receptacle.
If 28 Vdc is not present, replace circuit breaker (chapter 9.)
STEP 5. Check wiring and electrical continuity.
Repair or replace defective wiring (paragraph 9-5 and Appendix F).
2. Mechanical cargo release malfunctioning.
STEP 1. Depress mechanical CARGO RELEASE pedal and check that cargo hook releases.
If cargo hook does not open, replace broken cable, damaged pulley, or secure cable connections
(paragraph 14-267).
STEP 2. Depress mechanical CARGO RELEASE pedal and check that cargo hook releases.
If cargo hook does not release, adjust cable(s) (paragraph 14-269).
3. Cargo suspension assembly power failure.
Ensure that circuit breaker does not open when cargo suspension assembly is energized.
If circuit breaker opens, correct short in system, repair/replace defective wiring, or replace faulty
circuit breaker (paragraph 9-12 and Appendix F).
I U.S. GOVERNMENT PRINTING OFFICE: 1993 765-023/30333

14-102 Change 5
TM 55-1520-210-23-2
14-265. Removal — Cargo Suspension Assembly. es. Inspect link (19, figure 14-32) for maximum 0.020
inch radial play. Inspect yoke (24) for maximum 0.020
a. Remove pylon access door (9, figure 14-31) in
inch radial play with shear pin not installed. (Reference
cabin.
NOTE below). There shall be no space between yoke
b. With electrical power off, disconnect electrical (24) and its support (bushing, bearing, and spacer) with
cable (21, figure 14-32) at receptacle located on right the shear pin installed. Inspect shear pin for maximum
lower side of structural lift beam. looseness of 0.003 inch.
c. Detach upper control cable (10) from support NOTE
clamp (12). Remove cotter pin and detach ball terminal If a maximum of 0.020 inch radial play in
of cable from connector (9). yoke (24) exists, items 32, 33, and 34 in
d. Unhook and remove three restraint springs (22) figure 14-32 must be replaced. Item (34)
from structure and suspension assembly. threaded bushing is bonded with EA 934
(29). When installing item (34), threads of
e. Remove cotter pin (18), nut (17), washers (16), items (34) and (32) must be coated with
and bolt (15) to detach link (19) from suspension bracket (C29) and installed wet. Torque (34) 20-25
(14). Remove suspension assembly. foot-pounds.
14-266. Inspection — Cargo Suspension Assem- c. Check electrical operation. Check continuity of
bly. circuits (paragraph 9-12 and Appendix F).
a. Inspect bolts (15 and 25), fittings (24 and 30)
and restraint springs (22) for damage, wear and service- 14-267. Repair or Replacement — Cargo Suspen-
ability. Inspect link (19) and its bushing for damage and sion Assembly.
wear. a. Replace any damaged or unserviceable attach-
ment bolts, fittings, clamps, or restraint springs on sus-
CAUTION pension assembly as necessary.
Wear of bolts, screws and pins in the car- b. On a suspension with fail-safe yoke attachment,
go suspension assembly can change the replace shear pin as necessary in attachment of lower
rigging of the mechanical release; and, if yoke to suspension shaft. Remove pin, align holes
they are sufficiently worn, an inadvertent through yoke and shaft, insert new pin, and secure with
release of external cargo can result. Wear cotter pin.
of the hardware attaching the cargo sus-
pension yoke to the cargo suspension 14-268. Installation — Cargo Suspension Assem-
shaft can be determined by removing two bly.
of the machine screws or the pin. NOTE
NOTE Make sure rubber bumper is installed on
Ensure clamp and eyebolt (6, figure 14-33) edge of lower skin of fuselage (paragraph
is installed 14.0 inches from center line of 14-286.d.).
hole in link (2).
a. Position suspension assembly with open side of
b. Inspect structural parts from main beam to the load beam (29, figure 14-32) forward and with link (19)
hook assembly for obvious maximum radial play of 0.003 aligned in suspension bracket (14). Install bolt (15),
inch. Inspect structural parts for dents, scratches, and washers (16), nut (17), and cotter pin (18). Link must
corrosion not to exceed a maximum depth of 0.035 inch- operate freely.
Change 15 14-103
TM 55-1520-210-23-2
NOTE 14-269. Adjustment - Cargo Suspension

Assembly.
Ensure that spring (22) with least amount of a. With pedal (2, figure 14-32) full aft and upper
coils (approximately 24) is installed in aft control cable (10) loose in support clamp (12) and
position. If amount of coils is the same, clamps (20 and 25), adjust lower and upper actuating
short spring will be installed aft. cables (3 and 5), at turnbuckle (4) to provide 20 TO 24
pounds cable tension. Safety turnbuckle with lockwire
(C155).
b. Install and connect three restraint springs (22)
between eyebolts on structure and clamps on b. Check at cargo hook (27) for correct positioning
suspension assembly. of parts with load beam (29) latched.
c. Adjust stop screw (13, figure 14-33) in cable

c. Route free end of upper control cable (10) aft lever (23) until screw holds lever approximately
and to the right of suspension bracket (14). Engage parallel to plane of bolts (21) in yoke (9). Secure screw
ball terminal in connector (9) and secure with cotter pin with check nut. Check lower control cable (20, figure
(11). Attach cable conduit in support clamp (12) and 14-33) in cargo hook (18) for required clearance.
secure with screw (13) to bracket.
(1) For hook assembly with lower control cable
(20) extending inside case, open hinged access door
d. Connect electrical cable (21) to receptacle on cover of hook and check that ball terminal of cable
located on lower right side of lift beam. is 0.43 TO 0.50 below seat of internal level (19).
(2) For hook assembly with lower control cable

e. Adjust and check mechanical and electrical (20, detail A and B) outside of case, check that ball
operation of suspension assembly (paragraph 14-269 terminal of cable is 0.12 TO 0.18 inch beyond seat of
and 14-263). internal latch (19).
14-104 Change 6
TM 55-1520-210-23-2
Figure 14-33. Caargo Suspension Assemblies
Change 5 14-105
TM 55-1520-210-23-2
d. Adjust conduit of upper control cable (3) to provide 14272. Removal - Release Cables. a. Remove floor
approximately 1.0 inch clearance from upper ball terminal access door (8, figure 14-31 ) and pylon access door (9) in
and secure with support clamp (12, figure 14-32). Set cabin.
lower end of conduit 0.12 TO 0.18 inch below clamp (10,
figure 14-33) and secure with damps (10 and 4). b. Disconnect upper control cable (10, figure 14-32)
from connector (9), by removing cotter pin (11) and lifting
e. Check that electrical and control cables have out ball terminal.
enough slack to allow full swing of suspension assembly.
Cables should not release load beam (17) during swing c. Cut lockwire and disconnect turnbuckle (4) from
test. and upper actuating cables (3 and 5).
f. Check operation of mechanical release system as d. To remove upper actuating cable (5) proceed as fol-
follows: lows.
(1) Check to ensure that cable lever (23, figure 14- (1) Upper pulley and spring bracket (7) may be left
32) is approximately parallel to plane of bolts (26). in place, or may be removed, by removing two attaching
screws, washers, and nuts. Lift bracket from lift beam.
(2) Attach a test load of 20 pounds to load beam
(29), (2) Detach ball terminal of upper actuating cable
(5) from connector (9) by removing cotter pin.
(3) Press pedal (2) against stop (1). Check that
spacer (8) and spring in bracket (7) are not bottomed out; (3) Remove connector (9), space (8), split guide,
that cable lever (23) is up but not stopped by conduit of and spring from end of upper actuating cable (5).
upper control cable (10), and that load beam (29) released
test load. Cable lever should not bottom against bottom of (4) Remove fairlead from pulley of bracket (7) and
cable conduit or damp. Adjust stop screw (28) as neces- pull upper actuating cable (5) out of bracket. Remove
sary. bolts, nut and washers to remove pulley from bracket.
(4) Release pedal (2) and check that cable returns e. To remove lower actuating cable (3) proceed as fol-
to locking position and that load beam (29) is latched. lows:
14-270. RELEASE CABLES.
14-271. Description - Release Cables. The

mechanical release system of the cargo suspension as-
sembly is connected by four cable assemblies: lower ac-
tuating cable (3, figure 14-32), upper actuating cable (5),
upper control cable (10), and lower control cable (20, fig-
ure 14-33). The actuating cables are routed through pul-
leys and fairleads down inside right wall of pylon support
structure and forward under cabin floor to a MANUAL
CARGO RELEASE pedal (2, figure 14-32) at pilots sta-
tion. The actuating cables are spring loaded by a coil
spring in the pulley and spring bracket (7).
14-106 Change 5
TM 55-1520-210-23-2
(1) Disconnect clevis on forward end of lower ac- (3) Attach clevis terminal of lower actuating
tuating cable (3) from arm on pedal (2) by removing cot- cable (3) to arm on pedal (2) with fairlead, washer and
ter pin, washer and pin. cotter pin.
(2) Remove fairleads from lower pulley and b. Install upper actuating cable (5) as follows:
bracket in pylon compartment and from three pulleys
(1) insert ball terminal end of upper actuating
under cabin floor. One pulley is located just aft of
cable (5) from outboard side of upper pulley bracket (7).
fuselage Station 52 bulkhead; two pulleys are just for-
Pull cable through tube of bracket.
ward of Station 102.
(2) Assemble spring, split guide, spacer (8), and
(3) On Serial No. 68-15214 and subsequent,
connector (9) on end of upper actuating cable (5) in-
remove nut, washer, screw and clamp from end of boot
board of bracket (7). Secure cable ball terminal to con-
on forward side of Station 123.0 bulkhead. nector with cotter pin. Pull parts into tube of bracket.
(4) Carefully pull lower actuating cable (3) cable
(3) Install fairlead through outboard side of
section forward through bulkhead grommets. bracket (7) and install cotter pin to secure upper ac-
(5) Remove and replace pulleys, with attaching tuating cable (5).
bolts, nuts, and washers, as necessary.
(4) If removed, place pulley and spring bracket (7)
on aft side of support bracket at right lower side of lift
14-273. Inspection - Release Cables. a.
beam. Secure with two screws, washers and nuts.
Inspect pulleys for wear and freedom of rotation.
c. Connect lower and upper actuating cables (3 and
b. Inspect lower and upper actuating cables (3 and 5) with turnbuckle (4).
5, figure 14-32) for broken strands, frayed wires, or
wear. d. Insert ball terminal of upper control cable (10) in
connector (9) and secure with cotter pin (11).
c. Inspect pulley brackets and grommets for cracks,
wear, and proper installation. e. Adjust release cables and check mechanical and
electrical operation (paragraphs 14-269 and 14-263).
14-274. Repair or Replacement - Release f. Install floor and pylon access doors (8 and 9,
Cables. a. Replace worn and unserviceable lower figure 14-31).
or upper actuating cables (3 and 5, figure 14-32).
b. Replace pulleys showing wear, rough bearings 14-276. Adjust - Release Cables. (Refer to
or deterioration. paragraph 14-269).
c. Replace pulley brackets, grommets and fair- 14-277. PEDAL ASSEMBLY.

leads that show cracks, wear or deterioration.
14-278. Description - Pedal Assembly. A foot
14-275. Installation - Release Cables. a. pedal (2, figure 14-32) is provided for manual release of
Install lower actuating cable (3, figure 14-32) as follows: the cargo. The pedal is mounted on the floor at Station
23.00 and is connected to the cargo hook release
mechanism by a cable assembly.
(1) Insert threaded terminal of lower actuating
cable (3) through hole in Station 23 bulkhead into area
under cabin floor. 14-279. Romoval - Pedal Assembly. a.
Disconnect clevis terminal of lower actuating cable (34,
(2) Route cable through bulkhead grommets and
figure 14-32) from arm of pedal (2) by removing cotter
three pulleys below floor, and through lower pulley
pin and pin.
bracket in pylon compartment. Install fairleads with cot-
ter pins, at pulleys. b. Remove pedal (2) as an assembly by removing
five bolts with nuts and washers, to detach stop
assembly and eye bracket from Station 23 bulkhead.
On Serial No. 68-15214 and subse- 14-280. Inspection - pedal Assembly. a.

quent, route cable through boot on for- Inspect for wear of bushings in pedal or mounting fit-
ward side of Station 123.0 bulkhead tings.
and install clamp, screw Washer and
b. Inspect pedal for cracks and deterioration.
nut.
14-107
TM 55-1520-210-23-2
14-281. Repair or Replacement—Pedal Assem- d. Remove cargo hook (18) from yoke (9) by re-
bly. a. Replace bushings if unserviceable. moving two bolts (21), washers, nuts, and cotter pins.
b. Replace pedal assembly having cracks or other 14-286. Inspection—Cargo Hook. a. Inspect
damage that impair operation. cargo hook (18, figure 14-33) for cracks and damage
that would impair serviceability.
14-282. Installation-Pedal Assembly. a. Align
pedal (2, figure 14-32) as an assembly on front of b. Inspect hardware for security.
Station 23 bulkhead in cabin ahead of pilot’s seat.
c. Inspect moving parts of cargo hook (18) for wear,
b. Attach eye bracket to structure with two bolts, deterioration and corrosion.
washers, and nuts.
d. Replacement of rubber bumper PN 205-030-772-
c. Attach stop assembly with three bolts, washers, 25. Replace synthetic rubber bumper as follows:
and nuts.
(1) Clean bonding area on panel with naphtha
d. Check for snug fit of pedal (2) in bracket and (C178).
stop assembly. Adjust shims on pivot bolts as neces-
sary to eliminate end play and to align pedal with stop (2) Clean inside area of bumper with toluene
(1). (C288).
e. Connect clevis terminal of lower actuating cable (3) Brush a thin coat of adhesive (C40) approxi-
(3) to arm on pedal (2) with pin and cotter pin. mately 0.010 inch thick on bonding areas and inside
bumper.
f. Adjust suspension assembly and perform me-
chanical and electrical operational check (paragraphs (4) Allow approximately 1 hour drying time until
14-269 and 14-263). adhesive becomes tacky. Install bumper on panel (PN
205-030-772-87).
14-283. CARGO HOOK.
(5) Hold bumper in place for a minimum of one
14-284. Description—Cargo Hook. The cargo minute.
hook is a horizontal loading type with an automatic
pickup latch and has both electrical and mechanical (6) Allow a minimum of 24 hours drying time be-
load release provisions. Cargo quick release can be fore releasing aircraft for flight.
actuated electrically from a switch located on the pi-
lots cyclic control stick or manually through cables by 14-287. Repair or Replacement-Cargo Hook.
depressing a foot release pedal that is located be- a. Replace cargo hook (18, figure 14-33) if cracks are
tween the tail rotor control pedals. evident.
14-285. Removal — Cargo Hook. a. Disconnect b. Repair surfaces that display corrosion damage.
lower connector (24, figure 14-33) of electrical cable
(1) at cargo hook (18). c. Repair small nicks and scratches by honing
method.
b. Remove cotter pins securing ball terminals of
upper and lower control cables (3 and 20) to cable d. Inspect rubber bumper on panel (PN 205-030-
lever (23). Remove cables from lever. 772-85) to see if missing, torn or debonding from panel.
c. Remove cable lever (23) and spring (11) arm 14-288. Lubrication-cargo Hook. (Refer to para-
yoke (9) by removing pin (12), two spacers and cotter graph 14-262.
pin.
✩ U.S. GOVERNMENT PRINTING OFFICE: 1992654-121/41122

14-108 Change 4 PIN:040152-004
TM 55-1520-210-23-2
14-289. Installation — Cargo Hook. 14-291. OPERATING INSTRUCTIONS:

a. Align cargo hook (18, figure 14-33) to yoke (9) a. With load beam (33) in closed position, slide car-
with open side of load beam (17) forward. Install two bolts go supporting device over the cantilevered load beam,
(21), washers and nuts. Use one washer under bolt head past the spring loaded keeper (46) and into the throat of
and one washer under nut, maximum twelve washers the hook. The keeper will keep the cargo carrying sling
may be used as spacers. Torque nuts 50 TO 70 inch- ring from escaping the load beam. See Figure 14-34.
pounds, secure with cotter pins. b. Cargo is now ready to lift or transport.
b. Align cable lever (23) to yoke (9) with spring (11) c. To release load, master power switch must be on.
and two spacers, secure with pin (12) and cotter pin. Cargo may then be released remotely by the pilot by
c. If required, install lower control cable (20) to inter- engaging the push button release switch located on the
nal level (19) and guide (22). pilots/copilots cyclic stick.
d. Connect ball terminal of upper and lower control d. A mechanical release is provided for emergency
cable (3 and 20) to cable lever (23) and secure with cotter use in case of electrical matfunction. This release is pilot
pins. operated with a foot pedal. Mechanical release is needed
in an emergency only.
e. Attach connector (24) of electrical cable (1) to
e. Only momentary switch contact is required to re-
receptacle on cargo hook (18).
lease cargo. It is normal for release solenoid to chatter
f. Adjust cargo suspension assembly and perform while the release button is engaged. Since solenoid op-
mechanical and electrical operational checks (para- erates almost instantaneously, push button need be held
graphs 14-269 and 14-263). only momentarily (four seconds, maximum).
f. A manual release lever (14) is provided on the
14-290. Adjustment — Cargo Hook. (Refer to para- hook housing for ground crew use. See Figure 14-33.
graph 14-269).
g. When beam (33) is unlatched, it swings down,
Description: pivoting on trunnion pin, (34) until attached device slides
off load beam. After load is released, the load beam is
HAP-0001-01-1 External Cargo Hook is a cargo car- returned to latch position. If beam fails to relatch push
rying device used in conjunction with load carrying slings cargo release switch button. See Figure 14-34.
for the lifting and transporting of external loads by rotory
wing aircraft. This is a self-loading device with remote h. Avoid attachment of two separate sling simulta-
electrial release. Cargo may be free drop in flight, or neously when included angle between them is more than
released with assistance of ground crews, by use of a 45°, to compensate, use a single point sling connector as
external manual release lever. The cantilevered load shown in figure 14-33.1.
beam pivotes on one end and latches on the other is
automatically relatched after cargo is released. The hook 14-292. Operational Sequence:
assembly is bolted directly to a special framework at- a. Cargo sling is supported by load beam (33) and
tached as an integral part of the aircraft. retained in place by keeper (46). Load beam is supported
by trunnion pin (34) and beam latch (44). Latch (44) is
locked in place by an overcenter lever (1) and kept from
General specifications: vibrating loose by another overcenter trip link (43). See
Figure 14-34.
a. Operating capacity . . . . . . . . . . . . 4,500 lbs.
b. Drop capacity . . . . . . . . . . . . . . . . . 4,500 lbs. b. Rotary solenoid (10) is energized by load release
button (operater switch), it moves overcenter trip link
c. Size . . . . . . . . . . . . . . . 4 3/16” x 9 1/8” x 10”
(43), which in turn pivots toggle latch assembly (42) up-
d. Weight . . . . . . . . . . . . . . . . . . . . . . . . 9 1/2 lbs. ward, releasing over-center pivot link (1), which moves
e. Voltage requirement . . . . . . . . . 24-28 VDC. beam latch (44) about its pivot bolt (49) until load beam
f. Amperage . . . . . . . . . . . . . . . . . . . . . 14 amps. tip (33) can latch.
Change 14 14-109
TM 55-1520-210-23-2
c. Under influence of cargo load, beam (33) pivots e. The power on master switch and push button
about its trunnion pin (34) until load slides off the beam. release switch are located conveniently to the pilot.
d. Toggle latch (42) pivots upward, engages switch

actuator(44), causing safety switch (39) to snap open. Maintenance and Disassembly Instructions
Solenoid electrical circuit is then broken. NOTE
e. Spring (30) returns load beam (33), sharply strik-
ing beam latch (44), causing it to pivot back into latched NO SPECIAL TOOLS ARE REQUIRED.
position. Overcenter mechanism is returned to “latch and
lock” positions by spring (31).
14-294. Disassemble:
f. Pilot’s emergency release system and manual re-
lease are both operated through release lever assembly a. Disconnect cannon plug connector (24) and
(55). When either manual system is actuated, it is re- emergency release cable at cable lever (23). Remove
turned to latch position by release lever spring (53). Indi- bolt (21) and disconnect hook from its suspension as-
cator (52) denotes position of latching mechanism as sembly. See Figure 14-33.
open or latched by red line pointer on release mechanism b. Remove fastening bolts, washers, and nuts (21),
cover (51). (22), and (48). See Figure 14-34.
14-293. Installation: c. Remove cotter pin (58), nut (59) and washer (22).
a. HAP-0001-01-1 cargo hook is mounted to the d. Push bolt (23) through cover (47) leaving spring
aircraft by a cable and shackle arrangement attached (31) attached to bolt (23) and bolt retained in case (41).
through holes in each upper corner of the cargo hook
case, or bolted directly through these holes to a special e. Remove cotter pin (9), nut (8) washer (7) and bolt
frame mounted on bottom of the aircraft. Release cable (49).
and electrical harness connections are provided on the
frame. f. Gently pry case (41) and cover (47) apart. Exer-
cise caution not to damage aluminum case and cover.
b. Cargo hook assembly is mounted so loads are
allowed to swing laterally, transferring load stresses ver- g. Remove cover (47) from case (41). Ensure all
tically through cargo hook housing. Load riggers should loose parts stay in case (41).
avoid side loads that transfer stresses through housing NOTE
as moments.
Normally no other components need be
c. To install emergency release cable, move manu- removed for inspection, adjustment, or lu-
al release lever (55) until cable lock screw (54) appears brication unless unusual damage or wear
beneath access hole in manual release cover (51). Back has occured.
off screw (54) until cable can be passed beneath it and
into the slot. Tighten screw to prevent cable ball end from h. Solenoid may be removed by removing access
escaping. Adjust cable so there is 1/4”- 1/2” clearance cover screws (17), solenoid screws (30) and unsoldering
between ball and release arm (55). See Figure 14-34. wires from connector (13).
d. Assure suspension sysem is wired per Figure i. Manual release mechanism may be disas-
14-33.2 wiring diagram prior to fastening cannon plug to sembled by removing attach screws (2 & 4), screw heads
connector (13). See Figure 14-34. are staked.
14-110 Change 14
TM 55-1520-210-23-2
Figure 14-33.1. Rigging Method
Change 14 14-110.1
TM 55-1520-210-23-2
Figure 14-33.2. Wiring Diagram
14-110.2 Change 14
TM 55-1520-210-23-2
Figure 14-34. Cargo Hook
Change 14 14-110.3/(14-110.4 blank)

TM 55-1520-210-23-2
j. To disassemble components of latch assembly, actuator arm for alignment if required. Check electrical
staked pins (2) and (4) must be removed. Place pin to be connections. Clean or repair as needed.
removed on flat surface over hole large enough to acco-
i. Check solenoid (10) cross pin, bushings, and at-
modate pin, and press or drive out pin with proper sized
tach screws. Replace or repair if cross pin hole is elon-
punch.
gated, or if bushings, or solenoid screws are loose. Apply
14-295. Inspection: 28 VDC to solenoid and check its operation. Reference
14-294 h. for solenoid removal.
a. Manually operate mechanism and visually in-
spect components for wear, cracks, binding, burrs and j. Check operation of load beam (33). Apply voltage
corrosion. Pay special attention to wear surfaces on load to solenoid while manually pulling load beam against
beam (33), latch (44) and trip link (43). Check for burrs return spring (30). Open beam about 15° and release
that might inhibit movement of mechanism. See Figure while solenoid is still energized. Beam should swing back
14-33. and relatch.
b. Check latch bumper (37). Replace if worn 14-296. Lubrication:
enough to prohibit contact with latch (44) in open posi-
tion. a. Lightly oil keeper (46), pivot shafts, beam latch
bearings (44), and beam latch pivot bolt (49) with AN-O-6
c. Inspect shock absorber (28). If ware shows, trim oil or equivalent. See Figure 14-33.
off burred sides or replace shock absorber. Shock ab-
sorber has a life expectancy of approximately 1000 load b. Apply MIL-G-81322B (or equivalent) grease lib-
drops. erally to beam latch (44) where it seals to case.
d. Inspect all staked screws and pins (interior and c. Apply MIL-G-46017 (or equivalent) lubrication to
exterior) for tightness. Tighten and restake if loose. beam trunnion (34), switch actuator (40), bell crank (3),
manual release lever (55), and trip link (43).
e. Inspect bearings for corrosion, binding, or rough
operation. Replace if any above are found. Refer to para- 14-297. Assembly Instructions:
graph 14-294 j. for disassembly.
NOTE
f. Check springs to insure they are positioned cor- The following information is provided with
rectly and are functioning properly. Load beam spring the intent that components secured with
(31) and keeper spring (35) may be replaced without lock wire or staked in place have not been
separating case. disassembled.
g. Check that latch toggle (42) move easily over a. Insert keeper (46) pivot lug into case and attach
center to open position and back under spring tension. spring (35). See Figure 14-34.
Mechanism is designed to lock in latched position and
remain locked until released by bell crank (3). It should b. Install latch (44) linkage assembly.
remain in position until released by inertia of beam latch (1) Turn solenoid (10) cross pin to its clockwise
(33). An 8 to 12 pound load is required to over come limit.
beam return spring (31) to open beam when unlatched.
(2) Insert latch linkage assembly into case (41)
h. Safety switch (39) is operated by movement of
while holding linkage in unlatched position. Work gently
switch actuator (40). Latch assembly pivots to release
into place. Do not force.
load beam, causing switch actuator (40) to pivot into
switch (39), opening solenoid circuit. Check switch (39) c. Cheek movement of linkage to insure smooth
continuity while manually operating mechanism. Bend operation.
Change 14 14-111
TM 55-1520-210-23-2
l. Align cover (47) over case (41) and gently press

CAUTION into place.
If wiring is directed around spring retainer m. Align indicator (52) slot with mark on manual
pin (6), spring must be loaded first and release cover (51).
wire routed over pin.
n. Firmly press case (41) and cover (47) together.
d. Install bell crank return spring (35) on (5 & 6) pins.
o. Move load beam spring retainer bolt (23) through
e. Place bumper (37) into case (41). hole in cover.
f. Place shock absorber (28) into case (41). p. Install nut (59) on bolt (23) and screw down to
face of cover (47) do not tighten. Install cotter pin (58).
g. Pin load beam (33) into case (41) with trunnion
pin (34). q. Align latch (44) and insert pivot bolt (49) through
case and cover.
h. Attach beam return spring (31) over retainer pin r. Check for proper movement of mechanism by
(32). operating manual release lever (55).
i. Insert bolt (23) about 1/2 length through case (41) s. Insert bolts (48), washers (22), and tighten lock
and attach beam return spring (31) tang over bolt (23). nuts (21).
j. Place bell crank stop (38) over pin (26). t. Install washer (7) and castle nut (8). Finger tighten
nut (8). Back off nut until slot in castle nut (8) aligns with
k. Place switch (39) over pin (36). Place switch ac- pin hole in bolt (49). Install cotter pin.
tuator (46) over pin (25) and position actuator blade be-
tween switch and pin (36) with top of actuator blade point- Final check: Support cargo hook in vertical position and
ing to center of case. Install cover (47). hang 12 pound load from beam. Energize solenoid and
NOTE weight should drop from load beam. Beam will swing
back and relatch. Should beam latch (44) be in latched
Lightly coat edge surface of cover (47) position and beam tip (33) still unlatched energize the
with Proseal 760 B-2 sealing compound or solenoid circuit momentarily and beam should relatch.
similar material. Sealant should be used
sparingly. Care should be exercised to 14-298. Painting:
keep sealant from contacting moving sur-
faces. Keep all moving surfaces free of paint.
14-112 Change 14
TM 55-1520-210-23-2
CHAPTER 15
AUXILIARY POWER PLANTS
(Not Applicable)
15-1/(15-2 blank)
TM 55-1520-210-23-2
CHAPTER 16
MISSION EQUIPMENT
16-1. EXTERNAL STORES SUPPORT. e. The corrosion and/or mechanical damage

limits for the external stores are as follows:
16-2. Description — External Stores Support. (a) Hardpoints: Negligible damage; none.
Four external stores supports can be installed on the Reparable damage: Not to exceed a minimum
helicopter. Each assembly consists of a forward and thickness of 0.335 inch after clean up. Damage
aft support beam attached to the fuselage, a cross requiring replacement; damage in excess of
beam installed between the two support beams, and 0.335 inch minimum thickness.
two sway braces attached diagonally between the
support beams and the center of the cross beam. (b) Mount holes in Hardpoints: Negligible
damage; damage less than 0.010 inch in depth.
16-3. Removal — External Stores Support. a. Reparable damage; elongation not to exceed
Remove nuts (22 and 12, figure 16-1), washers (21 0.4380 inch I.D. after clean up. Damage requiring
and 13), and bolts (20 and 14) attaching sway braces replacing; elongation in excess of 0.4380 inch; or
(16) to support beams (5 and 23) and cross beam (15). that has a tearout thickness less than 0.660 inch.
Remove sway braces.
b. Remove nuts (8), washers (7), and bolts (6) 16-6. Repair or Replacement — External Stores
attaching cross beam (15) to support beams (5 and 23) Support. a. Replace support beams (5 and 23, figure
and remove cross beam. 16-1) if cracked or if bushings in attachment point are
worn sufficiently to allow movement when parts are
c. Remove nuts (2), washers (3), bolts (4), and assembled.
cotter pins (1) attaching forward and aft support
beams (5 and 23) to fuselage and remove support b. Repair small nicks and scratches by polish-
beams. ing out with 400 grit sandpaper (C233). Coat
repaired areas with primer (C206).
c. Replace sway braces (16) if bent, dented or if

riveted clevis end is excessively worn. Adjustable
clevis end can be replaced separately.
of solvent vapors.
1640 Cleaning — External Stores Support.

Clean parts by washing with a bristle brush (C52)
and solvent (C261).
Do not use fasteners other than clevis
16-5. Inspection — External Stores Support. a. bolts to prevent casting failures.
Inspect bushings in support beams (5 and 23, figure
16-1) and in tangs of cross beam (15) for excessive 16-7. Installation — External Stores Support.
wear and damage. a. Position each support beam (5 and 23, figure
b. When external stores have been mounted 16-1) on helicopter and secure to structure with
on the aircraft, inspect support beams (5 and 23) bolts (4) and nuts (2).
and cross beam (15) for corrosion and cracks. Pay
particular attention to attaching points of support b. Position cross beam (15) between outer ends
beams. Perform a dye penetrant inspection (refer of forward and aft support beams (5 and 23) and
to TM 43-0103, inspecting for fatigue cracks in install attaching bolts (6), washers (7), and nuts (8).
an area approximately six inches adjacent to the
upper attachment point and any other area where c. Attach sway braces (16) to cross beam (15)
indications of cracks are found. and support beams (5 and 23) using bolts (22 and 12),
c. Inspect for loose, missing, or improperly washers (21 and 13) and bolts (20) and 14). Adjust
installed hardware. clevis on sway brace, if necessary, to align with
d. Inspect sway braces (16) for damage and eyebolt in cross beam.
excessive wear in clevis mounting holes.
16-1
TM 55-1520-210-23-2
1. Deleted 13. Washer

2. Nut 14. Bolt
3. Deleted 15. Crossbeam
4. Bolt 16. Sway brace
5. Support beam, aft 17. Bolt
6. Bolt 18. Washer
7. Washer 19. Nut
8. Nut 20. Eyebolt
9. Nut 21. Washer
10. Washer 22. Nut
11. Eyebolt 23. Support beam, fwd
12. Nut
Figure 16-1. External Stores Support Assembly
16-2 Change 2
TM 55-1520-210-23-2
16-8. EMERGENCY JETTISON 16-11. Cleaning — Emergency Jettison Release

RELEASE MECHANISM. Mechanism.
16-9. Description. A series of cables, actuated by a

manually operated jettison lever located by the pilots
seat, enables the pilot to mechanically jettison
externally carried stores or equipment. These cables Cleaning materials are flammable and
are equipped with adjustable fittings which facilitate toxic. Avoid skin contact and breathing
final rigging and adjustment during installation of of solvent vapors.
store or equipment on the external stores support.
a. Clean lever (20, figure 16-2), support (25),
16-10. Removal — Emergency Jettison Release and bellcrank (3) by washing with a bristle brush
Mechanism. a. Remove access plate from lower (C52) and solvent (C261).
fuselage skin below external stores forward support
beam. b. Wipe cables with a clean cloth moistened
with solvent (C261).
b. If external stores are installed, disconnect

stores release cables from lateral release cables (2, 16-12. Inspection — Emergency Jettison
figure 16-2). Release Mechanism. a. Inspect pulleys for wear,
damage, and freedom of rotation.
c. Remove three cotter pins, washers and flat b. Inspect cables for broken or frayed wires.
head pins attaching cable assemblies to bellcrank (3).
Remove two lateral release cable assemblies (2) from c. Inspect grommets for wear.
grommet and pulleys.
d. Inspect lever assembly for serviceability and
d. Remove cotter pin, nut, washer, and bolt damage.
attaching bellcrank (3) and remove bellcrank.
e. Inspect support assembly bushing for wear.
e. Remove nuts, washers, spacers, screws, and
f. Inspect bellcrank for damage or wear at cable
clamps attaching cable guard (23) to pedestal.
attachment holes and center pivot hole.
Remove cotter pin and pin attaching longitudinal
release cable (18) to emergency release lever
assembly (20). Remove cable guard and grommet 16-13. Repair or Replacement — Emergency
(22). Jettison Release Mechanism. a. Replace worn and
unserviceable pulleys and grommets (figure 16-2).
f. Remove cotter pins, pins, nuts, washers and
bolts holding longitudinal release cable pulleys (24) to b. Replace frayed or unserviceable cables.
pulley brackets and remove pulleys.
c. Replace damaged or unserviceable lever
assembly.
g. R e m o v e g r o m m e t s ( 1 9 ) w h i c h g u i d e
longitudinal release cable (18) and remove release
d. Replace support assembly if bushing is worn
cable.
or unserviceable.
h. Remove cotter pin, nut, washer and clevis bolt e. Replace bellcrank if cable attachment holes or
attaching lever assembly (20) to support assembly center pivot hole is worn.
(25).
16-14. Installation — Emergency Jettison
i. Remove nuts, washers, bolts, and spacers Release Mechanism. a. Position support assembly
attaching support assembly (25) to pedestal and (25, figure 16-2) on pedestal and install attaching
remove support assembly. bolts, spacers, washers, and nuts.
16-3
TM 55-1520-210-23-2
Figure 16-2. Manual Release Mechanism (Sheet 1 of 2)
16-4
TM 55-1520-210-23-2
1 . Pulley 14. Lower cable assembly

2 . Lateral release cable assemblies 15. Grommet
3 . Bellcrank 16. Lateral release cable pulleys
4 . Manual release mechanism 17. Electrical release controls
5 . External stores support assembly 18. Longitudinal release cable assembly
6 . Pylon support 19. Grommets
7 . Pylon assembly 20. Emergency release lever assembly
8 . Auxiliary fuel tank 21. Control panel
9 . Barrel 22. Grommet
10. Cable assembly 23. Cable guard
11. Pulley brackets 24. Longitudinal release cable pulleys
1 20 Upper guard tube 25. Support assembly
13. Lower guard tube
Figure 16-2. Manual Release Mechanism (Sheet 2 of 2)
b. Position emergency release lever assembly k. Reinstall removed access panels.

(20) on support assembly (25) and install attaching
clevis bolt, washer, nut, and cotter pin. 16-15. LITTER RACK SAFETY.
c. Thread, longitudinal release cable (18) 16-16. Description — Litter Rack. Two differ-
through bulkhead openings and install grommets ent litter rack installations may be used in UH-
(19). 1H/V helicopters. One installation accommo-
dates six litters (three on a side, one above the
d. Position longitudinal release cable pulleys other) parallel to cabin center line in aft cabin
(18) in pulley brackets and install passenger compartment, and outboard transmis-
washers, nuts, pins and cotter pins. sion support structure (figure 16-3). The other
installation accommodates three litters (one
above the other) parallel to, and just forward of,
e. Thread forward end of longitudinal release
the aft cabin passenger compartment aft bulk-
cable (18) through cable guard (23) and attach to head (figure 16-4). Litters can be quickly in-
emergency release lever assembly (20) by installing stalled for transporting patients, or rapidly
pin and cotter pin. removed for carrying cargo or personnel.
f. Position cable guard (23) and install grommet 16-17. Inspection — Litter Rack. a. Inspect litter
(22) and attaching clamps, screws, spacers, washers, support straps for material deterioration and broken
and nuts. stitching. Check fitting on ends of straps for damage
and proper operation.
g. Position bellcrank (3) and install attaching
screw, washer, nut, and cotter pin. b. Inspect litter support brackets for damaged
mounting studs and proper operation of latch.
h. Position aft end of longitudinal release cable
c. Inspect seat belt extensions for material
(18) and inboard end of lateral release cable
assemblies (2) on bellcrank (3), and attach with flat deterioration, broken stitching, and damaged end
head pins, washers, and cotter pins. fittings.
d. Inspect shelf assembly (11, figure 16-3) for
i. Position lateral release cables (2) through damage and loose or missing hardware.
grommet and pulleys (1).
16-18. Removal — Litter Rack. a. Remove six
j. When external stores are installed, connect litter rack installation (figure 16-3) as follows:
stores release cables to lateral release cables (2).
Adjust and rig release mechanism in accordance with (1) Remove and store safety belts (7) when
each external store. litters are removed.
16-5
TM 55-1520-210-23-2
1. Tension fitting 7. Safety belts

2. Strap assembly 8. Tiedown ring
3. Stud lock 9. Floor stud
4. Stanchion 10. Support brackets
5. Support bracket 11. Shelf Assembly
6. Roof studs
Figure 16-3. Litter Rack Installation (6 Litters)
16-6
TM 55-1520-210-23-2
1. Tension Fitting
2. Strap assemblies
3. Stud locks
4. Stanchion
5. Support brackets
Figure 16-4. Litter Rack Installation (3 Litters)
16-7
TM 55-1520-210-23-2
(2) Release tension on each strap assembly STA. 158.5, W.L. 28.75, 42.91 and 57.07. Attach
(2). Unhook strap fitting from cargo tie-down ring, each bracket by positioning four studs in upper ends
loosen upper fitting and detach strap from roof stud. of plate slots. Then press downward to force studs
into narrow ends of slots.
(3) Remove brackets (10) from keyhole slots in
pylon support walls and brackets (5) from stanchions (4) Install two stanchions (4) between roof
(4). Release stanchion stud locks (3) from roof and studs and deck fittings at locations shown. Secure
deck studs. brackets (5) on each stanchion in same manner used
to secure brackets to wall plates in preceding step.
(4) Remove bolts and washers to detach shelf
assemblies (11) with plates from cabin aft bulkhead. (5) Safety belt extensions (7) is used in
conjunction with safety belts from seat installation.
b. Remove three litter rack installation (figure Two required each litter.
16-4) as follows:
b. Install three litter rack (figure 16-4) as follows:
(1) Remove and store safety belts when litters
are removed. (1) Attach two strap assemblies (2) to roof
studs and cargo tiedown rings in floor at locations
(2) Release tension on each strap assembly shown. Apply tension to straps at roof fittings.
(2). Unhook strap fittings from cargo tiedown rings,
loosen upper fitting, and detach strap from roof stud. (2) Install two stanchions (4) between roof
studs and deck fitting at locations shown.
(3) Remove support brackets (5) from
stanchions (4). (3) Secure support brackets (5) to stanchions
by positioning four studs in upper end of slots in
16-19. Repair — Litter Rack. a. Replace litter plates on stanchions. Press downward on brackets to
support straps and seat belt extension for material force studs into narrow end of slots.
deterioration or damaged end fitting.
(4) Use two seat belt extensions and two
b. Replace litter support brackets if mounting safety belts from seats for each litter.
studs are damaged or if latching mechanism is
16-21. SMOKE GENERATING SUB-
damaged.
SYSTEM.
c. Replace shelf assembly (11, figure 16-3) if
damaged. Replace damaged or missing hardware for 16-22. Description -- Smoke Generating Sub-
attaching shelf. system. The smoke generating subsystem basically
consists of the oil tank and hoses, pump and motor
16-20. Installation — Litter Rack. a. Install six assembly and nozzle ring. A new designed bench
litter racks (figure 16-3) as follows: seat and door panel is necessary to accept the smoke
generating subsystem. The tank capacity is 50 gal-
(1) Attach two strap assemblies (2) to roof lons and provides approximately three minutes of
studs and cargo tiedown rings in floor at locations smoke generator operation.
shown. Apply tension to straps at cabin roof fittings.
16-23. Removal -- Smoke Generating Sub-
(2) Install four shelf assemblies (11) with system.
plates on cabin aft bulkhead at locations provided
with threaded inserts at W.L.41.0 and 56.51. (Plates
are interchangeable. Shelf assemblies P/N 205-070-
770-1 are for left side and 205-070-770-2 for right
side). Use two bolts (AN4-5A) in each shelf and plate Make sure all electrical power is
with washers (AN960PD416), one washer under bolt turned off before performing any
head and one washer next to bulkhead. maintenance on smoke generating
subsystem.
(3) Install support brackets (10) on right and a. Remove switch by disconnecting connector on
left side walls of pylon support on plates located at switch cord from connector in roof.
16-8
TM 55-1520-210-23-2
1. Clamp 15. Screw

2. Clamp 16. Washer (2 reqd)
3. Screw 17. Nut
4. Washer 18. Spacer
5. Nut 19. Oil Tank
6. Clamp 20. Hose
7. Clamp 21. Hose
8. Bracket 22. Coupling
9. Screw (2 reqd) 23. Coupling
10. Washer (2 reqd) 24. Washer (4 reqd)
11. Nut (2 reqd) 25. Bolt (4 reqd)
12. Clamp 26. Pump
13. Bracket 27. Screw (3 reqd, typical 4 places)
14. Screw 28. Seat
Figure 16-5. Oil Pump and Motor Installation
b. Remove clamps (1, 2, 6, and 7, figure 16-5) on

pump inlet hose (20) and remove hose.
c. Remove pump (26) and motor assembly.
(1) Remove floor clamps (12) securing hoses
and wiring harnesses and replace screws (15) in
cabin floor.
16-9
TM 55-1520-210-23-2
Figure 16-6. Control Box Installation
(3) Remove control box (2)

(2) Disconnect hoses (20 and 21) and wiring
harness and remove from cabin floor.
f. Remove hose (9, figure 16-7) between nozzle
ring (12) and tailpipe fairing.
(3) Remove pump (26) and motor attaching
parts and remove pump and motor. g. Remove nozzle ring attaching parts and nozzle
ring (12).
d. Remove quantity indicator and bracket;
reinstall screws and washers. h. Remove vent hose clamps (1, figure 16-8)
from cabin floor, disconnect and remove vent hose
e. Remove control box (2, figure 16-6).
(10).
(1) Disconnect cables (6 and 7). i. Unhook tank tiedown straps (3, figure 16-9)
and remove oil tank.
(2) Remove attaching hardware.
16-10
TM 55-1520-210-23-2
Figure 16-7. Nozzle Ring Bracket Installation
j. Release fasteners and remove passenger seat m. Remove attaching bolts and remove door
(8, figure 16-10). from cabin floor Install original door using existing
hardware. Secure forward seat legs to floor fittings
k. Remove tank tiedown straps (3, figure 16-9).
l. Reinstall two-man seats and center seat (8, n. Remove attaching bolts and washers (3, 4,
16-10), Do not secure forward legs of center figure 16-7), and remove brackets (2 and 11) from
seat tailpipe fairing.
16-11
TM 55-1520-210-23-2
16-24. Inspection and Cleaning — Smoke 16-25. Installation — Smoke Generating

Generating Subsystem. Aircraft shall be in- Subsystem.
spected for internal oil accumulation at the
tailboom bulkheads. Any oil accumulation shall NOTE
be removed. Tailboom of aircraft shall be
Door (paragraph 16-23 m.) must be
washed after each day of smoke generating
installed prior to tank installation.
subsystem operation.
Figure 16-8. Vent Hose Installation (Sheet 1 of 2)
16-12
TM 55-1520-210-23-2
1. Clamp (2 reqd) 14. Washer (2 reqd)

2. Bracket (2 reqd) 15. Nut (2 reqd)
3. Bracket (2 reqd) 16. Seat
4. Bolt (2 reqd) 17. Hose
5. Washer (2 reqd) 18. Clamp
6. Screw (4 reqd) 19. Bolt
7. Spacer (2 reqd) 20. Spacer
8. Washer (4 reqd) 21. Washer
9. Nut (4 reqd) 22. Washer
10. Hose 23. Spacer
11. Leg 24. Bolt
12. Tube 25. Clamp
13. Screws (2 reqd)
Figure 16-8. Vent Hose Installation (sheet 2 of 2)
16-13
218-260 0 - 88 - 21
TM 55-1520-210-23-2
Figure 16-9. Oil Tank Installation

16-14
TM 55-1520-210-23-2
a. Position tank on cabin floor, centered 1.62 (12, figure 16-8) because four rivet
inches to left of aircraft centerline, on forward side of heads protrude near one end of the
bulkhead, FS 128.00 (figure 16-9). tube, rework tube as follows: Remove
two rivets at fitting end. Clean up
b. Install new passenger seat (figure 16-10) as rivet holes with number 19 drill
follows: (0.166) diameter. Apply zinc chromate
primer (C219) to bare surfaces. Slide
NOTE
legs over tube assembly and install
If the two aft legs (11, figure 16-8) two screws (13, figure 16-8), two
cannot be installed on tube assembly washers (14), and two nuts (15).
Torque nuts 7 TO 15 inch-pounds.
1. Tube (ref)
2. Stanchion (ref)
3. Oil tank
4. Nut (2 reqd)
5. Base (2 reqd)
6. Leg (2 reqd)
7. Leg (2 reqd)
8. Seat assembly
9. Cushion 205706-46A
Figure 16-10. Seat Installation
16-15
TM 55-1520-210-23-2
(1) Release attaching fasteners and remove (2) Install oil quantity transmitter to cover
the left and right two-man seats (16) across aft area of plate, using gasket and existing hardware. Position
cabin. Leave upper seat back support tubes in place. transmitter so that electrical connector will be toward
right end of tank when installed.
(2) Release attaching fasteners and remove
center seat (8, figure 16-10). Slide out lower center (3) Reinstall cover plate on bottom of tank,
tube and reinstall for reuse. using existing hardware.
(3) Install two legs (6) on underside of seat at (4) Install union in one end of adapter tube.
outboard forward corners, using six screws.
(5) Connect opposite end of adapter tube to
(4) Install nut (4) on each leg base (5) and fitting in bottom of tank.
screw base into insert in leg.
(6) Raise tank approximately six (6) inches
(5) Install legs (7) at the remaining positions above cabin floor and temporarily block in this
on forward edge of seat, using six screws. position using any suitable material near ends of
tank.
(6) Position seat in aircraft. Insert tubes on aft
edge of seat into existing brackets on stanchions (2, (7) Connect 90 degree end of hose (20, figure
figure 16-10) at aft cabin bulkhead. Secure with 16-5) to union in adapter tube.
existing pins and latches and adjust clamps on seat
tubes as necessary. (8) C o n n e c t e x i s t i n g s t o w e d e l e c t r i c a l
connector on wiring harness to connector of quantity
NOTE transmitter in bottom of tank.
Do not secure seat legs to the floor
fittings until steps d. (6) through (11) (9) Route hose forward and up through
have been accomplished. opening in floor; so that hose extends up through
forward cutout in new door.
(7) Secure aft legs (11, figure 16-8) of seat to
floor fittings (10) Remove blocking and allow tank to rest
on cabin floor.
(8) Secure forward inboard legs (7, figure 16-
10) of seat to floor fittings. (11) Secure oil tank to floor, as shown in
figure 16-9, using four straps.
(9) Adjust forward outboard leg bases (5) to fit
snugly to floor. Tighten jamnut (4). (12) Install one coupling (22, figure 16-5) in
45 degree end of hose (20).
(10) Position cushion (9) on seat and tie
cushion to tubes at aft edge of seat. (13) Secure hose to cabin floor, using bracket
(13) spacer (18), screw (15), washer (16), clamp (12),
(11) Hook straps of seat backs to existing screw (14), washer (16), and nut (17).
upper support tubes (1) and adjust as necessary.
(14) Connect one end of vent hose (21) to top
C. Install brackets on tailpipe fairing as follows: fitting toward left end of tank.
(1) Position brackets (2 and 11, figure 16-7) (15) Route hose (21) aft and outboard around
over nutplates. left side of pylon island along cabin floor, to existing
connector in bulkhead, FS 166.00. Connect elbow to
(2) Secure each bracket (2 and 11) to fairing connector in bulkhead.
using two bolts (3) and washers (4).
(16) Secure vent hose as follows:
d. Install oil tanks as follows:
(a) Locate row of holes in outboard side of
(1) Remove center cover plate from bottom of vertical angle at left forward corner of pylon island at
tank. Remove shipping plug from cover plate. FS 128.00.
16-16
TM 55-1520-210-23-2
(b) Secure hose (10, figure 16-8) at fourth (6) Connect 90 degree end of hose (5) to elbow
hole up from floor, using bracket (2), washer (5), bolt in tailpipe fairing.
(4), bracket (3), clamp (1), two screws (6), two washers
(8), and two nuts (9). (7) Connect coupling half (8) on hose to
coupling half in service deck. Using cover (6) and
(c) Secure hose at second hole up from retainer (7).
floor, using bracket (2). washer (5), bolt (4), bracket (3),
clamp (1), two screws (6), two washers (8), and two (8) Install tailpipe lower fairing.
nuts (9).
g. Install control box as follows:
(d) Locate inboard row of screws securing (1) Open left aft electrical compartment doors.
cabin floor between FS 128.00 and FS 166.00.
(2) Remove attaching bolts (5, figure 16-6)
(e) Remove screw approximately 12 inches and remove front cover of control box (2).
aft of forward corner of island.
(3) Position control box shell (3) in forward
(f) Secure hose (10) at forward screw hole, inboard corner of electrical compartment, against left
using clamp (25), bolt (24), washer (22), and spacer main beam web and near bulkhead, FS 211.00, under
(23). shelf (1).
(g) Remove screw and secure hose at aft (4) Secure control box to beam at existing
screw hole (as shown) using clamp (18), bolt (19), nutplates, using four bolts (5) and four washers (4).
washer (21), and spacer (20).
(5) Install control box front cover, using
e. Install nozzle ring as follows: bolts and washers previously removed. Lockwire
(C155) bolts.
(1) Position nozzle ring (12, figure 16-7) on
brackets with inlet fitting at bottom and slightly to left (6) Locate large connector on existing cable
of aircraft center line. Align bosses on nozzle ring (7). Install connector on control box.
with holes in brackets (2 and 11).
(7) Locate small connector on existing cable
(2) Secure nozzle ring (12) to brackets (2 (6). Install connector on control box.
and 11), using four bolts (3) and four washers (4).
Lockwire (C155) bolts to nozzle ring. (8) Lockwire (C155) connectors.
h. InstaII quantity indicator and bracket

f. Install hoses (5) and (9) (figure 16-7) as
assembly as follows:
follows:
(1) Remove sixth and seventh screws
(1) Loosen fasteners and remove lower right outboard from center post, along top edge of right
tailpipe fairing. windshield.
(2) Install elbow in hole in right side of upper (2) Position indicator and bracket and align
tailpipe fairing using washer and nut. Do not tighten with existing holes. Holes in bracket may be
nut at this time. elongated, as necessary, to accommodate screw
spacing.
(3) Connect 90 degree end of hose (9, figure
16-7) to nozzle ring. (3) Secure bracket, using two screws and
existing washers and nuts previously removed.
(4) Connect opposite end of hose (9) to elbow
in fairing. Position hose to prevent chafing on skin, (4) Connect connector from wiring harness to
and tighten nut on elbow. back of quantity indicator.
(5) Install coupling half on straight end of i. Install pump and motor assembly as follows
hose. (figure 16-5):
16-17
TM 55-1520-210-23-2
(1) Assemble the following parts into each (12) Remove one screw from near inboard
port of pump. Do not completety tighten nuts on end of row of screws approximately 10 inches
unions. forward of bulkhead, F.S. 166.00. Secure hose and
wiring harness at screw hole.
(a) Install union with nut and packing in
pump port. (13) Secure hose and wiring harness
approximately midway between aft connector and aft
(b) Install elbow with packing on union. floor attach point.
(c) Install coupling half (23, figure 16-5) (14) Secure hose and wiring harness
with packing in elbow. approximately midway between the two floor attach
points.
(2) Install pump (26) and motor under right
end of seat, using four bolts (25) and four washers k. Install switch (U6374) as follows:
(24). Do not tighten aft outboard bolt at this time.
(1) Locate small electrical connector in cabin
(3) Position elbows as shown and tighten all roof outboard and aft of right overhead console.
pump fittings.
(2) Install connector on switch cord to
j. Install hose (6, figure 16-11) and cable (17) as connector in roof.
follows:
(3) Stow switch in spring clip located in cabin
(1) Install connector on cable (17) to connector roof approximately two inches aft of overhead
in right side of bulkhead F.S. 166.00. console.
(2) Route wires inboard and forward under l. Complete pump inlet hose installation as
two man seat, to pump motor. follows (figure 16-5):
(3) Connect wire number P111B4 to terminal (1) Route hose (20, figure 16-5) which
on pump motor. extends up from center of floor forward of oil tank
(19), outboard to the right along forward edge of tank,
(4) Remove aft outboard pump mounting bolt to pump (26). Connect coupling (22) on hose, to
and secure wire number P112B4 to pump base with coupling (23) on upper (inlet) pump port.
pump mounting bolt.
(2) Secure hose to forward inboard seat leg
(5) Install union (22) in one end of hose (6). and DEE ring in tank.
(6) Install elbow (20) with packing (21) on

union (22). 16-26. Servicing -- Smoke Generating Sub-
system Tank. a. Perform the following procedures
(7) Install coupling half (18) with packing (19) before servicing the tank:
in elbow (20).
(1) Inspect all supports and tighten if
(8) Install coupling half (22) in opposite end of necessary.
hose.
(2) Inspect nozzle ring and nozzles for
(9) Connect end of hose with elbow installed looseness or missing nozzles.
in bottom (outlet) port of pump.
(10) Route hose inboard and aft to coupling in (3) Depress the tank level fog oil circuit
bulkhead, F.S. 166.00. Connect hose to coupling. breaker in the overhead panel and observe the oil
level gage in the cockpit.
(11) Remove one screw from cabin floor aft of
pump. Secure hose and wiring harness at screw b. If the oil level gage indicates less than full, fill
hose. oil tank as follows:
16-18
TM 55-1520-210-23-2
1. Clamp 12. Clamp (2 reqd)

2. Clamp 13. Clamp (2 reqd)
3. Screw 14. Screw (2 reqd)
4. Washer 15. Washer (2 reqd)
5. Spacer 16. Nut (2 reqd)
6. Hose 17. Cable
7. Clamp 18. Coupling half
8. Clamp 19. Packing
9. Screw 20. Elbow
11. Spacer 22. Union
Figure 16-11. House and Wiring Assemblies
16-19
TM 55-1520-210-23-2
(9) Connect pump to bulkhead hose assembly

to OUT (outlet) port of pump and motor assembly.
c. Perform the following procedures after

Do not use any alternate fluids in the servicing the tank:
oil tank. The prescribed fluid is fog oil
(C191). (1) Open circuit breakers in overhead panel.
(1) Disconnect the hoses from the inlet and (2) Check oil tank and hose connections for
outlet ports on the pump and motor assembly. leaks, A grazing 0.50 caliber or larger round may
result in a non-self-sealing leak in the oil tank.
(2) Remove the quick disconnect fitting from
the dip tube, insert strainer (Part No. U6697) into the 16-27. ARMAMENT SUBSYSTEM
flared end of the dip tube and replace the fitting on the 7.62MM MACHINE GUN M23.
tube.
16-28. Description — Armament Subsystem
(3) Connect one end of the filling hose to the 7.62MM Machine Gun M23. T h e a r m a m e n t
IN (inlet) port of the pump and motor assembly. subsystem M23 is attached to external stores hard
Connect the other end of this hose to the dip tube, point fittings on both sides of the helicopter (figure
then insert the dip tube into the fog oil shipping drum. 16-12). The two flexible 7.62 millimeter machine
guns M60D (figure 16-13) are free pointing but
(4) Connect the hose from the oil tank to the limited in azimuth, elevation, and depression by cam
OUT (outlet) port of the pump and motor assembly. surfaces and stops on pintles and pintle post
assemblies of the two mount assemblies on which
the M60D machine guns are mounted. An ejection
control bag is latched to the right side of each M60D
Keep personnel clear of vent located on

the left underside of the helicopter during
filling operation. If the oil tank is
overfilled, excess fog oil will spill from
the vent.
(5) Depress SMOKE GEN PUMP CONT circuit

breaker. Depress operating switch push button and
observe oil level guage as pump and motor assembly
operate. When guage indicates F (full), release push
button.
NOTE
The oil tank holds approximately 50.0

gallons of fog oil (C191).
(6) Open the circuit breakers.
(7) Disconnect filling hose from IN (inlet) port

of pump and motor assembly and from fog oil shipping
drum.
(8) Disconnect the hose from the OUT (outlet)

port of the pump and motor assembly and connect it to Figure 16-12. Armament Subsystem M23,
the IN (inlet) port. Machine Gun M60D in Stowed Position, RS
16-20
TM 55-1520-210-23-2
machine gun to hold the spent cases and links.

Cartridges travel from ammunition box and cover
assemblies to M60D machine gun through flexible
chute and brace assemblies.
Unload machine gun prior to removal.
1 6 - 2 9 . R e m o v a l — Armament Subsystem Refer to TM 9-1005-262-14.
7.62MM Machine Gun M23. Dismantle the
subsystem only to the point required for removal and
retain mounting hardware to prevent loss. Removal a. Ammunition Chuting and Accessories (figure
procedures are-for the (right-left) gun assembly. 16-14).
Figure 16-13. 7.62 Millimeter Machine Gun M60D - Right Rear and Left Front Views
16-21
TM 55-1520-210-23-2
(3) Remove cotter pin, nut, washer, and bolt

from the upper and lower clevis portions of each
beam; remove beam-tube assembly.
(4) Cut and remove Iockwire from the socket

head cap screws from each mounting beam, remove
six cap screws and washers, and remove the
mounting beams from the base tube assembly.
16-30. Maintenance and Repair -– Armament

Subsystem 7.62MM Machine Gun M23. Refer to
TM 9-1005-262-14.
16-31. Installation — Armament Subsystem

7.62MM Machine Gun M23. a. Mount Assembly
M23.
(1) Assemble one mount assembly for

Figure 16-14. Installation or Removal of
installation on right side of aircraft and one for
Brace Assembly or Chute Assembly
installation on left side.
(1) Remove gun from traversing lock (figure

16-12).
(2) Remove ammunition chute assembly and

accessories from gun and ammunition box (figure 16-
15).
b. Ejection Bag (figure 16-16).
(1) Depress latch lever to unlock ejection bag

and separate rear bracket from the mounting plate at
the bottom of the receiver (figure 16-17).
(2) Depress rear bracket safety latch lever,

slide bag brackets on mounting points and plate, and
separate bag mounting points from gun adapter.
c. Machine Gun and Adapter (figure 16-18).
(1) Remove quick release pin to release gun

and adapter from pintle.
(2) Lift gun to separate gun from the pintle and

pintle post.
d. Mount Assembly.
(1) Unlatch and lift ammunition box and cover

assembly from tube assembly brackets (figure 16-19).
(2) Remove cotter pin and plain round nut Figure 16-15. Chute Assembly on Machine Gun
from pintle post; lift the pintle post assembly from the
tube assembly (figure 16-20). M60D and Ammunition Box and Cover Assembly
16-22
TM 55-1520-210-23-2
NOTE
The pintle post assembly is inserted

through the opening in the tube assem-
bly which has recesses to receive the
locating bosses on pintle post collar.
The pintle post assembly is positioned
so that traversing lock is outboard.
(d) Insert pintle post assembly through tube

assembly and secure with nut and cotter pin.
(3) To assemble left hand mount assembly
mounting components (figure 16-21), position tube
assembly accordingly and follow steps (a) through (d)
Figure 16-16. Ejection Bag
in a. (2) of this paragraph.
NOTE (4) Install left hand mount assembly as follows:
The mount assemblies installed on the

(a) Position ends of forward and aft beams
right side and left side of UH-1 helicop-
on helicopter lower hard points as shown in figure
ters for this subsystem are composed
16-21.
of identical parts. The base tube assem-
bly is marked to aid in installation. Near (b) Secure each beam to bracket with 1/4-28
one end, one side is stamped TOP x 1-21/32 clevis bolt, washer, and nut. Ensure bolt
FRONT FOR RH ASSY and the opposite heads are toward front of helicopter.
side is stamped TOP FRONT FOR LH
(c) Lock each nut in place on bolt with cotter
ASSY
pin.
(2) To assemble right hand mount assembly (d) Raise mount assembly until other beam
mounting components refer to figure 16-20 and mounting points mate with helicopter upper hard point
proceed as follows: fittings.
(e) Secure each beam to bracket with 1/4-28
(a) Position tube assembly for right hand x 1-21/32 clevis bolt, washer, and nut. Ensure bolt
mounting. heads are toward front of helicopter.
(b) Position forward and aft beams to tube (f) Lock each nut in place on bolt with cotter
assembly with clevis-like ends inboard. pin.
NOTE (5) To install right hand components, position
accordingly and repeat steps (a) through (f) above.
Although similar in appearance, the
forward and aft beams are not b. Ammunition Box and Cover Assembly.
interchangeable. The aft beam is the (1) Install box in brackets on tube assembly
longer and bulkier. (figure 16-19) with loading instructions decal facing
inboard.
(c) Attach beams to tube assembly with
these 3/8-24 x 1 1/2 cap screws and three washers on (2) Secure box in brackets with latch on each
each end. Lock (C155) the screws. end of box.
Change 7 16-23
TM 55-1520-210-23-2
Figure 16-17. Ejection Bag Removal and Installation
16-24
TM 55-1520-210-23-2
TO INSTALL: POSITION MACHINE GUN MOUNTING BRACKET

IN PINTLE AND SECURE WITH MOUNTING PIN,
Figure 16-18. Machine Gun M60D Position on Pintle — Left Side View
c. Machine Guns M60D. safety latch lever. Slide bag brackets aft on mounting
points and plate.
(1) Install one machinegun M60D on the rlght
hand and one on the left hand mount assemblies. (c) Position rear bracket of bag behind
mounting plate on bottom of receiver.
(a) Refer to figure 16-18 and position gun
adapter into right hand mount. (d) Release latch lever to lock bag in place.
(b) Secure gun to pintle with quick release (e) See that bag is securely attached to gun.
pin.
(2) Install bag on gun on left hand mount
(c) Install gun on left hand mount assembly assembly as in steps (a) through (e) above.
plntle as in steps (a) and (b) above.
e. Ammunition Chuting and Accessories
(2) Check that each gun moves freely in (figure 16-14).
azimuth and can be depressed to traversing lock
(figure 16-12). (1) R e f e r t o f i g u r e 1 6 - 1 5 a n d i n s t a l l
ammunition chuting and accessories on each mount
d. Ejection Bag (figure 16-16). assembly.
(1) Install an ejection bag on each gun. (2) Ensure chuting is securely attached to gun
and ammunition box.
(a) Refer to figure 16-17 and posltlon bag on
right of gun on right hand mount assembly. NOTE
Tighten nuts on clamp assemblies to
(b) Position forward arm bracket of bag in snug and tighten another quarter turn.
front of matching forward mounting points on gun Do not tighten these nuts so much the
adapter. At the same time, press down on rear bracket. ammunition flow is restricted.
16-25
TM 55-1520-210-23-2
Figure 16-19. Ammunition Box and Cover Assembly—Removal
(3) Check that chuting flexes without binding 16-22) is installed on the other side of the helicopter. The
through all movements of gun. base tube assemblies are interchangeable, allowing for
installation of machine gun M60D or machine gun
(4) Stow gun in traversing lock. XM213 on either side of the helicopter. The guns are
centrally positioned above the cargo deck of the helicop-
16-32. ARMAMENT SUBSYSTEM - M59.
ter and are manually operated by an operator/crew gun-
ner. The guns can be elevated, depressed, or traversed
16-33. Description — Armament Subsystem —
within specified limits. One forward beam, one aft beam,
M59. Armament subsystem M59 consists basically of
and one base tube assembly (parts of subsystem M23
the major components of armament subsystem M23 (re-
mount assembly) are utilized when installing the caliber
fer to TM 9-1005-262-15) and the following major compo-
.50 machine gun XM213 portion of armament subsystem
nents: a modified caliber .50 machine gun XM213, an
M59 (figure 16-23). For a description of the main compo-
ammunition tray assembly, a bag and frame assembly, a
nents of the 7.62 millimeter machine gun M60D portion
cradle assembly, a brass deflector assembly, a pintle
of armament subsystem M59, refer to TM
post assembly, two armament subsystem M59 identifica-
9-1005-262-15.
tion plates, and miscellaneous attaching hardware. Ar-
mament subsystem M59 is designed for application to
UH-1H helicopters. One 7.62 millimeter machine gun WARNING
M60D, mounted on its pintle post assembly, is installed
on one side of the helicopter; one caliber .50 machine Unload machine gun prior to removal (TM
gun XM213 mounted on its pintle post assembly (figure 9-1005-304-12).
16-26 Change 14
TM 55-1520-210-23-2
Figure 16-20. Armament Subsystem M23 Mount Assembly — Exploded View
16-27
TM 55-1520-210-23-2
Figure 16-21. Armament Subsystem M23 Mount — Left Side
16-28
TM 55-1520-210-23-2
Figure 16-22. Caliber .50 Machine Gun XM213
16-34. Removal — Armament Subsystem — c . Machine Gun .50 Caliber XM213.

M59. Disassemble this equipment only to the point
required to perform the removal procedures and (1) Remove cotter pin, two washers, and
retain all mounting hardware as necessary to prevent headed straight pin (figure 16-23), to release the gun
loss. receiver assembly from the aft end of the cradle
assembly as shown in figure 16-26.
a. Ammunition tray assembly. Depress the
latch lever on the left side of cradle assembly and lift (2) Remove Iockwlre and the two bolts used to
the tray assembly until the V-portion of the tray clears secure the machine gun to the cradle assembly.
the V-slots in the block of the cradle assembly bracket
as shown in figure 16-24.
b. Bag and frame assembly. Depress the latch

lever on the right side of the cradle assembly and lift
the bag and frame assembly until the V-portion of the Closely follow the instructions for gun-
frame clears the V-slots in the block of the cradle cradle separation to avoid component
assembly bracket as shown in figure 16-25. damage.
16-29
TM 55-1520-210-23-2
Figure 16-23. Armament Subsubsystem M59 Main Components
16-30
TM 55-1520-210-23-2
Figure 16-24. Installation/Removal of Ammunition Tray Assembly
Figure 16-25. Installation/Removal of Bag and Frame Assembly
16-31
TM 55-1520-210-23-2
Figure 16-26. Installation/Removal of Caliber .50 Machine Gun XM213
16-32
TM 55-1520-210-23-2
(3) Move the gun downward, then aft to clear

the receiver assembly rivets and the headed straight
pins used to secure the cradle assembly to the pintle
post assembly, and Iift the gun from the cradle
assembly.
d. Cradle assembly. Remove both headed

straight pins (figure 16-27) and Iift the cradle
assembly clear of the pintle post assembly.
e. Brass Deflector Assembly. At the aft and

forward bracket on the base tube assembly; pull the
two quick release pins (figure 16-28), release the
forward and aft latches, and remove the deflector
mount assemblies from the base tube assembly.
f. Mount Assembly (paragraph 16-29 d.).
16-35. Repair or Replacement — Armament

Subsystem – M59. (TM 9-1005-304-12.)
16-36. Installation — Armament Subsystem —

M59 a. Mount Assembly (paragraph 6-31 a.).
Figure 16-28. Brass Deflector
Assembly — Right Side Shown
b. Brass Deflector Assembly. Position the

deflector mount assemblies on the forward and aft
bracket assemblies of the base tube assembly and
secure with the two latches; install the two quick
release pins, one each through the aligned holes on
either side of the forward and aft bracket assemblies
of the base tube assembly (figure 16-28).
c. Cradle Assembly. Position cradle assembly

on pintle post assembly and align holes, install the
two headed straight pins to secure the cradle
assembly to the pintle post assembly (figure 16-27),
d. Machine gun .50 caliber XM213.
To avoid damage to components when

installing machine gun XM213, follow
closely the procedure prescribed.
From aft end of cradle assembly, move weapon

downward first, then forward to clear rivets on
receiver assembly and headed straight pins that
secure cradle assembly to pintle post assembly
(figure 16-27). Raise weapon upward until holes in
16-33
TM 55-1520-210-23-2
cradle assembly are aligned with mating holes in cradle assembly and press downward on the tray
recoil adapter assembly of machine gun XM213. assembly until it is fully seated in the cradle assembly
Install the two bolts (figure 16-26) to secure machine bracket.
gun XM213 to cradle assembly; secure the two bolts
to cradle assembly with Iockwire (C127). Align
elongated holes in the arms on aft end of the cradle 16-37. MINE DISPERSING
assembly with mating holes in the lower aft end of SUBSYSTEM M56. (TM 9-1345-201-
machine gun XM213 receiver assembly; install 12.)
headed straight pin, two washers, and cotter pin to
secure aft end of cradle assembly to receiver 16-38. MINE DISPENSER CONTROL
assembly of machine gun XM213 (figure 16-26).
PANEL.
e. Bag and Frame Assembly. Position bag and
frame assembly above the bracket of the cradle 16-39. Description — Mine Dispenser Control
assembly (right side of weapon) and engage the V- Panel. The dispenser control panel (figure 16-29) can
portions of the frame assembly with the mating V- be located on any blank space of the pedestal as the
slots in the block of the cradle assembly bracket as installation is not permanent. The dispenser control
shown in figure 16-25; depress the latch lever on the panel utilized for the mine dispersing subsystem M56
cradle assembly and press downward on the bag and is also used for the scatter minefield marking system
frame assembly until it is fully seated in the cradle M58. The controls necessary for jettisoning the
assembly bracket. complete mine dispersing assemblies, for selecting
quantity of mines, and the SAFE-STBY-ARM switch
f. Ammunition Tray Assembly. Position are located on the panel. The dispenser control panel
ammunition tray assembly above the bracket of the also contains an INTERVAL select switch for
cradle assembly (left side of weapon) and engage the automatic fire, MINES-MARKERS or PAIRS-
V-portions of the tray assembly block with the mating SINGLES mode selector and a FIRE switch. There is a
V-slots in the block of the cradle assembly bracket as panel light dimmer and four indicator lights on the
shown in figure 16-24; depress the latch lever on the panel; ARM, READY, FIRING and EMPTY.
Figure 16-29. Mine Dispenser Control Panel
16-34
TM 55-1520-210-23-2
16-40. Removal — Mine Dispenser Control c. Disconnect wiring harness assembly from
Panel. connector on the back of the dispenser control panel.
d. Remove wiring harness from left side of

pedestal. Place side panel over left side and fasten
panel in place. Place blank space cover over pedestal
and fasten in place.
Inspect dispenser control panel SAFE-
STBY-ARM switch to ensure that it is in 16-41. Repair or Replacement — Mine Dispenser
the SAFE position. Control Panel. (AVIM) (TM 9-1345-201-30.)
a. Open side panel of pedestal console. 16-42. Installation — Mine Dispenser Control
Panel. For installation and electrical checkout of
b. Remove four screws from dispenser control dispenser control panel and wiring harness
panel and remove panel from pedestal console (figure assembly, refer to figure 16-30 and TM 9-1345-201-
4-30). 12.
Figure 16-30. M56 Wiring Harness Assembly
16-35
TM 55-1520-210-23-2
16-43. M56 MINE DISPENSER. NOTE
Refer to paragraph 16-48 b. for external

16-44. Description -– M56 Mine Dispenser. The mechanical jettison release mechanism.
mine dispenser (6, figure 16-31) is attached to the
pylon assembly on both sides of the helicopter and k. Remove nuts (5), flat washers (4) and
consists of a bomb dispenser and a cargo of anti-tank, attaching bolts (3, figure 16-33) to disconnect the
anti-vehicular mines in canisters. pylon support assembly with pylon assembly
attached from the external stores assembly.
16-45. Removal — M56 Mine Dispenser.
l. Remove (outboard) fwd and aft tube fittings (2
NOTE and 4, figure 16-34) and two nuts and bolts (inboard)
to disconnect pylon assembly from pylon support
Set the helicopter master battery switch assembly.
to the OFF position. A minimum of two
men are required to perform
downloading operations. m. Remove external stores support assembly.
(paragraph 16-3).
a. Install intervalometer safety pin (2, figure 16-
31) (with red flag). 16-46. Repair or Replacement — M56 Mine
Dispenser (AVIM). (TM 9-1345-201-30.)
b. Disconnect electrical power receptacle from
dispenser subsystem (6). 16-47. Installation — M56 Mine Dispenser.
c. Position bomb loader under the dispensing NOTE

subsystem (6) and raise the bomb loader until it
makes contact with the subsystem. Remove pylon Set the helicopter battery switch to
assembly safety pin (3) from pylon assembly. the OFF position. A minimum of two
men are required to perform the up
d. Loosen the four sway brace jamnuts (1) and loading operation.
raise sway braces to avoid contact with the
dispensing subsystem (6). a. Install external stores support assembly
(paragraph 16-7).
e. Carefully raise the dispensing subsystem (6)
so that the suspension lugs disengage with hooks on
pylon assembly releasing the dispensing subsystem NOTE
on the bomb loader.
Following steps b. and c. shall be
f. Lower dispenser (6) from aircraft. performed on workbench.
g. Remove nut, flat washer and bolt to

disconnect the forward support tube assembly (1, b. Position pylon assembly (3, figure 16-34) on
figure 16-32) from the support tube fitting (6) on pylon support assembly (8).
pylon.
c. Loosely attach pylon assembly (3) with 2
h. Remove nut, flat washer and bolt to (inboard) nuts and bolts and (outboard) fittings (2 and
disconnect support tube assembly from forward hard 4) to pylon support assembly. Assemble so that
point (2). fittings (2 and 4) can be turned for installation of tube
assembly.
i. Remove nut, flat washer and bolt to disconnect
the aft support tube assembly (3) from the aft support d. Position pylon support assembly (8) with
tube fitting (5) on pylon. pylon assembly (3) attached against external stores
support assembly. Align eight bolt holes and install
j. Remove nut, flat washer and bolt to disconnect bolts, flat washers and self-locking nuts. Ensure a
support tube assembly from aft hard point (4). washer is under each bolt head and under each nut.
16-36
TM 55-1520-210-23-2
1. Sway braces 5. Pylon support assemblies

2. Intervalometer safety pin (red flag) 6. Disperser subsystem
3. Pylon assembly safety pin (red flag) 7. Pylon assembly
4. Support tube assembly (strut) 8. External stores support assembly
Figure 16-31. M56 Mine Dispensing Subsystem
16-37
218-260 0 - 88 - 22
TM 55-1520-210-23-2
1. Forward tube assembly

2. Forward hardpoint
3. Aft tube assembly
4. Aft hardpoint
5. Aft support tube fitting
6. Forward support tube fitting
Figure 16-32. M56 Support Tube Fittings
16-38
TM 55-1520-210-23-2
1. Pylon support assembly

2. Pylon assembly
3. Bolt (8 reqd)
4. Washer (8 reqd)
5. Nut (8 reqd)
6. External stores support
Figure 16-33. M56 External Stores Support Assembly
NOTE assembly to the hard point with bolt, flat washer and
self-locking nut.
The friction dampers shall be inspected
at 5 mission intervals. The friction i. Align tube assembly (1, figure 16-32) with fwd
damper breakout forces shall be adjusted support tube fitting (6) on pylon support assembly by
within specified limits of 50 TO 150 extending or compressing tube assembly (1).
pounds. Friction dampers that cannot be
adjusted within specified limits shall be j. Securely fasten bolt, washer and nut on fwd
replaced (paragraph 16-48 a.). hard point (2) and support tube fitting (6) on pylon
support assembly. Tighten support fitting and nut.
e. Position aft support tube assembly (3, figure NOTE

16-32) into place on aft hard point with bolt, flat
washer and self-locking nut. Ensure sway braces (1, figure 16-31) will
not interfere with connecting dispensing
f. Align tube assembly (3) with fitting (5) on pylon subsystem to pylon assembly.
support assembly by extending or compressing tube
assembly (3). k. With dispenser bomb loader, carefully raise
the dispenser (6, figure 16-31) up to pylon assembly
g. Securely fasten bolts, washers and nuts on aft (7) so that suspension lugs will engage with pylon
hard point (4) and support tube fitting (5) on pylon hooks.
support assembly. Tighten support fitting and nut.
l. Lower sway braces and make contact with
h. Position support tube assembly (1) into place dispensing subsystem (6) and tighten the four sway
on fwd hard point (2). Loosely secure the tube brace jamnuts (1). All braces shall be fingertight only.
16-39
TM 55-1520-210-23-2
m. Remove bomb loader from the helicopter.

n. Connect electrical power receptacle to
dispenser subsystem (6).
When suspension lugs engage hooks on
pylon assembly (7), install safety pin (3) 16-48. Adjustment — M56 Mine Dispenser. a.
with red flag in pylon assembly. Remove Strut damper.
safety pin before each flight. Install
intervalometer safety pin (2) with red (1) Push in and turn piston rod of friction
flag. Remove safety pin before each damper assembly into cylinder and engage boss on
flight. piston with slot of strut.
1. Fwd beam support assembly 6. Aft beam support assembly

2. Fwd support tube fitting 7. Aft brace assembly
3. Pylon assembly 8. Pylon support assembly
4. Aft support tube fitting 9. Fwd brace assembly
5. Cross beam support assembly
Figure 16-34. M56 Pylon Support Assembly and Pylon Assembly
16-40
TM 55-1520-210-23-2
(2) Turn piston rod (with boss engaged in slot) 16-51. MACHINE GUN – M6
as required to obtain 50 TO 150 pounds loading. Subsystem 7.62MM M60C.
b. Manual jettison.
1 6 - 5 2 . Description — Machine Gun M6
(1) Attach upper end of manual release cable Subsystem 7.62 MM, M60C. The M60C 7.62MM
to pylon assembly with flat head pin, washer, and machine gun is a basic M60 machine gun modified
cotter pin (1, 2, and 3, figure 16-35). With hand for use with the helicopter. Four guns are available in
tension on cable, adjust pulley support bracket (4) to the M6 subsystem installation. Two guns are
obtain proper cable alignment. This adjustment will mounted on each side of the helicopter, one above the
place the forward edge of the support bracket (4) other. The gun cover assemblies on the left-hand
between 3.6 and 4.6 inches aft of the aft edge of the guns face inboard, towards the helicopter, while
pylon support forward arm. those on the right-hand guns face outboard.
Ammunition is fed to the guns from above and
(2) Align manual release cable (5) over pulley cartridge cases are ejected downward. The guns are
in support assembly (6) on top of external stores attached to the mount assemblies in such a manner
support assembly. Align holes in upper cable guard that they can be quickly and readily removed and
tube (7) with holes in support assembly (6) and install replaced. All four machine guns are interchangeable
attaching pin washer and cotter pin. Thread lower and may be instaIled on either mount assembly. (TM
manual release cable (5) through lower guard tubes 9-1005 -243-12.)
(8).
16-53. Removal — Machine Gun M6 Subsystem
(3) Remove access panels from fuselage skin 7.62MM M60C. (figure 16-36.) a. Before removing
on left side of helicopter and from cabin floor on right the machine guns from the helicopter perform the
side of helicopter. Connect lower manual release following:
cable to existing release cable (10).
NOTE
Cable tension may be varied by In order to guard against danger in case

adjustment of the turnbuckle (9) located of accidental firing, all personnel should
between the upper and lower manual remain clear of the firing pattern. NO-
release cables. STEP markings on armament should be
observed at all times.
1 6 - 4 9 . A R M A M E N T SUBSYSTEM M6
(1) Ensure helicopter battery switch is OFF
– 7.62MM MACHINE GUN – M60C. and external power is disconnected.
16-50. Description — Armament Subsystem
M6 — 7.62MM Machine Gun — M60C. T h e (2) Set OFF-SAFE-ARMED switch to OFF.
Quad 7.62MM machine gun subsystem is de-
signed for use on the UH-1H/V helicopter. It con- (3) Make sure that control panel indicator
lights are out.
sists, basically of four M60 7.62MM machine
guns, two machine gun mounts equipped with
(4) Make sure machine guns are in “out-of-
turret adapters (3, figure 16-36) which are
battery” position.
attached to each of the forward external stores
support assemblies (4). Also included are the am-
b. Unload machine guns as follows:
munition feed group, the electrical-hydraulic
power source, for control and operation of the (1) Rotate latch lever (6) counterclockwise and
machine guns, and the sighting station. open cover (7).
NOTE
(2) Depress spring loaded ammunition chute
The installation is applicable to UH- latches (8) on receiver and disconnect ammunition
1H/V serial numbers 63-12956 thru chute from gun. Carefully fold loose end of
65-12895. ammunition chute over gun mount assembly.
16-41
TM 55-1520-210-23-2
Figure 16-35. M56 Mine Dispenser – Release Mechanism
16-42
TM 55-1520-210-23-2
1. Electrical cable — helicopter to turret adapter 11. Cocking handle

2. Hydraulic lines — helicopter to turret adapter 12. Firing solenoid assembly
3. Turret adapter 13. Gun bolt
4. External stores support 14. Gun latch
5. Cover plate 15. Cartridge drive
6. Gun cover latch lever 16. Ammunition chute — cartridge drive to machine gun
7. Gun cover 17. Ammunition chute — ammunition box to catiridge drive
8. Ammunition chute latches 18. Control panel
9. Charger cylinder assembly 19. Electrical cable — machine gun to turret adapter
10. Finger latch 20. Hydraulic lines — machine gun to turret adapter
Figure 16-36. Machine Gun Adapter Kit and Controls Installation
16-43
TM 55-1520-210-23-2
c. Close cover (7) and ensure lever (6) locks cover and engage machine guns in gun latch pawls. Close
in place and lock spring loaded Safety latches,
d. Use a 3/16 inch off-set drift pin, or other c. Connect electrical connector to mating
suitable tool, to depress plunger in aft end of charger receptacle on firing solenoid assembly (12).
cylinder assembly (9) piston. This action unlocks a
detent inside the charger cylinder assembly, which d. Position spring loaded finger latch (10) aft of
relieves h y d r a u l i c p r e s s u r e a n d p e r m i t s cocking handle (11) bolt. Engage finger latch with
disengagement of spring loaded finger latch (10) bolt.
attaching charger cylinder assembly (9) to machine
gun cocking handle (11) Disengage finger latch (10) e. Refer to paragraph 16-61 and TB 55-1520-
and rotate latch and charger cylinder assembly piston 208-10/3 for Ioading and arming machine gun.
to clear cocking handle bolt
e. Press upon underside of firing solenoid (12)to NOTE

trip sear. This action permits the gun bolt (13), cocking
handle (11) and charger cylinder assembly (9) piston Installation of all four machine guns is
to move forward to “battery”’ position and remain in the same.
that position
16-56. MOUNT AND ADAPTER -- M6
f. Disconnect electrical connector firing
solenoid (12). SUBSYSTEM 7.62 MM M60C
MACHINE GUN
g. Depress spring loaded safety latches on gun
latch (14) and unlock gun latch. Disengage machine 16-57. Description — Mount and Adapter — M 6
gun from gun latch pawls. Remove machine gun from Subsystem 7.62MM M60C Machine Gun. The two
helicopter. gun mount assemblies (figure 16-36) each support
two 7.62MM machine guns and contain necessary
NOTE equipment for movement of machine guns and
ammunition. Each mount is capable of moving the
Removal of all four machine guns is the two guns through a vertical arc of plus nine degrees
same. and minus 66 degrees from centerline position. They
can also move both guns horizontally from 12 degrees
NOTE Inboard to 70 degrees outboard. All four guns move
simultaneously, but when either mount moves the
Refer to TM 9-1005-243-12 for attached gun to the 12 degree inboard position a
cleaning, lubrication and detail solenoid switch is activated and movement and firing
maintenance procedures of the M6 of those guns iS automatically stopped. Movement of
7.62 MM, M60C, machine guns, the guns is controlled by means of hydraulic power,
Each gun mount is equipped with an -electrically
16-54. Inspection and Repair — Machine Gun operated cartridge drive which moves the
M6 Subsystem 7.62MM M60C. (TM 9-1005-243- ammunition from the ammunition boxes to the
12.) machine guns. The inboard end of each gun mount is
attached to a turret adapter, which, in turn, is
16-55. Installation — Machine Gun M6 attached to an external stores support assembly. A
Subsystem 7.62MM, M60C. a. Before installing hinge at the junction of the mount and adapter
machine guns on helicopter perform the following: permits the mount to be swung to one side for-easy
access to hydraulic and electrical connectors.
(1) Ensure battery switch is OFF and external
power is disconnected.
NOTE
(2) Set OFF-SAFE-ARMED switch to OFF.
Left-hand and right-hand gun mounts
b. Depress spring loaded safety latches on gun a n d t u r r e t a d a p t e r s are not
latch (14, figure 16-36) and unlock gun latch. Position interchangeable.
16-44
TM 55-1520-210-23-2
16-58. Removal — Mount and Adapter — M6 h. Remove eight nuts, washers and bolts
Subsystem 7.62MM, M60C Machine Gun a. attaching turret adapter (3) to external stores support
Remove M60C machine guns (paragraph 16-53). assembly (4) and remove adapter.
b. Depress spring loaded ammunition chute

latches (8, figure 16-36) at top and bottom of cartridge NOTE
drives (15) and release ammunition chutes from
cartridge drives. Remove cartridge drive to machine Turret adapter (3) may be inspected by
gun ammunition chutes (16) and place on helicopter Fluorescent Penetrant method, (TM 55-
aft cabin fIoor or other suitable location. Fold 1500-204-25/1). Before proceeding
ammunition box to cartridge drive ammunition with such impaction complete the
chutes (17) back onto aft cabin floor. following steps i. and j.
c. Remove eight nuts, washers, and bolts i. Back off check nut attaching electrical
attaching gun mount to turret adapter (3). Carefully receptacle to adapter plate and remove receptacle
swing gun mount open. and attached cable (1).
j. Remove four nuts, washers and bolts

attaching each hydraulic mounting flange to turret
adapter and remove mounting flanges. Back off quick
disconnect, check nuts and remove hydraulic quick
Each gun mount weights approximately disconnects from turret adapter.
60 pounds. Use two men to remove each
mount as outlined in the following step d. k. Refer to TM 9-1005-243-12 for further
information.
16-59. Installation — Mount and Adapter — M6

Subsystem 7.62MM M60C Machine Gun.
Use care not to damage hydraulic lines
(20) at quick disconnects on turret NOTE
adapter (3) and immediately cap or cover
male and female connectors to prevent If adapter (3) has been completely
entrance of foreign material. Disconnect disassembled, complete steps a. and b.
electrical cable from receptacle on turret
adapter (3) and cap or cover electrical
connector and receptacle to prevent a. Position hydraulic quick disconnect in adapter
entrance of foreign material. (3, figure 16-36) and install check nuts. Position
hydraulic mounting flange over each check nut and
d. Position one man on each side of the gun install four attaching bolts, washers and nuts.
mount and carefully raise the mount from the hinge
pins on the turret adapter (3). Move gun mount to b. Thread electrical cable (1) through turret
location where it will not be damaged. adapter (3) and position electrical receptacle. Install
attaching check nut.
e. Disconnect hydraulic lines (2) at helicopter
fuselage quick disconnects. Cap or cover lines and c. Position adapter (3) to external stores support
connectors to prevent entrance of foreign material. assembly (4) and install eight attaching bolts,
washers and nuts.
f. Back off check nuts connecting hydraulic lines
(2) to turret adapter (3) quick disconnects. Disconnect d. Uncap or uncover electrical cable (1),
hydraulic lines from quick disconnects. Remove, and connector and receptacle at helicopter fuselage skirt.
cap or cover hydraulic lines and connectors to prevent Connect electrical cable to receptacle.
entrance of foreign material.
e. Uncap or uncover hydraulic lines (20), adapter
g. D i s c o n n e c t e l e c t r i c a l c a b l e ( 1 ) f r o m (3), quick disconnects and helicopter fuselage quick
receptacle to prevent entrance of foreign material. disconnects. Connect lines (20) to quick disconnects.
16-45
TM 55-1520-210-23-2
16-60. AMMUNITlON FEED GROUP —

M6 SUBSYSTEM 7.62MM, M60C
MACHINE GUN.
Each gun mount weighs approximately
60 pounds. Use two men to install each 16-61. Description — Ammunition Feed Group
mount as outlined in the following step f.
— M6 Subsystem 7.62MM M60C Machine Gun.
The ammunition feed group (figure 16-37) consists,
f. Position one man on each side of the gun
basically, of eight ammunition chutes, twelve
mount and carefully engage gun mount half hinge on
ammunition boxes and an ammunition box tray
the adapter (3) hinge pins.
equipped with three hold-down strap assemblies.
Four ammunition chutes, two on each side of the
g. Uncap or uncover electrical cable connector
helicopter, connect the top of the cartridge drive
and turret adapter (3), receptacle and connect
assemblies to the machine guns. A comparable
electrical cable (19) to receptacle.
installation connects the ammunition boxes to the
bottom of the cartridge drive assemblies. The chutes
h. Uncap or uncover hydraulic lines and turret
connecting the ammunition boxes to the bottom of
adapter (3) quick disconnects and connect hydraulic
the cartridge drive assemblies pass through an
lines (20) to quick disconnects.
opening in the cargo floor and the fuselage. The
ammunition boxes are mounted on the ammunition
box tray, located in the helicopter cargo area, and are
held firmly in place by three hold-down strap
assemblies. The sheet metal ammunition boxes are
arranged in three groups of four boxes each. Each box
Use extreme care when closing the gun is capable of holding approximately 450 rounds of
mount assembly to avoid pinching or ammunition, with a total capability of 5434 rounds,
kinking the hydraulic hoses and to assure weighing 353.21 pounds. The ammunition box tray is
that they do not interfere with servo attached to the helicopter cargo area floor by means
valves in the gun mount assembly. Make of 16 screws. The three hold-down strap assemblies
certain that the small two-pin plug is secure the ammunition boxes and tray to footman’s
properly mated with the receptacle on loops in the cargo area floor.
the charger control valve. DO NOT force
gun mount assembly into position. 16-62. Removal — Ammunition Feed Group —
M 6 Subsystem 7.62MM M60C Machine Gun. a.
i. Carefully swing gun mount to the closed Accomplish paragraph 16-34 steps a. and b.
position and install eight bolts, washers, and nuts
attaching the gun mount to the turret adapter (3). b. Depress the spring loaded ammunition chute
latches (8, figure 16-36) which connect the chutes
j. Position loose end of ammunition box to (16) to the top of the cartridge drives (15), and
cartridge drive ammunition chutes (16) to bottom of disengage chutes from cartridge drives.
cartridge drives (15). Depress spring loaded
ammunition c h u t e l a t c h e s ( 8 ) a n d c o n n e c t NOTE
ammunition chutes (17) to cartridge drives (15).
Ammunition chute clamps may be
removed from chutes before storage.
k. Position cartridge drive to machine gun
ammunition chutes (16) to top of cartridge drives (15).
c. Depress the spring loaded ammunition chute
Depress spring loaded ammunition chute latches {8)
latches (8) which connect the chutes (17) to the
and connect ammunition chutes (16) to cartridge
bottom of the cartridge drives (15) and the
drives (15).
a m munition boxes. Withdraw chutes through
opening in the cargo floor and fuselage.
l. Install M60 7.62MM M60C machine guns
(paragraph 16-55).
NOTE
m. Refer to TM 9-1005-243-12 for further Removal of the right and left-hand
information. ammunition chutes is the same.
16-46
TM 55-1520-210-23-2
1. Ammunition box clamps 4. Ammunition chute latches

2. Ammunition boxes 5. Ammunition box tray
3. Strap assemblies
Figure 16-37. Ammunition Pad Group
d. Release three ammunition box hold-down 16-63. Installation — Ammunition Feed Group —
strap assemblies (3, figure 16-37) at lower, forward M6 Subsystem 7.62MM M60C Machine Gun. a.
side of ammunition box tray (5). Remove strap Position ammunition box tray (5, figure 16-37) in
assemblies (3) and ammunition box clamps (1). helicopter and install 16 attaching screws.
NOTE
e. Remove ammunition boxes (2) from
helicopter. The two existing screws (forward and aft
of the ammunition tray) which comprise
f. Remove 16 screws attaching ammunition box the second group inboard from the left-
tray (5) to cargo area floor and remove tray from hand side of the helicopter, must be
helicopter. replaced.
16-47
TM 55-1520-210-23-2
b. If ammunition boxes are not loaded, complete NOTE

the following: Installation of left and right hand
machine gun ammunition chutes is the
(1) Unsnap clamps (1) on top of ammunition same, except the right-hand lower gun
box covers and remove covers. chute is connected to the end box of the
fourth row of ammunition boxes and the
(2) Fold the allowable maximum quantity of right-hand upper gun chute is connected
ammunition into boxes with links up, single-link end to the end box of the third row of
first. Projectiles must point to the left for feed to the
ammunition boxes.
left-hand machine guns and to the right for feed to the
right-hand guns. 16-64. CONTROL PANEL – M6
SUBSYSTEM 7.62MM M60C MACHINE
(3) Position the twelve ammunition boxes (2)
on the ammunition box tray (5). GUN.
16-65. Description — control Panel — M6

(4) Connect the ammunition belts together at
Subsystem 7.62MM M60C Machine Gun. T h e
adjoining boxes.
control panel (18, figure 16-36) is located in the lower
left-hand corner of the pedestal between the pilot and
(5) Crimp over the trailing link hanging out of
copilot. it contains the OFF-SAFE-ARMED switch, a
the end of the third box in each row with a pair of
gun selector switch, an ARMED (red) safelight, a
pliers. Inspect ail ammunition to make sure that it is
SAFE (green) light and necessary fuses, amplifiers
laying properly in all boxes.
and resistors.
(6) Install covers on all ammunition boxes.
16-66. Removal — Control Panel — M6
c. Position ammunition box clamps (1). Hook Subsystem 7.62MM M60C Machine Gun. a. Make
three hold-down strap assemblies to footman’s loops sure that the helicopter master battery switch is in the
along aft side of ammunition box tray (5) and position OFF position and that external power is disconnected.
snugly over ammunition boxes. Position other ends of
strap assemblies footman’s loops forward of b. Release quick-disconnect fasteners attaching
ammunition box tray (5). Tighten and secure hold- armament control panel assembly to pedestal and
down strap assemblies (3). carefully raise panel assembly from pedestal.
d. Position one end of ammunition chutes (16, c. Disconnect electrical connectors at back of
figure 16-36) to top of cartridge drives (15). Depress panel and remove panel assembly. Cap or cover
ammunition chute latches (8) and connect chutes to electrical connectors to prevent entrance of foreign
drives. Allow opposite ends of these two chutes to material.
hang over the gun mount assembly.
16-67. Installation — Control Panel — M6
e. Position one end of ammunition chutes (17) to Subsystem 7.62MM M60C Machine Gun. a.
bottom of cartridge drives (15). Depress ammunition Uncap or uncover electrical connectors and connect
chute latches (8) and connect chutes to drives. At a to back of control panel assembly.
short distance behind the gun mount assembly, grasp
the two ammunition chutes and position the lower b. Position control panel assembly in pedestal
chute on top of the upper chute. Secure in this and engage quick-disconnect fasteners.
position with an ammunition chute clamp
approximately midway between the gun mount 16-68. SIGHT STATION – M6
assembly and the opening in the helicopter fuselage. SUBSYSTEM 7.62MM M60C MACHINE
f. Extend free ends of left-hand ammunition GUN.
chutes through the opening in the helicopter fuselage
and cargo area floor into the cargo area. Connect the 16-69. Description — Signt Station — M6
lower machine gun chute to the end box of the second Subsystem 7.62MM M60C Machine Gun. T h e
row of ammunition boxes and the upper machine gun sighting station is attached to the cabin roof above
chute to the end box of the first row of ammunition and forward of the copilot’s station. The purpose of
boxes (figure 16-37). this equipment is remote alignment of machine guns.
16-48
TM 55-1520-210-23-2
16-70. Removal — Sight Station — M6 pedestal at approximate center. Two terminal blocks
Subsystem 7.62MM M60C Machine Gun. a. Make are provided for electrical wiring interconnection.
sure that the helicopter master battery switch is in the
OFF position and the external power is disconnected. 16-74. Removal — Gun Firing Relay M6
Subsystem 7.62MM M60C Machine Gun. a. Make
b. D i s c o n n e c t e l e c t r i c a l c o n n e c t o r f r o m sure that the helicopter master battery switch is in the
receptacle on sighting station mounting pad bracket OFF position and that external power is disconnected
and cap or cover connector and receptacle to prevent
entrance of foreign material. b. Release quick disconnect fasteners and
remove access panel from floor under pilots seat.
c. Disconnect electrical wiring from relay and

cover wire ends with tape.
The sighting station is a delicate,
precision instrument. Do not drop or jar d. Remove four attaching nuts, washers and
at any time. screws and remove relay.
c. Manually support the sighting station and 16-75. Installation — Gun Firing Relay M6
remove the four bolts and washers attaching it to the Subsystem 7.62MM M60C Machine Gun. a.
mounting pad on the cabin roof. Position gun firing relay in pedestal and install four
attaching screws, washers and nuts.
d. Carefully remove sighting station from the b. Remove tape from wire ends and-connect
helicopter. electrical wiring to relay.
16-71. Installation — Sight Station — M6 c. Position access panel to floor and engage
Subassembly 7.62MM M60C Machine Gun. fasteners.
16-76. ROCKET SYSTEM – XM3.
16-77. Description — Rocket System XM3.

The sighting station is a delicate, Complete electrical provisions for installing the XM3,
precision instrument. Do not drop or jar 2.75 rocket installation are included in helicopter
at any time. Serial No. 63-12956 through 65-12895. The 2.75
inch, XM3, fixed rocket installation includes two
NOTE launcher pods (1, figure 16-38); one on each side of
the helicopter. Each pod consists of four modules,
each of which contains six launcher tubes, thus
Thick edge of the mounting plate must be
giving the helicopter a total armament capability of
forward toward the nose of the
forty-eight modified Navy Type Mark IV, Mod Vl,
helicopter.
rockets. Each launcher pod may be adjusted from plus
six degrees to minus six degrees by manually
a. Carefully position sighting station and align
mounting holes. Install four attaching washers and operating the adjustable link assembly (3) the aft end
of which is pinned to the actuator bracket (4).
bolts.
Manually adjustable back-up bearings act as
mechanical stops to limit the launcher at plus 8
b. Uncap or uncover electrical connector and
receptacle and engage connector with receptacle. degrees to minus 18 degrees relative to the
helicopter. launcher pods can be jettisoned by means
16-72. Gun Firing Relay — M6 of explosive bolts. Each pod is attached to an adapter
assembly (5) by means of four quick release
Subsystem 7.62MM M60C Machine
attachment pins. Each adapter assembly is attached
Gun. to a crank assembly (6) which mates to the center hole
in the external stores support assembly (7)
16-73. Description — Gun Firing Relay — M6 crossbeam. The external stores support assembly iS
Subsystem 7.62MM M60C Machine Gun. The gun attached to the aft “hardpoints” on the helicopter
firing relay is mounted on a bracket inside the fuselage structure.
16-49
TM 55-1520-210-23-2
Figure 16-38. MX3 Fixed 2.75 Rocket Installation
16-50
TM 55-1520-210-23-2
a. Rocket Components. Other components of stored apart from usable rounds, and
this installation include an armament control panel proper personnel contacted for
assembly and a sight light panel assembly, located in disposition. Unnecessary personnel shall
the lower left-hand corner of the pedestal; a Mark 8 be kept well away from the front and rear
sight assembly, mounted on the right-hand side of the of loaded launchers and launchers in the
instrument panel just above the helicotper altimeter; process of being loaded or unloaded. The
cyclic control stick trigger switches; a junction box, helicopter shall not be fueled when
and necessary electrical wiring, circuit breakers and rockets are nearby or in the launchers.
relays. The system is capable of selective firing from While launchers are being loaded or
the cabin, by either the pilot or copilot in the following unloaded the helicopter shall be pointed
modes: away from personnel and installations.
(1) Pair, single — one from each pod. NOTE

Handling of the 2.75 inch FFAR is similar
(2) Ripples of 1-2-3-4-6 or 24 pairs (up to 48 to that of other aircraft rockets. It should
rounds). be transported to and from the assembly
area and loaded and unloaded in
b. Rocket — 2.75 Inch. The 2.75 inch folding accordance with standard handling
fin aircraft rocket (figure 16-38) (FFAR) used with the practices.
XM3 fixed system is a standard Navy Type IV, Mod Vl,
which has been modified to impart a ballistic spin of b. Disconnect the battery.
fifteen revolutions per second by scarfing the thrust
nozzles at a twenty-four degree angle. Each rocket
c. Electrically ground the helicopter to an earth
weighs 18 pounds, with the warhead containing 1.4 ground.
pounds of HEX-1 explosive. A shear release of 100
pounds is required for the shear wire in the detent d. Release the launcher firing pin assembly from
rod. Rockets are fixed with an average thrust of 761 the fin retainer assembly and swing the firing pin
pounds and have a burning distance of 6000 feet. assembly clear of the breech.
16-78. Rocket Removal – Rocket System XM3. e. Release and remove aluminum shear wire
a. Set the helicopter master battery switch to the OFF from detent rod.
position.
NOTE
Rocket may be loaded and unloaded
from either the muzzle or the breech end
of the launcher tube.
Before removing an unfired round from
the launcher, make sure that the firing f. Release launcher latch and carefully remove
circuit has been made safe at the rocket rocket from launcher tube.
armament control panel and that the
rocket jettison circuit breakers have been g. Install fin protector as soon as rocket has been
pulled. Handling of the rockets shall be removed from launcher tube.
confined to trained personnel. Smoking
shall be prohibited in the vicinity of h. Visually inspect synchronized elevator and
rockets at all times. No spark producing forward section of tailboom for possible damage
devices or power tools shall be used in caused by rocket debris.
the vicinity of rockets at any time.
Precautions shall be taken in handling 16-79. Rocket Loading — Rocket System XM3.
unshielded rockets in the vicinity of radio a. Obseve all safety precautions outlined in
and radar transmitters, as there is the paragraph 16-78.
possibility of squibs actuating
prematurely. A motor or rocket which b. Make sure that the armament control panel
has been dropped shall not be used but counter reads 000 and the ZERO indicators on the
shall be labeled “Dropped Round” panel and junction box are illuminated.
16-51
TM 55-1520-210-23-2
c. Pull out the two rocket jettison circuit 16-80. LAUNCHER AND ADAPTER.
breakers.
d. Set the helicopter master battery switch to the 16-81. Description — Launcher and Adapter. A
OFF position. launcher and adapter (figure 16-38) are attached to
each side of the helicopter fuselage. Each launcher
e. Disconnect battery. contains four six rocket modules which are attached
to the adapter assembly. All modules are
f. Electrically ground the helicopter to an earth interchangeable with respect to attachment points
ground. and alignment. Switch boxes are on top of the module
on the left-hand side of the helicopter (looking down
g. Make sure the JETTISON switch cover on range) and on the bottom on the right-hand side. The
the armament control panel is wired with copper adapter assembly is an open, rectangular, aluminum
break wire (C305). frame which is attached to the crank by means of two
explosive bolts.
h. Make sure the launcher firing pin assembly is
clean and will make good electrical contact. Swing 16-82. Removal — Launcher and Adapter. a.
the firing pin assembly clear of the breech. Remove all unfired rockets (paragraph 16-78).
i . Remove the fin protector from the rocket fins. b. Disconnect electrical connectors from
Make sure the fin retainer and contact button are in explosive bolts, adapter assembly and switch box on
place and that the launcher latch retaining groove inside module. Cap or cover connectors to prevent
and contact disc are free from grease and foreign entrance of foreign material.
material.
c. Remove module assemblies by pulling
attachment pins.
d. Cut Iockwire and remove two explosive bolts

If a gap exists between the front end of attaching adapter assembly to crank assembly.
the rocket motor and the rocket head Remove adapter assembly.
when assembled hand-tight, the rocket
shall not be used. 16-83. Cleaning — Launcher and Adapter.
Launcher tubes should be cleaned, after each day’s
NOTE firing, with bore cleaner, or hot, soapy water. The
firing contacts should be examined after each day’s
Rocket may be loaded and unloaded firing and thoroughly cleaned. Wipe the firing
from either the muzzle or the breech end contacts with waste or rags soaked in bore cleaner
of the launcher tube. until clean of all residue. Use a wire brush to aid in
cleaning the firing contacts.
j. Push the rocket into the Iauncher tube until the
launcher latch seats firmly in the launcher latch
retaining groove on the rocket.

of solvent vapors.
Use of improper wire may cause rocket to
hang up and not launch.
k. Position aluminum shear wire (C300) in

detent rod and crimp to retain. Petroleum products such as bore
cleaner, dry cleaning solvent, mineral
l. Swing the Iauncher firing pin assembly back in spirits paint thinner and lubricants may
place until the pin assembly snaps into the fin damage electrical components, wiring,
retainer assembly. and rubber parts.
16-52
TM 55-1520-210-23-2
16-84. Installation — Launcher and Adapter. c. Remove nut, washer and bolt attaching aft
a. Position adapter assembly to crank assembly end of the adjustable link to the actuator bracket.
and install attaching explosive bolts. Lockwire Remove adjustable link.
C155) bolts.
d. Remove teflon bearings from threaded holes
b. Assemble module assemblies to adapter in actuator bracket.
assembly with attachment pins.
e. Remove nut, washers and bolt attaching
c. Uncap or uncover electrical connectors and actuator bracket to aft end of crossbeam and remove
connect connectors to switch box on inside moduIe actuator bracket. Reinstall bolt, washers and nut to
and to adapter assembly. attach crossbeam to aft support.
NOTE f. Cut Iockwire and remove four nuts, washers

and bolts attaching stop brace and bracket to plate
Do not connect electrical connectors to and spacer assembly. Remove bracket.
explosive bolts until just before flight.
g. Cut Iockwire and remove four bolts attaching
16-85. ADJUSTABLE LINK, stop brace to crank assembly. Remove stop brace.
ACTUATOR BRACKET AND CRANK
h. Remove crank shaft retainer nut from
ASSEMBLY. outboard end of crank shaft and remove keeper, key,
crank assembly, bearing retainer and roller bearing
16-86. Description — Adjustable Link, Actuator from crossbeam.
Bracket and Crank Assembly. Each launcher has an
adjustable link (figure 16-38) with the forward end i. Remove crank shaft, with keeper, plate and
mounted in a yoke formed by the upper end of the spacer assembly, key, bearing retainer and roller
crank and the plate and spacer assembly. The aft end bearings, as a unit from the inboard side of the
of the adjustable link is pinned to the actuator bracket. crossbeam.
The actuator bracket is an open box type structure
with extended sides which form lugs for pinning the j. Remove nuts, washers, and bolts attaching
aft end of the adjustable link to the aft end of the bearing housings to the external stores support
crossbeam. The actuator bracket also receives the crossbeam and remove bearing housings.
threaded ends of the adjustable backup bearings. The
crank assembly is an aluminum box section unit. In 16-88. Installation — Adjustable Link, Actuator
conjunction with a steel shaft, bearings and other Bracket and Crank Assembly. a. Position bearing
miscellaneous components, the crank assembly is housings to external stores support crossbeam and
attached to the crossbeam of the external stores install attaching bolts, washers, and nuts.
support and serves as the mounting point for the
adapter assembly. b. Assemble roller bearings, bearing retainer,
short key, plate and spacer assembly (with flat side
16-87. Removal — Adjustable Link, Actuator outboard), and keeper to the end of the crank shaft
Bracket and Crank Assembly. which has the short keyway. Secure loosely with
shaft retainer nut.
c. Insert the items assembled in step b. above
into the external stores support crossbeam in such a
Ensure all power is off. manner that the plate and spacer assembly is on the
inboard side of the crossbeam.
a. Remove launcher and adapter (paragraph 16- d. Assemble roller bearing, bearing retainer,
82). crank assembly, long key, keeper, and shaft retainer
nut to outboard end of crankshaft.
b. Cut Iockwire and remove bolt attaching the
forward end of the adjustable link to the yoke formed e. Tighten both retainer nuts until there is no
by the upper end of the crank and the plate and spacer looseness but crankshaft rotates freely. Lock both
assembly. nuts with tangs of keepers.
16-53
TM 55-1520-210-23-2
f. Align one end of stop brace with crank c. Disconnect electrical connectors at back of
assembly so that stop brace is above crossbeam. panel and remove panel assembly. Cap or cover
Install four bolts to attach stop brace to crank electrical connectors to prevent entrance of foreign
assembly and Iockwire (C157). material.
g. Position bracket and other end of stop 16-92. Installation — Armament Control Panel
brace to plate and spacer assembly. Install four Assembly. a. Uncap or uncover electrical connectors
attaching bolts, washers, and nuts and Iockwire and connect to back of control panel assembly.
(C157).
h. Remove nut, washers, and bolt attaching b. Position control panel assembly in pedestal
externaI stores support crossbeam to aft support. and engage quick disconnect fasteners.
Position actuator bracket to aft end of crossbeam and
install bolt, washers, and nut previously removed. 16-93. PANEL ASSEMBLY — SIGHT
LIGHT.
i. Install teflon backup bearings in threaded
holes. Torque front and bottom rear bearings one
16-94. Description — Panel Assembly Sight
turn. Torque top rear bearing one and one-half turns.
Light. The sight light panel assembly is located in the
Starting point for these torque values is 0.002 inch
lower left-hand corner of the pedestal just forward of
between the bearing arc and the teflon backup
the armament control panel. The purpose of this
bearing.
panel is to control the power to the Mark 8 sight lamp.
This action, as well as the intensity of illumination, is
j. Position aft end of adjustable link to actuator
accomplished by means of a rheostat. The sight lamp
bracket and install attaching bolt, washer, and nut.
has two filaments, either of which may be used for
illumination. A switch on the sight light panel
k. Position forward end of adjustable link to
assembly affords the operator a choice of FIL 1 or FIL
the yoke formed by the upper end of the crank 2. The panel also is equipped with two standard panel
and the plate and spacer assembly. Install attach- lights.
ing bolt and Iockwire (C157).
16-95. Removal — Panel Assembly Sight Light.
16-89. PANEL ASSEMBLY –
ARMAMENT CONTROL.
Ensure all power is off.

16-90. Description — Armament Control Panel
Assembly. The armament control panel (figure 16- a. Make sure that the helicopter master battery
38) is located in the lower left-hand corner of the switch is in the OFF position and that external power
pedestal. The controls necessary for jettisoning the is disconnected.
two pod assemblies, for turning on system power, for
selecting the number of pairs of rounds, and the b. Release quick-disconnect fasteners attaching
SAFE-ARMED switch are located on the panel. It also armament control panel assembly to pedestal and
contains a counter to record the number of pairs of carefully raise panel assembly from pedestal.
rounds fired, a SYSTEM POWER ON light, an ARMED
light, a ZERO light, a SAFE light, a JETTISON POWER c. Disconnect electrical connectors at back of
ON light, and a JETTISON COMPLETE light. panel and remove panel assembly. Cap or cover
electrical connectors to prevent entrance of foreign
16-91. Removal — Armament Control Panel material.
Assembly. a. Make sure that the helicopter master
battery switch is in the OFF position and that external 16-96. Installation — Panel Assembly Sight
power is disconnected. Light. a. Uncap or uncover electrical connectors and
connect to back of control panel assembly.
b. Release quick-disconnect fasteners attaching
armament control panel assembly to pedestal and b. Position control panel assembly in pedestal
carefully raise panel assembly from pedestal. and engage quick-disconnect fasteners.
16-54
TM 55-1520-210-23-2
16-97. SIGHT ASSEMBLY – MARK 8. b. Disconnect electrical connectors from

junction box and cap or cover to prevent entrance of
16-98. Description — Sight Assembly Mark 8. foreign material.
The pilot sight (figure 16-38) is used as an aid in
maintaining alignment of the helicopter with the c. Remove six bolts and washers attaching
target during firing of a missile. The sight is mounted junction box to shelf assembly and remove junction
on a support assembly, attached to the right-hand box from helicopter.
side of the instrument panel, in front of the pilots seat.
The pilot sight consists of a sight body, a lamp and 16-104. Installation — Armament Junction Box.
housing, and a Mark 4 Mode O reflector assembly. A a. Position junction box in helicopter and install six
small control panel on the center console contains an attaching washers and bolts.
FIL 1 — FIL 2 switch and an intensity control for
illumination of the reticle. b. Uncap or uncover electrical connectors and
connect to junction box.
16-99. Removal — Sight Assembly Mark 8. a. 16-105. BLOOD BOTTLE HOOKS.

Remove four nuts and bolts attaching pilot sight (1 O,
figure 16-38) to support assembly, and remove pilot 16-106. Description — Blood Bottle Hooks. Six
sight. blood bottle hooks (three on each side) are mounted in
the cabin roof structure within easy reach of the
medical attendant station, to permit administering
blood or glucose to litter patients in flight,
16-107. Inspection — Blood Bottle Hooks.

The pilot sight is a delicate, optical Inspect blood bottle hooks for damage and security of
instrument. Handle with care. mounting.
b. Remove five nuts, washers, and screws 16-108. Repair or Replacement — Blood Bottle
attaching pilot sight support assembly to right-hand Hooks. a. Tighten or reinstall loose or improperly
side of instrument panel, and remove support installed hooks.
assembly.
b. Replace damaged hooks.
16-100. Installation — Sight Assembly Mark 8. a.
Position pilot sight support assembly on instrument 16-109. CABLE – PARATROOP
panel and install attaching screws, washers, and STATIC LINE.
nuts.
b. Position pilot sight (10, figure 16-38) against 16-110. Description — Paratroop Static Line. A
support assembly and install attaching bolts and nuts. paratroop static line cable may be installed on the
center of the aft cabin bulkhead. This installation
16-101. ARMAMENTJUNCTION BOX. consists of a cable (1, figure 16-39), a compression
tube (2), attach plates (3), fitting (4), and attaching
hardware.
16-102. Description — Armament Junction Box.
The junction box (12, figure 16-38) connects to 16-111. Removal — Paratroop Static Line. a.
electrical connector at center of pylon in cabin and Remove cotter pins and washer attaching cable (1,
contains the circuits necessary for firing the rockets figure 16-39) to fitting (4) and remove cable.
and for jettisoning the two pod assemblies. It also
contains a RESET button which cycles the stepping b. Remove nuts, washers, and bolts securing
switch to zero and a zero light which illuminates attach plates (3) to fittings (4) and remove attach
when stepping switch is in zero position. plates
16-103. Removal — Armament Junction Box. a. c . Remove bolts and washers securing fittings
Ensure the battery switch is in the OFF position and (4) to aft cabin bulkhead and remove fittings and
external power is disconnected. compression tube (2) from bulkhead.
16-55
TM 55-1520-210-23-2
Figure 16-39. Paratroop Static Line Cable
d. Remove nuts (5) and washers on end of c. Install flat washer, Iockwasher, and nut (5) on
compression tube (2). Remove pins (6) from end of compression tube.
compression tube and separate tube from fittings (4).
16-112. Installation — Paratroop Static Line. a. d. Position compression tube (2) and fittings (4)
Install nut (5, figure 16-39), Iockwasher, and flat to aft cabin bulkhead and install attaching washers
washer on compression tube (2). Position fittings (4) and bolts. Tighten both nuts (5) on compression tube
on compression tube. Align holes in tube and fittings against fitting.
and insert pins (6).
b. Position static line cable (1) on pins (6) and e. Position attach plates (3) to fittings (4) and
install washers and cotter pins. install bolts, washers, and nuts.
16-56
TM 55-1520-210-23-2
16-113. M130 Countermeasures Dispensing Set NOTE

(figure 16-41). (If installed).
a. The M-130 Dispenser Set is a countermea- Mount (6) must be aligned and drilled
sures system provided to defend against threats pro- before installation. After initial installa-
vided to defend against threats from antiaircraft mis- tion, mount remains on aircraft.
siles. The dispensers, attached to supports mounted
on the left and right aft external fuselage hardpoints,
dispense chaff to prevent or hinder Iockon by radar d. Position the mount against the fuselage over
guided systems, or flares to decoy heat-seeking the four nutplates at the forward edge of the access
(infrared) guided missiles. Either flares or chaff can be opening (FS166.4). Make sure the edge distance from
dispensed from the right side dispenser. Only chaff can the nut plate to the top edge of the mount is 5/16 inch,
be dispensed from the left side dispenser. and the mount is centered vertically over the nutplates.
b. The system is made up of two interchangeable NOTE

dispenser assemblies with a 30 cartridge payload for
each; a control panel mounted on the cockpit pedestal;
support assemblies that mount the dispensers on the The undrilled boss on the mount (6)
aircraft; and an electronic module and associated wir- should make contact with the bracket
ing. A safety pin and flag is provided to prevent inad- on the support assembly (3). if the sur-
vertent actuation of the system. faces of the boss and the bracket are not
parallel, the mount maybe repositioned
16-114. Removal - Right Side Support Assembly slightly, or material may be removed
(figure 16-42). from the mount (6) boss.
a. Disconnect cable assembly (4) from access
panel (7). e. Using a c-clamp or equivalent, clamp mount (6)
and support assembly (3) together at boss to bracket
b. Remove nuts (11 and 21 ) and spacers (10 and
mating surface.
20) from threaded studs on support assembly (3).
NOTE NOTE
Mount (6) remains installed on aircraft. Make sure mounting bolt head (8) to
mount (6) clearance is adequate.
c. Remove nut (15) washers (14) and bolt (13)
securing support assembly to mount (6).
f. Scribe the position of the two center access
opening nutplates on the fuselage to mount (6) mating
surface.
g. Unclamp the mount and drill two .203 diameter

holes at the scribed marks.
To be sure support assembly dimensions
are not distorted, side loads must not be h. Install mount using two bolts (8) and washers
applied to threaded studs during removal. (23). Scribe the position of the upper and lower nut-
plates on the mount. Remove the mount and drill a
d. Slide support assembly (3) aft. Retain spacers .203 diameter hole at each scribed mark.
(10 and 20) for later use.
i. Reinstall the access panel leaving vacant the
16-115. installation - Right Side Dispenser Sup- four nutplates along the forward edge that correspond
port Assembly (figure 16-42). with the mount (6) mounting holes.
a. Remove access panel (55, figure 2-18). j. Install mount (6) with four bolts (8) and washers
b. Place one spacer (10 and 20, figure 16-42) over (23). Torque bolts to 30 inch-pounds and Iockwire
each threaded stud on support assembly (3). (C155) bolts in pairs.
c. Position studs through mounting holes on fuse- k. Drill a .266 diameter hole in the mount (6) boss
lage hard points (9 and 19). Place one spacer (10 and to lineup with existing hole in bracket.
20) on each threaded stud and install nuts (11 and 21).
Torque nuts 57 TO 63 inch-pounds and install cotter l. Install bolt (13) washer (14), and nut (15).
pins (12) Torque nut and secure with cotter pin (16).
Change 7 16-57
TM 55-1520-210-23-2
Figure 16-41. M130
16-58
TM 55-1520-210-23-2
1. Dispenser assembly 12. Cotter pin

2. Payload module assembly 13. Bolt
3. Support assembly 14. Washer
4. Cable assembly 15. Nut
5. Safety pin and flag 16. Cotter pin
6. Mount 17. Screw
7. Access panel assembly 18. Bolt
8. Bolt 19. External stores hardpoint
9. External stores hardpoint 20. Spacer
*10. Spacer 21. Nut
11. Nut 22. Cotter pin
23. Washer
‘Additional washers may be needed to take up slack between hardpoint and support assembly (3).
Figure 16-42. Flare/Chaff Support Assembly-Removal and Installation.
(16-59 blank)/16-60 Change 7

TM 55-1520-210-23-2
c. Remove nuts (10 and 14) and spacers (9

16-116. Installation — Flare Dispenser As-
and 13) from threaded stud on support assem-
sembly to Right Side Dispenser Support (fig-
bly (3).
u r e 1 6 - 4 2 ) . a . Remove payload module
assembly (2) from dispenser assembly (1).
Refer to TM 9-1095-206-13 and P.
To be sure that support assembly
b. Align dispenser assembly (1) with arrow dimensions are not distorted, side
marked FLARE on dispenser support (3). loads must not be applied to thread-
c. Insert bolt (17) in upper left corner of ed studs during removal.
dispenser assembly (1) and hole A shown on
view A. d. Carefully slide support assembly (3) aft.
Retain spacers (9 and 13) and washers (21)
d. Position dispenser assembly (1) until as- with assembly for future use.
sembly mounting holes line up with mounting
holes on dispenser support assembly (3). e. Install bolts (7) and washers (18) in for-
ward edge of access panel (6).
e. Install remaining bolts (17 and 18) and
torque 57 to 63 inch-pounds. 16-118.1. Installation — Left Side Dispens-
er Support Assembly (figure 16-43). a. Lo-
f. Connect cable assembly (4) to receptacle cate access panel (51, figure 2-18), and remove
on access panel (7). four attaching screws from forward edge.
b. Install one spacer (9 and 13, figure 16-
g. Install payload module (2) on dispenser 43) over each threaded stud on support assem-
support (1). Refer to TM 9-1095-106-13 and P.
bly (3).
16-117. Installation — Chaff Dispenser As- c. Position studs through mounting holes
sembly to Right Side Dispenser (figure 16- on fuselage hardpoints. Place one spacer (9
42). a. Remove payload module assembly (2) and 13) on each threaded stud and install nuts
from dispenser assembly (1). Refer to TM 9- (10 and 13). Torque nuts 57 to 63 inch-pounds
1095-206-13 and P. and install cotter pins (11).
b. Align dispenser assembly with arrow
marked CHAFF on dispenser support (3). NOTE
c. Insert bolt (17) into lower right corner of
dispenser assembly and hole B shown on View If gap exists between support as-
A. sembly (3) and access door, wash-
ers (19) may be used to fill gap.
d. Position dispenser assembly (1) until as-
sembly mounting holes line up with mounting d. Install bolts (7), washers (18), and wash-
holes on dispenser support assembly (3). ers (19, if required). Lockwire (C 156) bolts (4) in
pairs.
e. Install remaining bolts (17 and 18) and e. Connect cable assembly (4) to receptacle
torque 57 to 63 inch-pounds. on access panel.
f. Connect cable assembly (4) to receptacle

f. Refer to TM 9-1095-206-13 and P for
on access panel (7). functional test.
g. Install payload module (2) on dispenser
support (1). Refer to TM 9-1095-206-13 and P. 16-118.2. Electronic Module Assembly (fig-
ure 16-44). a. Install the support assembly (2)
16-118. Removal — Left Side Support As- on the ceiling of the aft radio compartment
with six bolts (5). Torque bolts 57 to 63 inch-
sembly (figure 16-43). a. Disconnect cable as-
pounds and Iockwire (C 155) in threes.
sembly (4) from access panel (6).
b. Install the module (1) on the support
b. Remove four bolts (7), washers (18), and
assembly (2) with bolts (6) and washers (7).
washers ( 19, if installed) that secure aft end of
Install clamp (4) on the aft outboard corner.
support assembly (3) to aircraft.
16-61
TM 55-1520-210-23-2
VIEW LOOKING FORWARD --LEFT SIDE
1. Dispenser assembly 12. External stores fitting (lower)

2. Payload module assembly 13. Spacer
3. Support assembly 14. Nut
4. Cable assembly 15. Cotter pin
5. Safety pin and flag 16. Screw
6. Access panel assembly 17. Bolt
7. Bolt 18. Washer
8. External stores fitting (upper) 19. Washer
9. Spacer 20. Washer
*1O. Nut 21. Washer
11. Cotter Pin
Figure 16-43. Chaff Support Assembly - Removal and Installation
16-62 Change 7
TM 55-1520-210-23-2
VIEW LOOKING INBOARD – LEFT SIDE
1. Electronics module
2. Support assembly
3. Panel insert
4. Cable damp
5. Bolt
6. Bolt
7. Washer
Figure 16-44. Electronic Module - Removal and Installation.
Change 7 16-63
TM 55-1520-210-23-2
Pages 16-64 through 16-93/(16-94 blank), including paragraphs 16-119

through 16-147, Figures 16-45 through 16-54 have been deleted.
16-64 Change 7
TM 55-1520-210-23-2
16-124. X Connector Guard b. Remove (as a minimum) the following

electronic equipment (Figure 16-49). Special
Description — The connector Guard (Figure 16- removal instructions are described in TM 32-
48) is installed on the EH-1X aircraft after the 5865-007-20.
AN/ALQ-151 mission cables, exiting from the
connector panel, (at Station 129) are in place. (1) Voice Power Sensor (6A6)
The purpose of this item is to protect the cables (2) Data Power Sensor (7A7)
from damage due to their proximity to the (3) Indicator Control (6A10)
mission operator’s feet. This item is designed (4) DF Control (6A11)
to withstand the abuse anticipated from use as (5) Communication Processor (6A12)
a footrest. (6) Power Supply (6A15)
(7) Power Supply (6A16)
16-125. Removal Connector Guard Assem- (8) Power Supply (6A17)
bly (Figure 16-48) (9) System Computer (6A18)
(10) DF Interface (6A19)
a. Loosen eight quick-release fasteners that (11) RFI Filter (6FL3)
attach connector guard (1) to channel assembly
(2) and angle (3). c. Remove (as a minimum), the following
electronic equipment (Figure 16-50). Special
b. Apply slight pressure to flex connector removal instructions are described in TM32-
guard (1) upwards and aft simultaneously and 5865-007-20.
remove.
(1) Key Generator (GA3)
c. Remove two nuts (8) and two washers (5) (2) Security Computer (6A4)
securing channel assembly (2).
N O T E
d. Remove channel assembly (2) and two
quick-disconnect type stud fittings (4). All other equipment may remain in
console. Removal of above items, as
called out in above two paragraphs,
NOTE
will reduce console weight by
Angle (3) must be removed to allow about 320 pounds to about 180
unfastening of insulation blanket. pounds.
Nut (9) is not a blind type, therefore,
a second person is required. d. Remove two bolts (16) and two washers
(17) that attach base rack to mounting points
e. Remove screw (12), nut (13) and washer located on aft bulkhead and one bolt on trans-
(14). mission housing (Figure 16-53).
f. Remove clamp (11). e. Remove four bolts (16) and four washers
(17) that attach base rack to cargo deck (Figure
g. Remove two bolts (7), two washers (6) 16-53). Stow hardware for reuse.
and two nuts (9).
f. Remove Base console from Aircraft.
h. Angle (3) is now free for removal.
16-126. Removal — Base Rack (Figure 16-

46) Do not disturb alignment points for
this rack.
a . Disconnect cable connections to rack at
transmission bulkhead and disconnect panel 16-127. Removal — ECM Rack (Figure 16-
on base rack. 51)
16-65
TM 55-1520-210-23-2
a. Disconnect all cable connections to con- 16-128. X AN/ASN-86 Inertial Navigation

sole. Set Description — The AN/ASN-86 Inertial
Navigation System (INS) provides geographical
data to the AN/ALQ-151 system. The electronic
equipment is located in the left hand cargo bay
Dust Covers should be in place alcove (Figure 16-52). This system’s major com-
before equipment removal to pro- ponents are: gyro (45), computer (40), ARN-103
tect exposed pins and also to ease (41), gyro platform (1), gyro mount (2) and the
equipment removal. plenum assembly (3). Refer to TM 11-58841-
273-( ) for operation and system trouble shoot-
b. Connect dust covers to connector shells ing.
on all three ECM electronic equipments.
16-129. X Removal — Support Shelf As-
sembly (5, Figure 16-52)
Weight is approximately 100 Ibs. a. Disconnect cable connectors to comput-

er (40) and ARN-103 (41).
c. Insure that Push-To-Talk connector is re-
moved and remove ECM receiver, (7A1) Figure b. D i s c o n n e c t q u i c k r e l e a s e f i t t i n g s a t
16-51 from aircraft. lower face of computer (40) and ARN-103 (41).
c. Disconnect upper portion of cooling

hose (12) attached to duct (28) on bottom of
Weight is approximately 70 Ibs. computer by releasing clamp (13).
d. Move ECM power supply (7A2) forward d. Remove computer and ARN-103 by slid-
in mounting tray. With about 5 inches of inter- ing units forward.
face available, rotate unit 60 degrees upwards
and remove from aircraft. e. Disconnect cable connectors to junction
box (4) Figure 16-52.
f. Screws (7) and (12) need not be removed

Weight is approximately 250 Ibs. to remove junction box (4).
e. Move ECM Transmitter (7A4) forward in g. Remove cooling hose (12) by loosening
mounting tray. With about 5 inches of interface clamp (13) to plenum assembly (3).
available, rotate unit 90 degrees upwards and
remove from aircraft. h. Remove two screws (10), and two wash-
ers (8) that secure bracket (stiffener) (6) to
f. Remove bolt (16) and washer (17) that support shelf assembly (5).
attaches ECM Rack to transmission housing
support bracket and stow for reuse. i. Remove two screws (11), and two wash-
ers (3) that secure junction box (4) to support
g. Remove four bolts (16) and four washers shelf (5).
(17) that attach ECM rack to cargo deck (see
Figure 16-53). Stow hardware for reuse. j. Junction Box (4) with bracket (stiffener)
(6) and angle (29) attached are now free for
removal.
k. Remove cooling hose (14) by loosening

two clamps (13).
Do not disturb alignment points for
the ECM rack. l. Refer to Figure 16-52 and remove bolt
(22) and washer (21) attaching support shelf
h. Remove ECM rack from aircraft. assembly leg (18) to cargo deck plate (23).
16-66
TM 55-1520-210-23-2
m. Remove seven bolts (42) and (44) and g. Remove three bolts (33) and three wash-
seven washers (43) attaching support shelf as- ers (34) that secure the gyro platform mount (1)
sembly (5) to transmission and aft bulkheads. to the gyro mounting interface (2).
h. Remove gyro platform mount.
n. Support shelf assembly (5), with leg (18)
attached, is now free for removal. i. Remove bolt (35) and washer (36).
16-130. X Removal — AN/ASN-86 gyro j . Remove five bolts (37) and five washers
(MX-8123). (36).
k. Remove gyro mount interface.
16-132. Removal — Bulkhead/Cargo Deck
Allow a minimum period of one
Interface.
hour to elapse following INS turn-
off before attempting removal of
gyro. Earlier removal could cause
damage to gyro mechanism. Do not remove following items un-
a. Disconnect connector (48), at lower face less absolutely required. Realign-
of gyro (47) (figure 16-52). ment of all racks/consoles is
required upon installation.
b. Loosen the screw clamps (46) on the
mount (1) and swing the clamps away from the a. Perform the following steps for removal
platform mounts. of the twelve console/rack mounting points.
c. Carefully lift and remove the gyro (45) b. Bend tab down on washer (18, Figure
from the mount (1). 16-53) and remove nut (24).
16-131. X Removal — AN/ASN-86 gyro c. Cut safety wire (19) and remove four
platform mount MT-4447 (figure 16-52). screws (21) and four washers (34).
d. Remove brackets (23) and nut plate (22).
e. Remove deck/bulkhead fitting [with foot
Removal of the gyro platform
(20) attached] from aircraft.
mount is not authorized without
proper re-alignment equipment. f. Remove other supports/brackets from
bulkheads as required.
a. Before removing gyro mount platform,
MT-4447 (1), an aircraft center line reference
must be obtained so that the gyro axis may be
maintained upon reinstallation. The following
parameters must be held in tolerance:
(1) Roll Axis: 0 Degrees, 60 Seconds Remove bow handle from right side
(2) Pitch Axis: 0 Degrees, 6 Seconds transmission housing before remov-
(3) Yaw Axis: 0 Degrees, 20 Seconds ing access panel.
b. Use a transit and determine the location
of a fore/aft centerline across two common
planes on the two MT-4447 V-blocks (46). 16-133. X Installation; AN/ALQ-151 Mis-
sion Consoles/Racks. The following sequence
c. Attach plumb lines at the aircraft nose
should be followed to efficiently install all
center point and from the tailboom skid. consoles/racks upon the cargo deck area
d. Use a transit and reference the aircraft (Figure 16-46). This equipment is designed to
center line with the MT-4447 axis. Retain for be installed on uneven and dimensionally in-
future use. consistent aircraft cargo deck surfaces.
e. Remove cooling hose (14) from gyro plat- a. Install bulkhead interface, paragraph 16-
form mount (1) by loosening clamp (13). 135 (Figures 16-52 & 16-53)
f. Scrape away sealing wax from mounting b. Install navigation rack, paragraph 16-
bolt heads (33). 136 (Figure 16-52)
16-67
TM 55-1520-210-23-2
c. Install ECM Rack, paragraph 16-140 b. Installation of support brackets (do not
(Figure 16-51) torque fully at this time) to transmission hous-
d. lnstall base rack, paragraph 16-141 ing using attachment positions 9 thru 20 (Table
(Figures 16-49 & 16-50) 16-1).
e. Install cable Guard, paragraph 16-142 (1) Install vertical supports (1 and 2, Fig-
(Figure 16-48). ure 16-53) with two spacers (3) in place. Use
two bolts (7), two plain washers (9) and two
f. Install operator seat, paragraph 16-143 lock washers (8) for aft points on angles. See
(Figure 2-48.10). details H and Q.
g. Install operator console, paragraph 16-
144 (Figure 16-53).
16-134 Pre Installation Instructions. Always position lock-washers
under bolt heads with plain wash-
ers on other side.
(2) Use eight screws (15) eight plain
Prior to installation, check all equip washers (12) and eight lock washers (13) with
ment installation points in the air- eight spacers (4) to attach remaining areas of
craft to assure that all fasteners vertical supports.
are of the type and size specified in
Table 16-1, and are in working
order. Check for damage to cargo
deck and bulkhead surfaces.
Do not fully tighten mounting bolts
a . All of the airframe mounting points are
at this time. Some parts may re-
shown on Table 16-1 and the Deck Mounting
quire relative adjustment during
Points are illustrated on Figure 16-53, Sheet 5.
later stages of the console/rack in-
b. T o o l s and installation equipment stallation.
required. Consoles/racks can be installed using
(3) Install horizontal supports (6) (Figs.
standard tools. However eight spacers are re- 16-53 details F and G) with two spacers (5) in
quired of material (aluminum, wood, etc.) capa-
place by using two bolts (10), two plain wash-
ble of supporting the racks. Approximate
ers (9) and two Iockwashers (8). install four
dimensions are: 0.75 thick, 0.75 to 2.00 wide,
bolts (11), four plain washers (12) and four
and 3.00 to 4.00 long. Iockwashers (13) to complete assembly.
16-135. Installation — Bulkhead Interface (Shown on details H and Q).
c. Installation aft bulkhead support (posi-
tion numbers 21 through 24 (Table 16-1) in
accordance with Figure 16-53, details N and P.
Insure that proper length base
mounting sections are installed so (1) Install brackets (14) to right side aft
the support shelf (5) mounting bolts bulkhead using four bolts (7), four plain wash-
remain normal to bulkhead. Place a ers (9) and four Iockwashers (8).
straightedge horizontally across (2) Do not torque bolts at this time to
support shelf (5) screw holes to in- allow for further alignment during the con-
sure that these holes will line up sole\rack installation. Station 150 with eleven
with those on the support shelf. screws (24).
a. Install three base mounting (hat) sections 16-136. Installation — Navigation Rack
(15), (16) and (17), Figure 16-52, to left aft (Figure 16-52).
bulkhead at station 166 using six bolts (20) and
six washers (21), at positions 28 through 33 a . Install new plate (23) on cargo deck at
(Table16-1). station 150 with eleven screws (24).
16-68
TM 55-1520-210-23-2
m. Secure cooling hose (12) to duct flange

b. Assemble support leg (18) to support
(28) by tightening clamp (13).
shelf (5) by using two bolts (19) and two wash-
ers (21). n. Secure other end of cooling hose (13) to
plenum assembly (3) by tightening clamp (13).
o. Secure quick release fittings at lower
Position plenum assembly so that face of computer and ARN-103.
cooling ducts point forward and
p. Secure cable connectors to computer
outboard.
and ARN-103.
c. Attach plenum assembly (3) to support
16-137. X Installation — gyromount inter-
shelf (5) by using twelve screws (25) and twelve
face (2, figure 16-52).
washers (26).
a. Insure that angle (38) is secured to gyro-
d. Secure support shelf (5) to transmission
mount interface (2) with two screws (39).
and aft bulkheads by using five bolts (42) and
(44) and five washers (43). Bolt (44) uses posi- b. Install gyromount interface (2) to cargo
tions 26 and 27 on Table 16-1 Bolt (42) uses deck by using bolt (35), washer (36) along with
positions 2, 29 and 30. five bolts (37) and five washers (36).
e. Secure support leg (18) to cargo deck- 16-138. X Installation — AN/ASN-86 gyro
plate (8) at position 40 (Table 16-1) using bolt platform mount, (Figure 16-52).
(22) and washer (21).
f. Secure cooling hose (14) to gyro plat-
form by using clamp (13), washers (8).
Insure that all mating surfaces
g. Secure two channel supports (30) to under MT-4447 are clean to avoid
junction box (4) with three screws (32) and alignment problems.
three washers (31).
a. Loosely attach MT-4447 (1) to gyro-
h. Secure two angles (29) to both channel mount interface (2) by using three bolts (33)
supports (30) with two screws (12) and two and three washers (34)
washers (8).
i. Secure bracket stiffener (6) to junction
box (4) using two screws (7), two washers (8), Use same plumb Iocations as those
and two nuts (9). in paragraph 16-131.
j. Secure above assembly to support shelf b. Use a transit and sight in across two
(5) by tightening four screws (10) (11) with four common planes on the MT-4447 V-Blocks
washers (8). [Sheet ?? (46)] and turn the MT-4447 (1) about
k. Install computer (40) and ARN-103 (41) its vertical axis to a point where angle with
by sliding units aft in their mounting trays. aircraft centerline is identical with that found in
(Sheet 2). procedure in paragraph 16-131.
l. Pass cooling hose (12) through proper c. Tighten and torque three bolts (33).
lightening hole in bracket (6). d. Seal area around bolt threads with wax
type sealant.
16-69
218-260 0- 88 - 23
TM 55-1520-210-23-2
e. Attach cooling hose (14) to mount (1) by (1) Position number 2 is shown in de-
tightening clamp (13). tail K.
(2) Position number 3 is shown in de-
16-139. X Installation — AN/ASN-86 gyro tail J.
MX-8123) (45, figure 16-52, Sheet 4). (3) Position number 4 is shown in de-
tail M.
a. Carefully place the MX-8123 (45) in the (4) Position number 5 is shown in de-
V-Block, (46) of the gyro mount (1). tail L.
b. Swing the clamp screws over the gyro c. Position four 0.75 thick spacers, para-
mounts and torque screws to 35 to 39 inch- graph 16-134.b, on deck under structural areas
pounds. where ECM rack will be located. Care must be
taken not to locate spacers where rivet heads
c. Connect the connector (48) to lower face or other rack and floor protrusions could inter-
position on the gyro (47). fere with placing the rack level to the aircraft
floor.
NOTE
If deck access plate must be re- d. Place ECM rack on top of deck fittings
moved for airframe inspection, do and spacers and adjust leveling foot (20) to
not detach (see figure 16-52) gyro- meet the floor.
mount (1) and gyromount interface
(2) from deckplate. Alignment of e. Center ECM rack on all four deck attach-
system will not be lost if airframe ment points (Positions 2, 3, 4 and 5).
mounting surfaces are clean before
installing. f. Install four mounting screws (16) and
four washers (17).
16-140. Installation — ECM Rack
NOTE
Do not tighten mounting s c r e w s ,
This rack is shown in position on rack position must remain adjusta-
Figure 16-53 and in detail on Figure
ble.
16-51.
a. Assemble deck mounting hardware to

g. Assemble hardware as shown in Figure
four locations as shown on Figure 2-14.3.2.
16-53 to vertical support (2). (See detail “H”).
and Table 16-1.
h. Check alignment of ECM rack as per-
(1) Position Number 3 on Table 16-1 is
formed above (step e) to align with vertical
shown graphically as fitting number 2 on Fig-
support (paragraph 16-135.b (2).) Move vertical
ure 2-14.3.2.
support to obtain proper alignment.
i. Torque fasteners, installing vertical sup-
shown graphically as fitting number one on
port to specifications as shown on Table 16-1.
Figure 2-14.3.2.
(3) Position Numbers 4 and 5 on Table

16-1 are shown graphically on Figure 2-14.3.2. Do not tighten deck hardware until
The attachment to the cargo deck is to a after console rack alignment is
threaded hole, shown as fitting number 3 on checked.
Figure 2-14.3.2.
b. Assemble rack mounting hardware to j . Recheck alignment of ECM Rack with

four locations as shown on Figure 16-53. floor points and snug mounting hardware.
16-70
TM 55-1520-210-23-2
16-141. Installation — Base Rack.

Do not tighten mounting screws,
N O T E rack position must remain adjusta-
This rack is shown in position on ble.
Figure 16-53 and in detail on Fig-
ures 16-49 and 16-50. g. Assemble hardware as shown in Figure
16-53 to vertical support (1). See detail Q.
a. Assemble deck mounting hardware to
four locations as shown on Figure 16-53 and h. Assemble hardware as shown in Figures
Table 16-1. 16-53 (Details N and P) to horizontal brackets
(14) on aft bulkhead (right side).
shown graphically as fitting Number 2 on Fig- i. Check alignment of base rack as per-
ure 2-14.3.2. formed above (Step d) to align with vertical
support (Figure 16-53). Move vertical support
(2) Position Numbers 6, 7 and 8 are to obtain proper alignment.
shown graphically on Figure 16-53.
j. Torque fasteners, installing vertical sup-
The attachment to the cargo deck is to three port to specifications as shown on Table 16-1.
threaded holes, shown as fitting Number 3 on
Figure 2-14.3.2 and on the cargo fitting as k. Check alignment of base rack to the aft
shown as fitting number 2. bulkhead brackets (14).
b. Assemble rack mounting hardware to l. Torque fasteners, installing horizontal

four locations as shown on figure 16-53. bulkhead brackets (14).
(1) Position Number 1 is shown in de-

tail U.
(2) Position Number 6 is shown in de- Do not tighten deck hardware until
tail T. after console rack alignment is
(3) Position Number 7 is shown in de- checked.
tail S.
(4) Position Number 8 is shown in de-
tail R. m. Recheck alignment of ECM Rack with
floor points and snug mounting hardware.
c. Position four 0.75 thick spacers (refer-
ence Paragraph 16-134.b.) on deck under 16-142. Installation — Cable Guard. T h i s
structural areas where base rack will be locat- item will be located at the forward transmission
ed. Care must be taken not to locate spacers bulkhead between the ECM and Base Racks,
where rivet heads or other rack and floor pro- (Figure 16-48).
trusions could interfere with placing the rack
level to the aircraft floor. a. Install angle (3) by securing two bolts (7)
two washers (6) to two nuts (9) to the forward
d. Place base rack on top of deck fittings transmission bulkhead at Station 129.
and spacers and adjust leveling foot (20) to
meet the floor. N O T E
A second person is required be-
e. Center base rack on all four deck attach-
cause the nut (9) is not a blind type.
ment points (positions 1, 6, 7 and 8).
b. Install clamp (11) over mission cable
f. Install four mounting screws (16) and
with screw (12), washer (14) and nut (13).
four washers (17).
16-71
TM 55-1520-210-23-2
c. Snap two quick-release stud fittings (4) c. Check alignment of mounting holes with
to aircraft deck and set channel assembly (2) in the isolators installed on the transmission
place. bracket (Detail F and G).
d. Secure two nuts (8) and two washers (5) d. Adjust, by slightly shifting base and/or
to stud fittings (4). ECM Rack, to center the vibration.
e. Torque all mounting hardware for the

e. Locate position of connector guard (1)
base and ECM racks.
fasteners over mounting points. Work aft fas-
teners vertically to provide proper seating. Lo-
f. Adjust the transmission Housing (Figure
cate forward fasteners in line with their
16-53, Detail F and G) and ECM rack (Figure 16-
horizontal mating receptacles. Pressure must
53, Detail H) to level the operator console.
be applied to flex connector guard (1) so that
all fasteners can be seated.
N O T E
f. Tighten eight fasteners in place on con-
nector guard (1). The exposed shock mount cores
should be nearly equal on all
16-143. Installation — Operator Seat. This mounts. Level may have to be
seat is installed on specially designed tracks. slightly readjusted after loading
The seat faces aft and the installation is shown console.
in position on Figure 16-45 and in detail on
Figures 2-44.1 and 2-24.10. Refer to Para- g. Remove and discard all 0.75 inch thick
graph 2.252.14 for installation instructions. spacers as installed in Paragraphs 16-104.c.
and 16-141.c.
16-144. Installation—Operator Console. h. Tighten all screws and bolts to torque
(Figure 16-46 and Figure 16-47). values of MlL-P-11263 (see Table 16-1).
a. Install Operator Console through right i. Lock-wire leveling feet (Figure 16-53) in
hand side door opening. Stay close to transmis- accordance with MS 33540. Nine fittings are
sion forward bulkhead. Rotate console a quar- located on cargo deck, two on transmission
ter turn to clear base rack. Place console in housing and two on the right rear bulkhead.
position over the vibration isolators mounted
on the ECM and base racks, (Figure 16-53). 16-145. Description — Direction Finding
(DF) Antenna Assembly, (Figure 2-1.2) D e -
scription. The DF antenna set consists of a
group of four dipole antennas mounted on four
Check to ensure that bonding strap booms projecting from the tail section of the
(29) is in proper position relative to aircraft. Antennas receive RF signals of interest
vibration isolators (strap is under and are positioned so that a number of sepa-
isolator base). rate baselines may be formed for DF measure-
ments. Each antenna includes an electronic
b. Attach bolt (25) with lock-washer (26) matching network at the base of the two ele-
(under bolthead), and plain washer (27) in place ments, allowing the use of coaxial cables for
loosely at points lettered A through G (Fig- the distribution of RF energy.
ure 16-53).
16-72
TM 55-1520-210-23-2
16-146 Removal — DF Antenna Assembly

and Support Boom, Figure 16-54. Forward support boom (4) and aft
support boom (7) are not inter-
changeable.
a. Determine proper boom configuration

for installation.
Do not attempt to straighten bent
antenna elements. Replace entire b. Feed RF cable (2) entirely through boom
DF antenna assembly. support tube (4 and 7) so that connector exits
outside of boom support flange opening.
c. Secure boom support (4 and 7) to tail-

a. Remove five screws (5) that secure the boom interface plate with four bolts (6). Torque
DF antenna assembly (1) to the boom (4, 5). 13 to 17 inch pounds.
b. Position DF antenna assembly (1) a few d. Position the DF antenna assembly (1) to
inches outboard and disconnect RF cable (2). be installed near the appropriate support boom
(4 and 7) on the tailboom.
c. Remove DF antenna assembly for dispo-
sition. e. Connect RF Cable (2) to connector (3) on
face of DF antenna assembly (1).
d. Remove four bolts (6) that secure DF
antenna support boom (4 and 7) to tailboom
interface plates.
Do not pinch or damage RF cable
e. Remove DF antenna support boom (4 (2).
and 7) taking care to feed RF cable (2) through
tube. f. Position DF antenna assembly (1) on the
support boom (4 and 7) so that RF connector (3)
f. Stow RF cable (2) (loop as required) to is located inside the boom.
avoid damage.
g. Secure DF antenna assembly (1) to sup-
16-147 Installation - DF Antenna Assem- port boom (4 and 7) using six screws (5).
bly and Support Boom, 16-54. Torque the screws to 13 to 17 inch pounds.
16-73
TM 55-1520-210-23-2
TABLE 16-1 (Sheet 1 of 2)

AIRFRAME ATTACHMENT POINTS, EHIX MISSION EQUIPMENT
Pos. LOCATION
No. STA. BL. WL. TYPE *AREA
1 131.00 39.50R 22.00 CARGO FITTING, STUD
2 D
131,50 18.75L 22.00 CARGO FITTING, RING
3 D
131.00 39.50L 22.00 CARGO FITTING, RING D
4 98.75 18.50L 22.00 .25-28 UNF THD INSERT
5 D
98.75 40.50L 22.00 .25-28 UNF THD INSERT D
6 95.50 17.00R 22.00 .25-28 UNF THD INSERT
7 D
95.50 28.25R 22.00 .25-28 UNF THD INSERT
8 D
95.50 42.50R 22.00 .25-28 UNF THD INSERT
9 D
128.35 14.00L 62.20 .31-24 UNF THD INSERT
10 LT
128.52 14.00L 57.10 .31-24 UNF THD INSERT LT
11 . 128.72 14.00L 51.60 .31-24 UNF THD INSERT
12 LT
128.94 14.00L 45.20 .31-24 UNF THD INSERT
13 LT
130.65 14.00L 53.20 .31-24 UNF THD INSERT
14 A
128.34 14.00R 62.20 .31-24 UNF THD INSERT
15 RT
128.52 14.00R 57.10 .31-24 UNF THD INSERT RT
16 128.72 14.00R 51.60 .31-24 UNF THD INSERT
17 RT
127.94 14.00R 45.20 .31-24 UNF THD INSERT
18 RT
130.65 14.00R 53.20 .31-24 UNF THD INSERT
19 129.00 B
8.96L 54.40 .31-24 UNF THD INSERT
20 129.00 FT
8.96R 54.40 .31-24 UNF THD INSERT FT
21 166.00 16.70R 55.40 .31-24 UNF THD INSERT RB
22 166.00 24.40R 55.40 .31-24 UNF THD INSERT
23 166.00 RB
32.00R 55.40 .32-24 UNF THD INSERT
24 RB
166.00 39.60R 55.40 .32-24 UNF THD INSERT
25 45.00L RB
150.00 22.00 .25-28 UNF THD INSERT D
26 14.00L 42.75 .25-28 UNF THD INSERT
27 LT
14.00L 42.75 .25-28 UNF THD INSERT
28 LT
166.00 35.59
29 LB
166.00 35.59
30 LB
166.00 35.59
LB
31 166.00 55.34
32 LB
16600 55.34
33 LB
166.00 55.34
34 LB
134.75 17.25 22.00 .25-28 UNF THD INSERT
35 D
140.29 17,25 22.00 .25-28 UNF THD INSERT D
16-74
TM 55-1520-210-23-2
TABLE 16-1 (Sheet 2 of 2)

Pos. LOCATION
NO. STA. BL. WL. TYPE *AREA
36 151.29 17.25 22.00 .25-28 UNF THD INSERT D

37 134.75 32.25 22.00 .25-28 UNF THD INSERT D
38 145.75 32.25 22.00 .25-28 UNF THD INSERT D
39 151.29 32.25 22.00 .25-28 UNF THD INSERT D
40 150.00 53.00 22.00 .25-28 UNF THD INSERT D
41 112.00 0.00 22.00 CARGO FITTING STUD D
42 115.25 10.65R 22.00 CARGO FITTING STUD D
*Place where located on aircraft as follows:
D = Cargo Deck
FT= Forward Transmission Bulkhead
LT= Left Transmission Bulkhead
RT= Right Transmission Bulkhead
LB= Left Aft Bulkhead
RB= Right Aft Bulkhead
A = Attached to Left Hand Vertical Support Angle
B = Attached to Right Hand Vertical Support Angle
16-75
TM 55-1520-210-23-2
Figure 16-45 Airframe Equipment Locations, Unit 1
16-76
TM 55-1520-210-23-2
Figure 16-46 EH-1X Equipment Locations
16-77
TM 55-1520-210-23-2
VIEW LOOKING AFT

1. Connector Guard
8. Nut
2. Channel Assy
9. Nut
3. Angle
10. Spacer
4. Stud Fitting
11. Clamp
5. Washer, Plain 12. Screw
6. Washer, Plain
13. Nut
7. Bolt
14. Washer, Plain
Figure 16-48 Connector Guard Installation
16-78
TM 55-1-520-210-23-2
6A6 VOICE POWER SENSOR

6A7 DATA POWER SENSOR
6A9 RF PROCESSOR
6A10 INDICATOR CONTROL
6A11 DF CONTROL
6A12 COMM.PROCESSOR
6A13 INTERCEPT RECEIVER
6A14 DF RECEIVER
6A15 POWER SUPPLY
6A16 POWER SUPPLY
6A17 POWER SUPPLY
6A18 SYSTEM COMPUTER
6A19 DF INTERFACE
6FL1 VOICE FILTER
6FL2 DATA FILTER
6FL3 RFI FILTER
Figure 16-49 Base Rack Equipment Locations (side view), Unit 6
16-79
TM 55-1520-210-23-2
ITEM IDENTIFICATION
6A1 VOICE LINK RADIO
6A2 DATA LINK RADIO
6A3 KEY GENERATOR
6A4 SECURITY COMPUTER
6A5 J-3400 DISTRlBUTION BOX
Figure 16-50 Base Rack Equipment Locations (front view), Unit 6
16-80
TM 55-1520-210-23-2
Figure 16-51 ECM Rack Equipment Locations, Unit 7
16-81
TM 55-1520-210-23-2
Figure 16-52 Navigation System; AN/ASN-86 (Sheet 1 of 5)
16-82
TM 55-1520-210-23-2
Figure 16-52 Navigation System AN/ASN-86; Removal and Replacement

Aircraft Attach Points (Sheet 2 of 5)
16-83
TM 55-1520-210-23-2
Figure 16-52 Navigation System AN/ASN-86; Removal and Repalcement aircraft Attach Points (Sheet 3 of 5)
16-84
TM 55-1520-210-23-2
Figure 16-52 Navigation System; AN/ASN-86

Gyro Stabilized Platform and Mounting
(Sheet 4 of 5)
16-85
TM 55-1520-210-23-2
1. GYRO PLATFORM MOUNT 25. SCREW
2. GYRO MOUNT INTERFACE 26. WASHER
3. PLENUM ASSY 27. PLATE, SCREEN
4. JUNCTION BOX 28. PLATE, DUCT
5. SUPPORT, SHELF 29. ANGLE, SUPPORT
6. BRACKET, STIFFENER 30. CHANNEL, SUPPORT
7. SCREW 31. WASHER
8. WASHER, PLAIN 32. SCREW
9. NUT, LOCKING 33. BOLT
10. SCREW 34. WASHER
11. SCREW 35. BOLT
12. HOSE, COOLING 36. WASHER
13. CLAMP 37. BOLT
14. HOSE, COOLING 38. ANGLE
15. BASE, MOUNTING 39. SCREW-
16. BASE, MOUNTING 40. COMPUTER, NAVIGATIONAL
17. .BASE, MOUNTING 41. TACAN, AN/ARN-103
1 8 . SUPPORT 42. BOLT
19. BOLT 43. WASHER
20. BOLT 44. BOLT
21. WASHER 45. GYRO MX-8123/ASN-86
22. BOLT 46. V-BLOCK & SCREW CLAMP
23. PLATE, STRUCTURAL 47. ELECTRICAL CONNECTOR 1J1
24. SCREW 48. ELECTRICAL CONNECTOR 1P1
Figure 16-52 Navigation System; AN/ASN-86 (Sheet 5 of 5)
16-86
TM 55-1520-210-23-2
Figure 16-53. Mission Racks/Console, Attachment Points to Airframe

(Sheet 1 of 6)
16-87
TM 55-1520-210-23-2
Figure 16-53. Mission Racks/Console Attachment Points to Airframe (Sheet 2 of 6)
16-88
TM 55-1520-210-23-2
Figure 16-53. Mission Racks/Console Attachment Points to Airframe

(Sheet 3 of 6)
16-89
`TM 55-1520-210-23-2
16-90 Figure 16-53 Mission Racks/Console, Attachment Points to Airframe (Sheet 4 of 6)
TM 55-1520-210-23-2
Figure 16-53. Mission Racks/Console
Attachment Points to Airframe (Sheet 5 of 6)
16-91
TM 55-1520-210-23-2
1. VERTICAL SUPPORT-LH 18. WASHER, TAB
2. VERTICAL SUPPORT-RH 19. SAFETY WIRE
3. SPACER 20. FOOT LEVELING
4. SPACER 21. SCREW, CAP
5. SPACER 22. NUT PLATE
6. HORIZONTAL SUPPORT 23. BRACKET
7 . SCREW, CAP 24. NUT, PLAIN
8. WASHER, LOCK 25. SCREW, CAP
9. WASHER, PLAIN 26. WASHER, LOCK
10. SCREW, CAP 27. WASHER, PLAIN
11. SCREW, CAP 28. ISOLATOR, VIBRATION
12. WASHER, PLAIN 29. STRAP, GROUND
13. WASHER, LOCK 30. SCREW
14. BRACKET 31. WASHER, PLAIN
15. SCREW, CAP 32. NUT
16. SCREW, CAP 33. WASHER
17. WASHER, LOCK 34. WASHER
Figure 16-53, Mission Racks/Console, Attachment

Points to Airframe (Sheet 6 of 6)
16-92
TM 55-1520-210-23-2
1. DF Antenna Assembly 5. Screw

2. RF Cable 6. B o l t
3. RF Connector 7 . Boom, Support, AFT
4. Boom, Support, FWD
Figure 16-54 DF Antenna Installation
16-93
TM 55-1520-210-23-2
CHAPTER 17
EMERGENCY EQUIPMENT
17-1. FIRST AID KITS. An additional fire extinguisher is mounted on the left jump
door panel.
17-2. Description — First Aid Kits. Four general pur-
pose type first aid kits have been provided in the cabin 17-9. Removal — Fire Extinguisher and Bracket.
area. Two kits are secured to the right center door post.
The other two kits are secured to the left door post. The a. Loosen retaining clamp from around upper sec-
first aid kits have been designed so they can be easily tion of the extinguisher by pulling the hinged lever. Ten-
removed for immediate use. sion on the extinguisher will be released so that the catch
on the hinged lever will be disengaged from the attaching
17-3. Inspection — First Aid Kits. ring.
a. Inspect first aid kit for broken or missing seal, and b. Grasp the fire extinguisher by the handle and
a legible, serviceable material condition tag. Refer to TM remove from the hanger bracket.
1-1500-204-23-1. c. Remove bolts and washers attaching hanger
b. Inspect first aid kits on door posts for loose or bracket to aircraft and remove hanger bracket.
missing fasteners.
17-10. Inspection — Fire Extinguisher and Bracket.
17-4. Removal — First Aid Kits. Pull outward on kit to
a. Refer to TM 1-1500-204-23-1 for inspection of
release from snap fasteners.
fire extinguisher.
17-5. Repair — First Aid Kits. b. Inspect hanger bracket for damaged retaining
a. If seal is broken or missing or material condition clamp and loose or missing hardware.
tag is missing, refer to TM 1-1500-204-23-1.
17-11. Deleted.
b. Tighten or replace loose or missing fasteners on
door post. 17-12. Installation — Fire Extinguisher and Brack-
et.
17-6. Installation — First Aid Kit. Position kit over
snap fasteners and push to engage fasteners. a. Position hanger bracket and install attaching
bolts and washers.
17-7. FIRE EXTINGUISHER AND BRACKET. b. Position fire extinguisher in hanger bracket with
17-8. Description — Fire Extinguisher and Brack- extinguisher handle opposite bracket.
et. The fire extinguisher is a portable hand operated c. Hook the latch of the retaining clamp handle
type. The fire extinguisher is located on the floor to the through ring on inboard section of the retaining clamp.
right of the pilot’s seat. For aircraft without armored seats Force free end of clamp handle to the right. This will close
installed, the fire extinguisher may be installed between the clamp and secure the fire extinguisher in the hanger
seats aft of the console. Refer to TM 11-5895-776-14-1. bracket.

TM 55-1520-210-23-2
ALPHABETICAL INDEX
Paragraph Paragraph
A Alignment-Main Driveshaft P/N 205-040-004 6-24

Allocation Chart-Maintenance . . . . . . . . . . . . . . . . . . . . B-1
Allocation Chart-Use of the Maintenance... B-2
AC Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-113
Alternating Current Power Distribution
AC Voltmeter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-298
System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-98
Acceptance/Rejection Criteria—Transmission
Altimeter—Barometric—Trouble shooting . . . . T8-10
Assembly—Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
AN/APR-39 (When Installed)--Radar Warning
Access & Inspection Provisions . . . . . . . . . . . . . . . . . . . . . F2-18
Indicating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-314
Access Covers & Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
Anticollision Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-211
Actuator Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-90
Anticollision Light System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-207
Actuator, Linear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-118
Appendix A—References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Adapter and Cap Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-77
Appendix C—Aircraft Inventory Master
Adapter and Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F14-20
Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
Adjustable Window-Crew Door . . . . . . . . . . . . . . . . . . 2-154
Appendix D-Illustrated Field Manufacture
Adjuster Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-115
Item List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1
Adjustment Procedures (Crashworthy)-circuit
Appendix E Intermediate Storage . . . . . . . . . . . . . . . . . . E-12
Arrangement-Adapter Cable . . . . . . . . . . . . . . . . . . . . F8-7
Appendix E—Storage, Short Term . . . . . . . . . . . . . . . . E-3
Aft Center Fuel Cell CoverPlate . . . . . . . . . . . . . . . . . . . . . 10-72
Appendix E Storage of Aircraft
Aft Landing Gear Attachment
Appendix E Flyable Storage . . . . . . . . . . . . . . . . . . . . . . . . . . E-2
Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-24.1, F-24.4
Armament Control—-Panel Assembly . . . . . . . . . . . 16-89
Air Blower––Combustion Heater . . . . . . . . . . . . . . . . . . . 13-57
Armament Couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-108
Air Blower—Exhaust Heater . . . . . . . . . . . . . . . . . . . . . . . . . 13-95
Armament Junction Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-101
Aircraft All Weather Covers . . . . . . . . . . . . . . . . . . . . . . . . . . F1-11
Armament Subsystem 7.62MM Machine
Aircraft Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-45
Gun M23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-27
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-46
Armament Subsystem M23 Machine Gun
Aircraft Inventory Master Guide Appendic C C-1
M60D in Stowed Position, AS . . . . . . . . . . . . . . . . . . . . F16-12
Aircraft Jacking and Leveling . . . . . . . . . . . . . . . . . . . . . . . . F1-9
Armament Subsystem—M59 . . . . . . . . . . . . . . . . . . . . . . . . . 16-32
Aircraft Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F1-8
Armament Subsystem M59 Main Compo-
Air Filter Switch—Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-4
nents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F16-23
Air Induction System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Armored Crew Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-247
Air Induction System, Non-Self-Purging
Armored Crew Seat Headguard . . . . . . . . . . . . . . . . . . . . . F2-48
Particle Separator-Description . . . . . . . . . . . . . . . . . 4-29
Attitude Indicating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-190
Air Induction System Louver and Filter type 4-14
Attitude Indicator—Troubleshooting............. T8-11
Air Induction System—Non-Self-Purging
Attitude Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-192
Particle Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Auxiliary Exhaust Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-84
Air Inlet Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Auxiliary Exhaust Heater—Heat Exchanger. 13-87
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Auxiliary Exhaust Heater System Schematic F13-10
Air Inlet Filters—Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Auxiliary Fuel Cell Fill Cap-Crashworthy.. 10-171
Air Inlet Screens—Non-Self-Purging Particle
Auxiliary Fuel Cell Fuel Gage-Crashworthy 10-167
Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
Auxiliary Fuel Cell Fuel Pump . . . . . . . . . . . . . . . . . . . . . . 10-157
Air Intake Bellmouth, Screen and Baffles—
Auxiliary Fuel Cell Pump Assembly—
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Crashworthy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-183
Air Intake, Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Auxiliary Fuel Cell Refuel Receiver—
Air Particle Separator-Self-Purging . . . . . . . . . . . . . 4-52
Crashworthy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-179
Air Particle Separator-Self-Purging-Air
Auxiliary Fuel Cell Shutoff Valve-Crash-
Induction System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43
worthy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-181
Air Particle Separator-Self-Purging-Inlet Auxiliary Fuel Provisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-156
Foreign Object Darnage (FOD) Screen . . . . . . 4-46
Auxiliary Fuel System—Servicing . . . . . . . . . . . . . . . . 1-4
Air Particle Separator-Self-Purging-Air
Auxiliary Fuel System—300 Gallon Crash-
Induction System—Description . . . . . . . . . . . . . . . . . 4-44
worthy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-161
Airspeed Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-172
Index 1
TM 55-1520-210-23-2
ALPHABETICAL INDEX
Paragraph Paragraph
Classification of Damage-Honeycomb
B
Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T2-5
Classification of Damage-Sheet Metal
Baffle Assembly—Induction . . . . . . . . . . . . . . . . . . . . . . . . . . 2-72
Barometric Altimeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Skins Forward Fuselage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T2-6
8-181
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-30
Cleaning & Treating Corroded Parts . . . . . . . . . . . . . T2-4
Battery Feeder Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-41
Cleaning-Power Plant Assembly . . . . . . . . . . . . . . . . . 4-4
Battery Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-39
Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-231
Battery System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-26
Clock—Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T8-15
Battery System—Troubleshooting . . . . . . . . . . . . . . . . . T9-1
Beam - Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Closed Circuit Refueling Receiver . . . . . . . . . . . . . . . . 10-83
2-58
Closed Circuit Refueling Receiver . . . . . . . . . . . . . . . . 10-88
Beam-Lift-Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-22
Cockpit Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-142
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-185
Cockpit Lights-Troubleshooting . . . . . . . . . . . . . . . . . T9-8
Bellcranks, Levers and Supports-Collective
Collective Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4
Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-47
Collective Jackshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-7
Bellcranks, Levers and Supports-Cyclic
Collective Levers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-68
Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-101
Collective Stick, Copilots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-34
Bellcranks, Levers and Supports-Elevator
Collective Stick, Pilots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-25
Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-179
Compass-Standby . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-225
Bellcranks, Levers, and Supports-Tail
Compass—Standby-Troubleshmting . . . . . . . . . T8-14
Rotor Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-164
Connector Replacement Chart . . . . . . . . . . . . . . . . . . . . . . . F-9
Blackout Curtains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-186
Console—Pedestal Lights—Instrument . . . . . . . . . 9-160
Blade, Main Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
Consumable Maintenance Supplies and
Blades, Tail Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-114
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
Blanket Receptacles—Heated . . . . . . . . . . . . . . . . . . . . . . . . 9-276
Consumable Maintenance Supplies and
Bleed Air and Defroster. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T1-1
Bleed Air Heating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-270
Control Assembly-Collective Jackshaft . . . . . . 11-17
Bleed Check Valve-Governor . . . . . . . . . . . . . . . . . . . . . 10-46
Control Panel, Mine Dispenser . . . . . . . . . . . . . . . . . . . . . . 16-38
Blood Bottle Hooks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-105
Control Panel-M6 Subsystem 7.62MM
Boost Pumps—Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-94
M60C Machine Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-64
Brake-Cyclic Controls, Magnetic . . . . . . . . . . . . . . . . 11-73
Control Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-19
Breakaway Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-155
Control Quadrant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-137
Breaker Valve—Siphon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-66
Control Relay—Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-83
Build-up-Universal Transmission Assembly F6-15
Control Tube and Quill—Tail Rotor . . . . . . . . . . . . . . 11-143
Bulb-Engine Oil Temperature . . . . . . . . . . . . . . . . . . . . . 8-90
Control Stick, Cyclic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-56
Bus Control Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-83
Control System Circuitry-Governor . . . . . . . . . . 9-252
Bus Relay—Nonessential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-87
Control System Circuitry-Hydraulic . . . . . . . . . . . 9-226
Control System, Collective . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4
C Control System, Elevator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-170
Control System, Flight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
Cabin Floor Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28 Control Tubes—Collective Control System.. 11-41
Cabin Roof Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-161 Control Tubes-Cyclic Control System . . . . . . . . 11-41
Cabin Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-47 Control Tubes—Elevator Control System . . . . . 11-173
Center Service Deck Panel Repair . . . . . . . . . . . . . . . . . F2-12 Control Tubes-Tail Rotor Control System.. 11-158
Check Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140 Controls & Accessories-Engine . . . . . . . . . . . . . . . . . . 9-242
Check Valve-Governor Bleed . . . . . . . . . . . . . . . . . . . . . 10-46 Controls, Tail Rotor Crosshead . . . . . . . . . . . . . . . . . . . . . . 5-107
Check Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26 Conversions—Decimal Equivalent . . . . . . . . . . . . . . . . F1-5
Chip Detector/Oil Contamination . . . . . . . . . . . . . . . . . . 4-101 Converter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F12-7
Circuit Breaker-AC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-91 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. T12-3
Circuit Breaker-DC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12 Converter & Motor Assy—L/R Configuration F12-7
Index 2
TM 55-1520-210-23-2
ALPHABETICAL INDEX (Continued)
Paragraph Paragraph
Cooler Assembly - Oil......................................... 6-217 DC Bus System - Generator -
Copilot Collective Stick....................................... 11-34 Troubleshooting (Helicopters S66-746
Corrosion -- Aluminum and Magnesium and Subsequent ................................................... T9-4
Alloy, Treatment ................................................. 1-20 DC Circuit Breakers ............................................. 9-12
Corrosion Damage Classification - DC Generator - Main............................................ 9-60
General............................................................... T-3 DC Voltmeter........................................................ 8-300
Coupling -- Quick Disconnect-Inspection ........... F6-23 Decimal Equivalent Conversions ......................... F1-5
Removal ............................................................. 6-151 Defroster Installation - Bleed Air .......................... 13-1
Couplings, Armament......................................... 7-108 Defroster Installation - Combustion
Couplings - Inner-Spherical on Main Heater and ........................................................... 13-14
Driveshaft - Inspection Criteria ........................... F6-3 De-ice Circuitry - Engine ...................................... 9-244
Course Indicator (ID-1347( YARN)..................... 8-221 Dimensions - Helicopter ....................................... FI-7
Covers - Aircraft ................................................. 1-45 Direct Current Power Distribution System............ 9-1
Cowling - Engine ................................................ 2-44 Dome Lights ......................................................... 9-151
Cowling - Transmission ...................................... 2-37 Doors -- Access Covers ....................................... 2-24
Cowling - Transmission & Engine ...................... F2-20 Cargo ................................................................... 2-114
Cowlings & Fairing.............................................. 2-35 Crew..................................................................... F2-28
Description.......................................................... 2-36 Nose..................................................................... 2-77
Crew Door Jettison (Ejection) Mechanism ......... 2-98 Drain Valve - Cell ................................................. 10-26
Crew Door Jettison Mechanism ......................... P2-31 Drive Quill - Tail Rotor.......................................... 6-125
Crew Doors......................................................... 2-84 Driveshaft Assembly - Main - Limits
Crew Doors - Latching Mechanism .................... 2-92 Chart P/N 205-040-004 ........................................ F6-10
Crew Seat - Armored.......................................... 2- Driveshaft Hangers .............................................. 6-167
247,F2-47 Aft Tailboom Installation....................................... F6-50
Crow Seat Belts.................................................. 2-241 Coupling Teeth Wear Patterns............................. F6-46
Crew Seat Coven ............................................... F2-45,2- Forward Tailboom Installation .............................. F6-49
225 Fuselage Installation ............................................ F648
Crew Seat -- Standard........................................ 2-216 Hanger ................................................................. F6-45
Critical Areas ...................................................... Repair Driveshaft - Main P/N SKCP228-1....................... 6-24.1
Limits - Drivesbaft - Main PIN 204-040-004...................... 6-13
Windshield & Windows....................................... F2-41 Driveshaft Main - Alignment
Cross Fitting ....................................................... 10-101 P/N 205-040-004.................................................. 6-24
Crosshead Controls, Tail Rotor .......................... S-107 Driveshaft - Main-Assembly and
Crossover Assemblies........................................ 10-59 Installation P/N 205-040-004................................ F6-9
Curtains -- Blackout ............................................ 2-186 Driveshaft - Main Disassembly
Cyclic Control Stick............................................. 11-56 P/N 205-040-004.................................................. 6-18
Cyclic Control System ........................................ 11-53 Driveshaft - Main - Cleaning
D P/N 205-040-004.................................................. 6-19
Driveshaft - Main - Inspection
Damage Classification -- General - P/N 205-040-004.................................................. 6-20
Corrosion ............................................................ 2-3 Drivesbaft - Main - Inspection of Installed
Damage Classification - P/N 205-040-004.................................................. 6-15
Honeycomb Panels ............................................ ’.n- Driveshaft Main -- Installation
Damage Limits - Intermediate Gearbox P/N 205-040-004.................................................. 6-23
Support nstalltion................................................ P2-62.1 Driveshaft Main P/N 205-040-004-
Damage Limits - Repair - Lift.............................. Beam Lubrication and Assembly .................................... 6-22
............................................................................ F2-21 Driveshaft - Main - Removal
Dampers and Adapters ...................................... 548 P/N 205-040-004.................................................. 6-17
Dampers - Friction .............................................. 6-149 Driveshaft Main P/N 205-040-004........................ 6-21
DC Bus System - General .................................. 9-56 Driveshaft - Main - Troubleshooting
DC Bus System - General P/N 205-040-004.................................................. T6-2,6-
Troubleshooting (Helicopter Prior to 16
S/N 66-746) ........................................................ T9-3
Change 10 Index 3
TM 55-1520-210-23-2
ALPHABETICAL INDEX (Continued)
Paragraph Paragraph
Driveshaft - Tail Rotor ..........................................6-159 Exterior - Lights System ..................................... 9-194
Droop Compensator Controls...............................4-126 External Oil Filter.......................................... F6-57,6-204
Dual Tachometer ..................................................8-14 External Power - Application .............................. 1-53
Dual Tachometer - Troubleshooting.....................T8-1 External Power Receptacle................................ 9-47
Ducts, Nozzles, Registers, Gaskets and External Power Relay......................................... 9-54
Miscellaneous Valves...........................................13-4 External Power System...................................... 9-43
E External Power System - Troubleshooting......... T9-2
External Stores Support ..................................... 16-1
EGT Indicator Scale & Friction Error Tolerances External Stores Support Assembly .................... F16-1
Plus or Minus Degrees Celsius ............................T8-6 Extinguisher and Bracket, Fire ........................... 17-7
Electrical - Component Location ..........................F9-1 F
Electrical Components (AC) - Common ...............9-91
Description............................................................9-92 Fairing - Tailpipe ................................................ 2-51
Electrical Components (DC) - Common ...............9-3 Feeder Relay - Battery ....................................... 9-41
Electrical Components - Miscellaneous ...............9-5 Field Relay - Generator...................................... 9-79
Electrical Equipment Location ..............................F9-2 Fifth Mount Support - Pylon ............................... 2-62
Elevator Assembly................................................2-286 Fire Detection System - Engine ......................... 12-1
Elevator, Bearing Limits........................................F2-55 Fire Extinguisher Bracket ................................... 17-7
Elevator Control Assy - Removal and Firewall and Tailpipe Assembly
Installation ............................................................F2-54 Installation .......................................................... 4-143
Elevator Control System.......................................11-170 Firewalls & Heat Shield ...................................... 2-66
Elevator Support & Horn Assy - Wear & First Aid Kits ....................................................... 17-1
Damage Limits .....................................................F2-56 Fittings & Screens, Lines, Manifolds.................. 6-81
Emergency Jettison Release Mechanism ............16-8 Fittings - Support Tail Rotor Driveshaft.............. 6-174
Engine Assembly..................................................4-6 Flasher - Navigation Lights ................................ 9-229
Engine Controls & Accessories ............................9-242 Flight Control System......................................... 11-1
Engine Cowling.....................................................2-44 Flight Control System (Electrical)....................... 9-260
Engine Cowling - Description ......................................................... 8-162
..............................................................................Transm Flight Safety Critical Aircraft Parts Program ...... 1-67
ission ....................................................................F2-20 Floor Panels - Cabin .......................................... 2-28
Engine De-Ice Circuitry.........................................9-244 Fluid Connectors - Torque Values ..................... TI-5
Engine De-Ice Circuitry - Troubleshooting............T9-15 Flyable Storage Appendix E............................... E-4
Engine Instruments ..............................................8-10 Force Gradient Cyclic Controls .......................... 11-40
Engine Mounts......................................................F2- Force Gradient - Tail Rotor Controls.................. 11-113
50,2-267 Force Trim System Circuitry .............................. 9-262
Engine Oil Pressure Indicator...............................8-60 Forward Door Window - Crew Door................... 2-147
Engine Oil Pressure Transmitter ..........................849 Forward Towing ................................................. 1-35
Engine Oil System - Servicing..............................1-5 Free Air Temperature Gage ............................... 8-305
Engine Oil Tank ....................................................4-84 Friction Dampers................................................ 6-149
Engine Oil Temperature Bulb ...............................8-90 Friction Damper Mount ...................................... F2-23.3
Engine Oil Temperature Indicator ........................8-80 Friction Damper Retaining Clip .......................... F2-23.1
Engine Quick Change Assembly..........................4-133 Fuel Boost Pump Cross Fitting .......................... 10-107
Engine Vibration Meter Receptacle......................9-120 Fuel Boost Pumps.............................................. 10-100
Equipment Lists ....................................................F-7 Fuel Boost Pump, Cartridge............................... 10-10.1i
Equipment Location - Electrical............................F9-2 Fuel Cap and Adapter Assembly ....................... 10-78
Exhaust Gas Temperature Indicating, System.....8-99 Fuel Cell Coverplate - Aft Center ....................... 10-72
Exhaust Gas Temperature Indicator ....................8-101 Fuel Cells - Crashworthy.................................... 10-1
Exhaust Heater - Air Blower .................................13-95 Fuel Cell Drain Valve ......................................... 10-27
Exhaust Heater - Auxiliary....................................13-84 Fuel Cell Sump Assembly .................................. 10-135
Exhaust System....................................................4-58 Fuel Check Valve ............................................... 10-150
Exhaust System - Clamp......................................4-60
Exhaust System - Tailpipe....................................4-67
Exterior - Cleaning................................................1-17
Index 4 Change 10
TM 55-1520-210-23-2
ALPHABETICAL INDEX
Paragraph Paragraph
Fuel Crossover Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60 Generator &DC Bus System . . . . . . . . . . . . . . . . . . . . . . . . . 9-56

Fuel Ejector Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-116 Generator &DC Bus System (Helicopters
Fuel Filter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20 Prior to S/N 66-7460)-Troubleshooting . . T9-3
Fuel Flapper Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-122 Generator &DC Bus System-Troubleshooting
Fuel Flapper Valve Plates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-128 (Helicopters S/N 66-746 and Subsequent). T9-4
Fuel Flow Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-145 Generator Drive Quill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-109
Fuel Governor Bleed Check Valve . . . . . . . . . . . . . . . . 10-47 Generator Field Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-79
Fuel Manifold Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-54 Generator-Main DC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-60
Fuel Motor Driven Shutoff Valve . . . . . . . . . . . . . . . . . . 10-40 Generator-Power Turbine Tachometer . . . . . . . . 8-22
Fuel Pressure Differential Transmitter . . . . . . . . . . . 4-147 Generator-Rotor Tachometer . . . . . . . . . . . . . . . . . . . . . . . 8-31
Fuel Pressure Transmitter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-33 Generator Shunt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-69
Fuel Quantity Transmitters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-112 Generator-Standby (Starter
Fuel Siphon Breaker Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-66 Generator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-2.1, 9-67
Fuel Warning System 20 Minute Float Generator-Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-126
Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-93 Governor Bleed Check Valve . . . . . . . . . . . . . . . . . . . . . . . . 10-46
Fuel Boost & Fuel Valve Circuity . . . . . . . . . . . . . . . . . . 9-248 Governor Control System Circuitry . . . . . . . . . . . . . . . 9-252
Fuel Pressure Indicating System . . . . . . . . . . . . . . . . . . . . 8-121 Governor Control System Circuitry-Trouble-
Fuel Pressure Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-128 shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T9-16
Fuel Quantity Indicating System . . . . . . . . . . . . . . . . . . . . 8-241 Ground Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32
Fuel Quantity Indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-248 Ground Handling Wheel Pump-Servicing.. 1-10
Fuel Quantity Indicator-Troubleshooting.... T8-16 Ground Handling Wheel Tires-Servicing . . . 1-11
Fuel Quantity System-Test (T68) . . . . . . . . 8-249 Ground Test Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-33
Fuel Quantity System-Test/Adjust (T68.1) . 8-249.1 Gun Firing Relay M6 Subsystem 7.62MM
Fuel Quantity Transmitter . . . . . . . . . . . . . . 8-252 M60C Machine Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-72
Fuel Solenoid Valve-Start . . . . . . . . . . . . . . 9-136
Fuel Train-Heater . . . . . . . . . . . . . . . . . . . . 13-36
Fuel Valve & Fuel Boost Circuitry . . . . . . . 9-248 H
Functional Check Low Fuel Caution System 10-19.1
Fuselage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Hangers-Driveshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-167
Fuselage Skin-Forward . . . . . . . . . . . . . . . . F2-4 Heat Exchanger-Auxiliary Exhaust Heater. 13-87
Fuselage Structure . . . . . . . . . . . . . . . . . . . . 2-3 Heat Shield—Firewalls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66
Heat Suppressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-51, 2-273
G Heated Blanket Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-276
Heater Air Pressure Switches . . . . . . . . . . . . . . . . . . . . . . . . . 13-52
Gages-Gil Level Sight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-75 Hinter Fuel Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-36
Gas Producer Tachometer Generator . . . . . . . . . . . . . 8-49 Heating System Circuitry-Bleed Air . . . . . . . . . . . 9-270
Gas Producer Tachometer Indicator . . . . . . . . . . . . . . . 8-40 Heater System Circuitry-Muff . . . . . . . . . . . . . . . . . . . . . 9-273
Repair or Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-46 Helicopter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-1
Gas Producer N1 Tachometer Generator Helicopter Assembly (EH-lH) . . . . . . . . . . . . . . . . . . . . . . . F2-1.1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-151 Helicopter Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F1-7
Gas Temperature Indicating System-Exhaust 8-99 High Performance Rescue
Gas Temperature Indicator-Exhaust . . . . . . . . . . . . 8-101 Hoist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F14-14.1, 14-145.1
Gaskets and Miscellaneous Valves-Ducts, Hinged Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-104
Nozzles, Registers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-4 Hinged Panel Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-32
Gearbox-Intermediate (420).......................... F6-51, 6-179 Hoisting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-47
Gearbox-Tail Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F6-52, 6-190 Hoisting-Component . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-50
Gearboxes-Intermediate (42 Degree) and Hoist, Rescue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1
Tail Rotor (90 Degree)-Servicing . . . . . . . . . . . . 1-8 Hoist System Circuitry-Rescue (Provisions) 9-286
Gearboxes-Transmission Assembly— Honeycomb Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Identification of Metal Particles . . . . . . . . . . . . . . . . . F6-14, 6-30 Classification of Damage . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Change 8 Index 5
TM 55-1520-210-23-2
Paragraph Paragraph
Honeycomb Panels-Classification of Indicating Systems-Tachometer . . . . . . . . . . . . . . . . . . 8-12

Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T2-5 Indicator-Airspeed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-172
Honeycomb Panels-Minor Damage Repairs F2-7 Indicator—Airspeed-Troubleshooting . . . . . . . . T8-9
Honeycomb Panels-Repair of Dents, Indicator-Engine Oil Temperature . . . . . . . . . . . . . . 8-80
scars & scratches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-6 Indicator—Exhaust Gas Temperature . . . . . . . . . . . . 8-101
Hook System Circuitry-Cargo . . . . . . . . . . . . . . . . . . . . . 9-283 Indicator—Fuel Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-123
Hoses, Oil Lines and Fittings . . . . . . . . . . . . . . . . . . . . . . . . . 4-77 Indicator-Fuel Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-243
Hoses, Tubing, Attaching Hardware . . . . . . . . . . . . . . 7-114 Indicator-Gas Producer Tachometer . . . . . . . . . . . 8-40
Hub and Blade Assembly, Main Rotor . . . . . . . . . . 5-3 Indicator (ID-1347( )/ARN)-Course . . . . . . . . . . 8-221
Hydraulic Control System Circuitry . . . . . . . . . . . . . . 9-266 Indicator Torque Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-143
Hydraulic Cylinder and Support, Tail Rotor.. 11-63.1 Indicator—Transmission Oil Pressure . . . . . . . . . . . 8-260
Hydraulic Filter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-46 Indicator—Transmission Oil . . . . . . . . . . . . . . . . . . . . . . . . . . 8-280
Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19 Indicator-Turn & Slip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-201
Hydraulic Pump & Tachometer Drive Quill.. 6-118 Indicator-Vertical Velocity . . . . . . . . . . . . . . . . . . . . . . . . . . 8-210
Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9 Indicators-Attitude . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-192
Hydraulic Reservoir-Servicing . . . . . . . . . . . . . . . . . . . . 1-9 Induction Baffle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-72
Hydraulic Servo Cylinder Assembly (Col- Inertia Reel-shoulder Harness-Crew
lective Control) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-80 Standard Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-231
Hydraulic Servo Cylinder Assembly Infrared Suppressor-Duct Assembly
(Cyclic Control) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-67 Outer Jacket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-279.1
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7-1, 7-1 Inlet Foreign Object Damage (FOD)
Screen-Air Particle Separator-Self-
Purging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46
I Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-49
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-51
Icing System Test Box Schematic . . . . . . . . . . . . . . . . . . F9-3 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-47
(ID-1347( )/ARN)-Course Indicator . . . . . . . . . . . 8-221 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-50
(ID-998( )/ASN & ID-250( )/ARN-Radio Inlet Screen-Non-Self-Purging Air Particle
Magnetic Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-223 Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Identification of Metal Particles-Trans- Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
mission Assembly & Gearboxes . . . . . . . . . . . . . . . . . F6-14, 6-30 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
Idle Stop System Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-256 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36
Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-130 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
Ignition Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-134 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35
Ignition Unit and Igniter Plug-Combustion Input D-rive Quill P/N 205-040-263 . . . . . . . . . . . . . . . F6-26, 6-101
Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-27 Input Drive Quill P/N 204-040-363 . . . . . . . . . . . . . . . F6-24, 6-92
Igniter Plug-Combustion Heater Ignition Input Drive Quills . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-90
Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 13-27 Input Driveshaft P/N 205-040-004-Lub-
Indicating System (AN/APR-39 (When rication and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F6-11
Installed-Radar Warning . . . . . . . . . . . . . . . . . . . . . . . . 8-314 Inspection-Acceptance/Rejection
Indicating System-Attitude . . . . . . . . . . . . . . . . . . . . . . ...! 8-190 Criteria-Transmission Assembly . . . . . . . . . . . . . 6-28
Indicating System-Engine Oil Temperature 8-78 Inspection-Main Driveshaft P/N
Indicating System-Exhaust Gas Temperature 8-99 205-040-004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Indicating System-Fuel Pressure . . . . . . . . . . . . . . . . . 8-121 Inspection of Installed Main Driveshaft
Indicating System-Fuel Quantity . . . . . . . . . . . . . . . . . 8-241 P/N 205-040-004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Indicating System-Torque Pressure . . . . . . . . . . . . . 8-141 Inspection of Roller Chain (Chain
Indicating System-Transmission Oil Removed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-258 Inspection-Special . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-58
Indicating System-Transmission Oil Inspection-Transmission Assembly . . . . . . . . . . . . 6-33
Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-278 Inspection-Transmission Oil Filter., . . . . . . . . . . . . 6-45
PIN: 040152-008
Index 6
TM 55-1520-210-23-2
ALPHABETICAL INDEX
Paragraph Paragraph
Installation-Main Driveshaft P/N Latch-Typical-Cargo Door . . . . . . . . . . . . . . . . . . . . . . . F2-35

205-040-004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23 Latching Mechanism Crew Doors . . . . . . . . . . . . . . . . . 2-92
Installation-Transmission Assembly . . . . . . . . . . . 6-40 Latching Mechanism—Crew Door . . . . . . . . . . . . . . . . F2-29
Installation-Transmission Oil Filter . . . . . . . . . . . . . 6-49 Launcher and Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-80
Instrument, Console, & Pedestal Lights . . . . . . . . . 9-160 Lead Spool Resistor—Thermocouple . . . . . . . . . . . . 8-111
Instrument Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 Leveling and Jacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-36
Instrument Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-315 Lever Assembly-Cyclic Controls, Tube and 11-65
Instrument Premaintenance Requirements . . . . . 8-8 Levers and Supports-Cyclic Control System,
Instruments-Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10 Bell Cranks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-101
Instruments-Flight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-161 Lift Beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58
Instruments-Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . 8-229 Lift Beam Damage Limits and Repair . . . . . . . . . . . F2-21
Instruments-Navigation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-219 Lift Beam-Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-22
Intermediate Storage-Appendix E . . . . . . . . . . . . . . . E-10 Lift Link-Pylon Mounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-142
Interior-Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16 Light—Anticollision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-211
Interior Lights System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-140 Light System—Anticollision . . . . . . . . . . . . . . . . . . . . . . . . . . 9-207
Intermediate Gearbox (42°) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-179 Light System—Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-169
Inverter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-97 Light—Transmission Oil Level . . . . . . . . . . . . . . . . . . . . . 9-236
Inverter Failure Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-111 Lighting Provisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-138
Inverter Power Relay—Main . . . . . . . . . . . . . . . . . . . . . . . . . 9-105 Lighting System, Instrument, 5 volt . . . . . . . . . . . . . . . 9-86.1
Inverter Power Relay Spare . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-107 Lights—Cockpit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-142
Inverter Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-109 Lights—Dome . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-151
Inverter System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-93 Lights—Navigation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-222
Inverter System—Troubleshooting . . . . . . . . . . . . . . . . T9-5 Lights-Navigation-Flasher............................. 9-229
Inventory Items List Component Diagram . . . . . FC-1 Lights System—Exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-194
Irreversible Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-100 Limits Chart-Main Driveshaft Assembly,
Isolation of Circuits for Alignment-RPM P/N 205-040-004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F6-10
Limit Warning Detector Models . . . . . . . . . . . . . . . . . T9-9 Linear Actuator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-118
Lines, Manifolds, Fittings and Screens . . . . . . . . . . 6-81
Lines, Manifold, Fittings and Screens—
J Transmission Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F6-19
Litter Rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-15
Jack Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-198 Loadmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-303
Jacking and Leveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-86 Lower Case Repair—Transmission Assembly
Jackshaft, Collective . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-7 (AVIM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37
Jettison (Ejection) Mechanism-Crew Door. 2-98 Lower Forward Cabin Windows . . . . . . . . . . . . . . . . . . . . 2-168
Jettison Release Mechanism-Emergency . . . . 16-8 Lubrication Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F1-6
Junction Box, Armament . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-101 Lubrication Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-30
Lubrication-Transmission Assembly . . . . . . . . . . 6-27
K
M
Kits, First Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-1
Machine Gun—M6 Subsystem 7.62MM, M60C 16-51
Machine Gun M60D in Stowed Position,
L
RS, Armament Subsystem M23 . . . . . . . . . . . . . . . . . F16-12
Machine Gun XM213, .50 Caliber . . . . . . . . . . . . . . . . . F16-22
Landing and Searchlight System . . . . . . . . . . . . . . . . . . . . 9-197 Magnetic Brake-Cyclic Controls . . . . . . . . . . . . . . . . . 11-73
Landing and Searchlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-200 Magnetic Brake-Tail Rotor Controls . . . . . . . . . . . 11-111
Landing Gear Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Magnetic Indicators—Radio (ID 998( )/
Landing Gear Crosstubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 ASN and ID-250( )/ARN) . . . . . . . . . . . . . . . . . . . . . . . . . 8-223
Latch-Cargo Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-122
Index 7
TM 55-1520-210-23-2
ALPHABETICAL INDEX
Paragraph Paragraph
Main and Tail Rotor System-Servicing . . . . . . . 1-7 Mission Antenna Mount Linear Actuator—
Main Beams at Station 129 (AVIM)-Repair Forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-297
of Cracked . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-65 Mission Antenna Mount Alignment Proce-
Main DC Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-60 dure—Aft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-322
Main Driveshaft P/N 205-040-004 . . . . . . . . . . . . . . . . . 6-13 Mission Antenna Mount Alignment Proce-
Main Driveshaft Assembly—Limits Chart dure—Forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-303
P/N 205-040-004. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F6-10 Mission Operator Seats . . . . . . . . . . . . . . . . . . . . . . . . . . 2-252,1, F2-48.1
Main Driveshaft Assembly and Installation Mixing Lever Assembly-Cyclic Controls . . . 11-87
P/N 205-040-004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F6-9 Mooring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-42
Main Driveshaft-Inspection Criteria for Mooring Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-204
Spherical Inner Couplings . . . . . . . . . . . . . . . . . . . . . . . . . . F6-12 Motor Driven Shutoff Valve . . . . . . . . . . . . . . . . . . . . . . . . . . 10-39
Main Inverter Power Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-105 Mount and Adapter—M6 Subsystem
Main Rotor Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27 7.6MM, M60C Machine Gun . . . . . . . . . . . . . . . 16-56
Main Rotor Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14 Muff Heater System Circuitry . . . . . . . . . . . . . . . . . . . . . . . . 9-273
Main Rotor Hub and Blade Assembly . . . . . . . . . . . 5-3 M56 Mine Dispenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-43
Adjustment, Collective Pitch Forces . . . . . . 5-8
Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Autorotation RPM Adjusting . . . . . . . . . . . . . . . . . . 5-10 N
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Navigation Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-219
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13 Navigation Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-222
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Navigation Lights Flasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-229
Operational Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 Navigation Lights System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-218
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12 Navigation Lights System—Troubleshooting T9-13
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 Nonessential Bus Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-87
Main Rotor Mast Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-134 Non-Self-Purging Particle Separator . . . . . . . . . . . . . 4-37
Main Rotor System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Non-Self-Purging Air Particle Separator—
Maintenance Allocation Chart . . . . . . . . . . . . . . . . . . . . . . . . B-1 Inlet Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance-Instrument . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
Manifold Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-53 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
Manifolds, Fittings, and Screens—Lines . . . . . . . 6-81 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36
Map and Data Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-210 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
Mark 8 Sight Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-97 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35
Master Caution Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-173 Nose Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-77
Master Guide—Aircraft Inventory Appendix C C-1 Nozzles, Registers, Gaskets and Miscella-
Metal Surfaces Bonded Panels—Repair of neous Valves—Ducts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-4
Voids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-10
Mine Dispenser Control Panel . . . . . . . . . . . . . . . . . . . . . . . 16-38
0
Mine Dispenser, M56 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-43
Mine Dispensing Subsystem . . . . . . . . . . . . . . . . . . . . . . . . . . 16-37
Oil Cooler Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-217
Minimum Breakaway Torque for Used All-
Metallic and Nonmetallic Self-Locking Nuts T1-7 Oil Cooler Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-91
Miscellaneous Electrical Components . . . . . . . . . . . Oil Contamination, Chip Detector . . . . . . . . . . . . . . . . . 4-101
9-5
Oil Filter—External . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F6-57, 6-204
Miscellaneous Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-240
Miscellaneous Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-229 Oil Filter—Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41
Mission Antenna Actuator System . . . . . . . . . . . . . . . . . 9-289 Oil Jets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-60
Oil Level Light—Transmission . . . . . . . . . . . . . . . . . . . . . 9-236
Mission Antenna Mount—Aft . . . . . . . . . . . . . . . . . . . . . . . . 9-310, F9-15
Mission Antenna Mount—Forward . . . . . . . . . . . . ...9-291. F9-11 Oil Level Sight Gages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-75
Oil Lines, Hoses, and Fittings . . . . . . . . . . . . . . . . . . . . . . . . 4-77
Mission Antenna Mount Linear Actuator—
Oil Pressure Indicator—Engine . . . . . . . . . . . . . . . . . . . . . 8-60
Aft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-316
Oil Pressure Indicating System—Engine . . . . . . . 8-58
Index 8
TM 55-1520-210-23-2
ALPHABETICAL INDEX
Paragraph Paragraph
Oil Pressure Indicating System - Power Plant Assembly . . . . . . . . . . . . . . . . . 4-1
Transmission . . . . . . . . . . . . . . . . . . . . . . . 8-259 Power Plant Electrical Cable Installation . . 4-153
Oil Pressure Indicator - Transmission . . . . 8-260 Power Receptacle-External . . . . . . . . . . . 9-47
Oil Pressure Switch - Engine . . . . . . . . . . . 4-147 Power Relay - Main Inverter . . . . . . . . . . . . 9-54
Oil Pressure Transmitter-Engine . . . . . . . . 8-69 Power Relay - External . . . . . . . . . . . . . . . . 9-105
Oil Pressure Transmitter-Transmission . 8-269 Power Relay - Spare Inverter . . . . . . . . . . . 9-107
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-50 Power System - External . . . . . . . . . . . . . . . 9-43
Power Turbine N2 Tachometer Generator
Oil System . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-74
Installation . . . . . . . . . . . . . . . . . . . . . . . . . 4-152
Oil System-Transmission . . . . . . . . . . . . . 6-201 Power Turbine Tachometer Generator . . . 8-22
Oil Tank, Engine . . . . . . . . . . . . . . . . . . . . . . 4-84 Premaintenance Requirements -
Oil Temperature Bulb - Engine . . . . . . . . . . 8-90 Instrument . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Oil Temperature Bulb-Transmission . . . . 8-289 Pressure Indicating System-Fuel . . . . . . 8-121
Oil Temperature Indicating Pressure Indicating System-Torque . . . . 8-141
System -Engine . . . . . . . . . . . . . . . . . . . . 8-78 Pressure Indicator - Fuel . . . . . . . . . . . . . . . 8-123
Oil Temperature Indicating System- Pressure Indicator-Torque . . . . . . . . . . . . 8-143
Transmission . . . . . . . . . . . . . . . . . . . . . . . 8-278 Pressure Relief Valve . . . . . . . . . . . . . . . . . . 6-67
Oil Temperature Indicator-Engine . . . . . . 8-80 Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . 7-53
Oil Temperature Indicator - Transmission 8-280 Pressure Transmitter-Fuel . . . . . . . . . . . . 8-132
Outer Coupling Lubrication . . . . . . . . . . . . . F6-6 Pressure Transmitter-Torque . . . . . . . . . . 8-152
Pylon Fifth Mount Support . . . . . . . . . . . . . . 2-62
Overhaul and Retirement Schedule . . . . . . T1-8
Pylon Mounts and Lift Link . . . . . . . . . . . . . . 6-142
Overheat Switch . . . . . . . . . . . . . . . . . . . . . . 13-34
14-130
Q
Overload Sensing Relay . . . . . . . . . . . . . . .
Overvoltage Relay . . . . . . . . . . . . . . . . . . . . . 9-85 Quantity Indicating System-Fuel . . . . . . . . 8-241
P Quantity Indictor-Fuel . . . . . . . . . . . . . . . . . 8-243
Quantity Transmitters-Fuel . . . . . . . . . . . . . 8-252
Panel Assembly -Armament Control . . . . 16-89 Quill-lnput Drive P/N 205-040-263 . . . . . . 6-101
Panel Assembly -Sight Light . . . . . . . . . . . 16-93 Quill-lnput Drive P/N 204-040-363 . . . . . . 6-92
Panel-Hinged . . . . . . . . . . . . . . . . . . . . . . . 2-104 Quill-Generator Drive . . . . . . . . . . . . . . . . . . 6-109
Panel -Master Caution . . . . . . . . . . . . . . . . 9-173 Quills-Input Drive . . . . . . . . . . . . . . . . . . . . . 6-90
Panels -Cabin Floor . . . . . . . . . . . . . . . . . . 2-28 R
Paratroop Static Line Cable . . . . . . . . . . . . . 2-192 Radar Warning Indicating System (AN/APR-39)
Paratroop Static Line Cable . . . . . . . . . . . . . 16-109 (When installed) . . . . . . . . . . . . . . . . . . . . 8-314
Parking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-39 Radio Magnetic Indicators (ID-998( )/ASN and
Part Numbers and Usable on Codes . . . . . 4-138 lD-250 ( )/ARN) . . . . . . . . . . . . . . . . . . . . . 8-223
Particle Separator-Non-Self-Purging . . . 4-37 Rearview Mirror . . . . . . . . . . . . . . . . . . . . . . . 2-175
Particle Separator Self-Purging - Air Inlet Receptacle -Engine Vibration Meter . . . . 9-120
Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-45 Receptacle - External Power . . . . . . . . . . . 9-47
Pedestal Lights-instrument, Console . . . . 9-160 Receptacles -Heated Blanket . . . . . . . . . . 9-276
Pilots Collective Stick . . . . . . . . . . . . . . . . . . 11-25 References -Appendix A . . . . . . . . . . . . . . A-1
Pilot - Static System . . . . . . . . . . . . . . . . . . . 8-163 Registers, Gaskets and Miscellaneous
Plate, Adapter Hoist . . . . . . . . . . . . . . . . . . . 14-84 Valves-Ducts-Nozzles . . . . . . . . . . . . 13-4
Plexiglass -Cleaning . . . . . . . . . . . . . . . . . . 1-18 Regulator-Voltage . . . . . . . . . . . . . . . . . . . 9-71
Power Distributing System - Alternating Reinforced Floor Mounting Plates and
Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-89 Base Assembly . . . . . . . . . . . . . . . F2-18.2, 2-27.1
Power Distribution System - Direct Relay
Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-39
Power Lever Controls . . . . . . . . . . . . . . . . . . 4-110 Battery Feeder . . . . . . . . . . . . . . . . . . . . . . 9-41
Change 7 Index 9
TM 55-1520-210-23-2
ALPHABETICAL INDEX
Paragraph Paragraph
Bus Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-83 RPM Limit Warning Detector—Saturn

External Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-54 Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-7
Generator Field . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-79 RPM Limit Warning Detector—SDI Model . F9-8
Inverter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-109 RPM Limit Warning System . . . . . . . . . . . . . . . . . . . . . . . . . . 9-181
Main Inverter Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-105 RPM Limit Warning System—Trouble-
Nonessential Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-87 shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T9-10
Overvoltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-85 Rubber Pressure Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-77
Reverse Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-81
Spare Inverter Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-107
Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-39 S
Repair of Cracked Spar Cap Angles on
Main Beams at Station 129 (AVIM) . . . . . . . . . . 2-65 Saturn Model RPM Limit Warning Detector F9-7
Repair of Damage Penetrating Titanium Scale and Friction Error Tolerances Plus
and Fiberglass Facings and Core-Honey- or Minus° Celsius—EGT Indicator . . . . . . . . . . . T8-6
comb Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-11 Schedule—Retirement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-65
Repair of Dents, Scars and Scratches— Schematic Diagram-Combustion Air Blower F13-6
Honeycomb Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-6 Schematic Diagram—Electric Motor Assembly F12-6
Repair of Voids in Metal Surfaces Bonded Schematic Diagram—Fuel Quantity Installation
Panels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-10 (Crashworthy) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8-5
Repair or Replacement—-Transmission Schematic—Icing System Test Box . . . . . . . . . . . . . . F9-3
(AVIM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35 Scissors and Sleeve Assembly . . . . . . . . . . . . . . . . . . . . . . . 5-74
Replacement Chart-Comector . . . . . . . . . . . . . . . . . . . . F-9 Screens—Lines, Manifolds, Fittings . . . . . . . . . . . . . . 6-81
Replacement Damaged Studs—Transmission Searchlight and Landing System . . . . . . . . . . . . . . . . . . . . 9-196
Assembly (AVIM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36 Seat Belts----crew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-241
Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-5 Seat Belts—Troop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-261
Reservoir, Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9 Seat Covers-Crew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-225
Rescue Hoist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1 Seat Cover/Stencil—Crew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-45
Rescue Hoist System Circuitry (Provisions).. 9-286 Seat--Crew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-44
Resistor—Therrnocouple Lead Spool . . . . . . . . . . . . 8-111 Seat-Crew-Armored . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-247
Retirement Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-65 Seating Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-49
Return to Overhaul—Transmission Assembly Seating Arrangement (EH-1H) . . . . . . . . . . . . . . . . . F2-49.1
(AVIM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38 Seats—Troop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-253
Reverse Current Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-81 Self-Locking Nuts—Reuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29
Rocket Launcher and Adapter . . . . . . . . . . . . . . . . . . . . . . . . 16-80 Service Deck—Right and Left . . . . . . . . . . . . . . . . . . . . . . . 2-19
Rocket System XM3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-76 Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Rotor Blades—Cleaning . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . 1-19 Auxiliary Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Rotor Blades—Tail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-114 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Rotor Hub, Main . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Rotor System, Main . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Engine Oil System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Rotor System Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . F5-5 Ground Handling Wheel Pump . . . . . . . . . . . . . . 1-10
Rotor Tachometer Generator . . . . . . . . . . . . . . . . . . . . . . . . . . 8-31 Ground Handling Wheel Tires . . . . . . . . . . . . . . . 1-11
RPM Limit Warning Detector . . . . . . . . . . . . . . . . . . . . . . . . 9-186 Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
RPM Limit Warning Detector—Bench Intermediate (42 degree) and Tail Rotor
Test Set Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-10 (90 degree) Gearboxes . . . . . . . . . . . . . . . . . . 1-8
RPM Limit Warning Detector-Cables for Mail and Tail Rotor System . . . . . . . . . . . . . . . . . . . . 1-7
Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F9-9 Smoke Generator Subsystem Tank . . . . . . . . . 16-26
RPM Limit Warning Detector-SDI Model.. F9-8 Transmission Oil System . . . . . . . . . . . . . . . . . . . . . . . . 1-6
RPM Limit Warning Detector Models— Servicing Points Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F1-1
Isolation of Circuits for Alignment . . . . . . . . . . . . T9-9 Servo Cylinder Assembly (Collective Control),
Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-80
Index 10
TM 55-1520-210-23-2
ALPHABETICAL INDEX
Paragraph Paragraph
Servo Cylinder Assembly (Cyclic Control), Standard Torque Values—Engine Quick

Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-67 Change Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-137
Sheet Metal Skins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20 Standards of Serviceability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-57
Sheet Metal Skins Forward Fuselage— Standby Compass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-225
Classification of Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . T2-6 Standby Compass—Troubleshooting . . . . . . . . . . . . T8-14
Short Term Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-3 Standby Generator (Starter Generator) . . . . . . . . . . 9-67
Shoulder Harness and Inertia Reel-Crew Start Fuel Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-136
Standard Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-231 Starter Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-126
Shunt-Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-69 Starter-Generator Installation . . . . . . . . . . . . . . . . . . . . . . 4-150
Sight Assembly, Mark 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-97 Starting System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-122
Sight Gages-Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-75 Static Line Cable—Paratroop . . . . . . . . . . . . . . . . . . . . . . . . 2-192, F2-43
Sight Light Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-93 Static Line Cable, Paratroop. . . . . . . . . . . . . . . . . . . . . . . . . . . 16-109
Sight Station-M6 Subsystem 7.62MM Storage and Shipment of High Performance
M60C Machine Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-68 Hoist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-145.110
Siphon Breaker Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-65 Storage of Aircraft-Appendix E . . . . . . . . . . . . . . . . . . E-1
Skid Saddles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26 Strap Splice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-24.3
Skid Shoes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 Structure-Fuselage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3, F2-2
Skid-Tail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-298 Structure-Tailboom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-294
Skid Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 Structural Repair Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . T2-1
Skin and Stringer Repair-Combined, . . . . . . . . . . . F2-15 Studs—Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T1-6
Skins-Sheet Metal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20 Support Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-72.1
Skins—Tailboom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-5 Support Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26
Sleeve Assembly, Scissors and . . . . . . . . . . . . . . . . . . . . . . . 5-74 Support-External Stores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-1
Sling Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-51 Support Fittings—Tail Rotor Driveshaft . . . . . . . 6-174
Slip Indicator—Turn. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-201 Suppressor—Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-273
Smoke Generator Subsystem. . . . . . . . . . . . . . . . . . . . . . . . . . 16-21 Suspension Assembly, Cargo . . . . . . . . . . . . . . . . . . . . . . . . . 14-146
Solenoid Valve-Start Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-136 Swashplate and Support Assembly . . . . . . . . . . . . . . . . 5-57
Solenoid Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-60
Spar Cap Angles on Main Beams at Station
129 (AVIM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-65 T
Spar Cap Angle Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-24
Spare Inverter Power Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-107 Tachometer Drive Quill—Hydraulic Pump . . . 6-118
Special Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-58 Tachometer—Dual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
Special Instructions-Engine Quick Tachometer—Dual—Troubleshooting . . . . . . . . . . T8-1
Change Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-136 Tachometer Generator—Gas Producer . . . . . . . . . . 8-49
Special Tools and Test Equipment . . . . . . . . . . . . . . . . . 1-24 Tachometer Generator Installation, Gas
Special Tools and Test Equipment . . . . . . . . . . . . . . . . . T1-2 Producer N1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-151
Spherical Couplings on Main Driveshaft— Tachometer Generator Installation, Power
Inspection Criteria P/N 204-040-010 . . . . . . . . . F6-3 Turbine N2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-152
Splice Fabrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-24.2 Tachometer Generator—Power Turbine . . . . . . . . 8-22
Splined Nut—Limits Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F6-4 Tachometer Generator—Rotor . . . . . . . . . . . . . . . . . . . . . . . 8-31
Spool Resistor—Thermocouple Lead . . . . . . . . . . . . 8-111 Tachometer Indicating Systems . . . . . . . . . . . . . . . . . . . . . 8-12
Spray Nozzle-Combustion Heater—Ex- Tachometer Indicator-Gas Producer . . . . . . . . . . . 8-40
ploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F13-4 Tailboom Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-280
Stabilizer Bar Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35 Tailboom Skins. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-5
Standard Crew Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F2-44, 2-216 Tailboom Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-294
Standard Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T1-4 Tailpipe-Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-67
Standard Torque procedures and Require- Tailpipe Fairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51
ments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28 Tail Rotor Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-114
Index 11
TM 55-1520-210-23-2
ALPHABETICAL INDEX
Paragraph Paragraph
Tail Rotor Control Chain Conversion Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . T9-14
Procedures . . . . . . . . . . . . . . . . . . . . . . . . . 11-154 Transmission Oil Pressure Indicating
Tail Rotor Control System . . . . . . . . . . . . . . 11-108 System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-258
Tail Rotor Crosshead Controls . . . . . . . . . . 5-107 Transmission Oil Pressure Indicator . . . . . 8-260
Tail Rotor Drive Quill . . . . . . . . . . . . . . . . . . 6-125 Transmission Oil Pressure Transmitter . . . 8-269
Tail Rotor Driveshaft . . . . . . . . . . . . . . . . . . . 6-159 Transmission Oil System . . . . . . . . . . . . . . . 6-201
Tail Rotor Driveshaft Support Fittings . . . . 6-174 Transmission Oil System-Servicing . . . . 1-6
Tail Rotor Gearbox . . . . . . . . . . . . . . . . . F6-52, 6-190 Transmission Oil Temperature Bulb . . . . . . 8-289
Tail Rotor Hub . . . . . . . . . . . . . . . . . . . . . . . . 5-98 Transmission Oil Temperature Indicating
Tail Rotor Hub and Blade Assembly. . . . . . 5-88 System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-278
Tail Rotor Hydraulic Cylinder and Transmission Oil Temperature Indicator . . 8-280
support . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-163.1 Transmission Vent Valve . . . . . . . . . . . . . . . 6-59.1
Tail Rotor System . . . . . . . . . . . . . . . . . . . . . 5-85 Transmission Pressure Transmitter and
Tail Skid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-298 Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F6-16
Temperature Bulb - Engine Oil . . . . . . . . . . 8-90 Transmitter and Switch-Transmission
Temperature Control Valve . . . . . . . . . . . . . 13-101 Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . F6-16
Temperature-Millivolts vs . . . . . . . . . . . . . . . T8-5 Transmitter -Engine Oil Pressure . . . . . . . 8-69
Test Box Schematic -icing System.. . . . . F9-3 Transmitter -Fuel Pressure . . . . . . . . . . . . 8-132
Test Circuit (Crashworthy) - Transmitter -Torque Pressure . . . . . . . . . . 8-152
Indicator Bench . . . . . . . . . . . . . . . . . . . . . F8-6 Transmitter -Transmission Oil Pressure . 8-269
Test Connections, Ground . . . . . . . . . . . . . . 7-33 Transmitters-Fuel Quantity . . . . . . . . . . . . 8-252
Testing Windshield Wiper . . . . . . . . . . . . . . . F12-8 Repair or Replacement . . . . . . . . . . . . . . . . 8-256
Thermal Valve . . . . . . . . . . . . . . . . . . . . . . . . 6-211 Treating Corroded Parts-Cleaning . . . . . T2-4
Thermocouple Lead Spool Resistor.. . . . . 8-111 Trigger Detent Mechanism . . . . . . . . . . . . . 11-64.1
Thermostat-Cabin . . . . . . . . . . . . . . . . . . . . . 13-47 Troop Seat Belts . . . . . . . . . . . . . . . . . . . . . . 2-261
ToolApplication- Use of Alignment Tool Troop Seats . . . . . . . . . . . . . . . . . . . . . . . . . . 2-253
Set (T47) . . . . . . . . . . . . .. . . . ... ... F6-8 Troubleshooting- Air Distribution System
Torque Application . . . . . . . . . . . . . . . . . . . . . F1-3 Helicopters S/N62-12351 through
Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . T1-4 64-13901 . . . . . . . . . . . . . . . . . . . . . . . . . T13-1
Torque Procedures andRequirements- Troubleshooting -Airspeed Indicator . . . . T8-9
Standard . . . . . . . . . . . . . . . . . . . . . . 1-28 Troubleshooting Anti-collision Light
Torque Values for Fluid Connectors . . . . . . T1-5 System . . . . . . . . . . . . . . . . . . . . . . . . . . . . T9-12
Torque Values for Studs . . . . . . . . . . . . . . . . T1-6 Troubleshooting -Attitude Indicator . . . . . T8-11
Torque Values, Standard - Engine Quick Change Troubleshooting -Barometric Altimeter . . T8-10
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4-137 Troubleshooting Battery System . . . . . . . . . T9-1
Towing . . . . . . . . . . . . . . . . . . . . . . . . . . ... 1-34. F1-8 Troubleshooting Clock . . . . . . . . . . . . . . . . . T8-15
Tracking and Operational Check . . . . . . . . 5-120 Troubleshooting Cockpit Lights . . . . . . . . . . T9-8
Tracks -Cargo Door . . . . . . . . . . . . . . . . . . 2-137 Troubleshooting Converter Assembly . . . . T12-3
Transformer- AC . . . . . . . . . . . . . . . . . . . . . 9-113 Troubleshooting DC Voltmeter . . . . . . . . . . T8-17
Transmission and Engine Cowling . . . . . . . F2-20 Troubleshooting Dual Tachometer . . . . . . . T8-1
Transmission Assembly . . . . . . . . . . . . . . . . 6-25 Troubleshooting- Electric Motor
Transmission Assembly -Build-Up-Universal Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . T12-2
F6-15 Troubleshooting Engine De-Ice Circuitry.. T9-15
Transmission Assembly and Gearboxes~. Troubleshooting Engine Oil Pressure
identification of Metal Particles . . . . . . 6-30, F6-14 Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . T8-2
Transmission Assembly (AVIM) - Replacement Troubleshooting Engine Oil Temperature
Damaged Studs . . . . . . . . . . . . . . . . . . . . . 6-36 Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . T8-3
Transmission Assembly - Universal Basic Troubleshooting Exhaust Gas Temperature
Configuration . . . . . . . . . . . . . . . . . . . . . . . F6-18 Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . T8-4
Transmission Cowling . . . . . . . . . . . . . . . . . 2-37 Troubleshooting External Power System . T9-2
Transmission Oil Filter . . . . . . . . . F6-20, 6-41, F6-21 Troubleshooting Fire Detector . . . . . . . . . . . T12-1
Transmission Oil Level Light . . . . . . . . . . . . 9-236 Troubleshooting Force Trim System
Transmission Oil Level Light - Trouble- Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . T9-17
Index 12 Change 7 *U.S. GOVERNMENT PRINTING OFFICE: 1995-655-121/20040 PIN: 040152-007

TM 55-1520-210-23-2
ALPHABETICAL INDEX
Paragraph Paragraph
Troubleshooting Fuel Pressure Indicator . . . . . . . T8-7 Valve-Thermal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-211

Troubleshooting Fuel Quantity Indicator . . . . . . . T8-16 Velocity Indicator—Vertical . . . . . . . . . . . . . . . . . . . . . . . . . . 8-210
Troubleshooting Generator and DC Bus Vent Blower-Combustion Heater . . . . . . . . . . . . . . . . 13-67
System (Helicopters Prior to S/N 66-746).. T9-3 Ventilation, Air Scoop Assemblies . . . . . . . . . . . . . . . . 13-9
Troubleshooting Generator and DC Bus Vertical Velocity Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-210
System (Helicopter S/N 66-746 and Sub- Vibration Meter Receptacle-Engine . . . . . . . . . . . . 9-120
sequent) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T9-4 Voltage Regulatory. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-71
Troubleshooting 5-Volt Instrument Lighting Voltmeter—AC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-298
System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T9-4.1 Voltmeter-DC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-300
Troubleshooting Governor Control System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-302
Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T9-16
Troubleshooting Cargo Suspension Assembly T14-3
Troubleshooting Inverter System . . . . . . . . . . . . . . . . . . . T9-5 W
Troubleshooting Landing and Search-Light
System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T9-11 Warning Detector-RPM Limit . . . . . . . . . . . . . . . . . . . . . 9-186
Troubleshooting Main Driveshaft Warning Indicating System (AN/APR-39)
P/N 205-040-004. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16, T6-2 (When Installed)—Radar. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-314
Troubleshooting Navigation Lights System... T9-13 Warning System—RPM Limit . . . . . . . . . . . . . . . . . . . . . . . 9-181
Troubleshooting RPM Limit Warning System T9-10 Wheels and Tire Assembly-Ground Handling
Troubleshooting Standby Compass . . . . . . . . . . . . . . . . T8-14 Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
Troubleshooting Starter System . . . . . . . . . . . . . . . . . . . . . T9-6 Window—Adjustable-Crew Door. . . . . . . . . . . . . . . 2-154
Troubleshooting Torque Pressure Indicator... T8-8 Window—Forward Crew Door . . . . . . . . . . . . . . . . . . . . . . 2-147
Troubleshooting-Transmission Oil Level Window—Upper-Crew Door . . . . . . . . . . . . . . . . . . . . . . 2-140
Light . . . . . . . . . ...” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T9-14 Windows-Cabin-Lower Forward . . . . . . . . . . . . . . 2-168
Troubleshooting-Turn and Slip Indicator . . . . T8-12 Windows-Cabin Roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-161
Troubleshooting—Transmission Assembly . . . T6-4 Windows-Crew Door Remove/Install . . . . . . . . . F2-42
Troubleshooting Vertical Velocity Indicator. T8-13 Windshield. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-133
Truck, Ground Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33 Windshield and Windows Critical Areas
Tube and Lever Assembly-Cyclic Controls 11-65 and Repair Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-41
Tubes-Cyclic Control System Control . . . . . . . . 11-95 Windshield Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2-40
Turn and Slip Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-201 Windshield Wiper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-9
Turn and Slip Indicator-Troubleshooting . . . . T8-12 Windshield Wiper Installation . . . . . . . . . . . . . . . . . . . . . . . F12-2
Twenty Minutes Fuel Warning System Windshield Wiper System Circuitry . . . . . . . . . . . . . . 9-280
Float Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-87 Windshield Wiper—Testing . . . . . . . . . . . . . . . . . . . . . . . . . . F12-8
Wiper Shaft-Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F12-5
Wiper System Circuitry-Windshield . . . . . . . . . . . 9-280
U Wiper—Windshield. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-9
Wiper-Windshield-Installation . . . . . . . . . . . . . . . . . F12-2
Universal Transmission Assembly—Basic Wiring Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........ . . . . . . . F-3
Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F6-18 Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-5
Universal Transmission Assembly—Build-up F6-15 symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-6
Upper Door Window-Crew Door . . . . . . . . . . . . . . . . 2-140 Wiring Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-4
Use of the Maintenance Allocation Chart . . . . . . B-2 Wiring Diagram Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-13
Use of Tool Set (T47)—TooI Application . . . . . F6-8
X, Y, Z
V
Valve Control Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-101

Valve-Pressure Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-67
Valve-Start Fuel Solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-136
Index 13/(Index 14 blank)

*U.S. GOVERNMENT PRINTING OFFICE: 1990 754-125/00125
CARL E. VUONO
R.L. DILWORTH
Distribution:

for UH-1H, UH-1V, Helicopter, Utility, EH-1H, Helicopter, Electronic Countermeasure
and EH-1X Helicopter, Electronic Countermeasure & Intercept.
These are the instructions for sending an electronic 2028
The following format must be used if submitting an electronic 2028. The subject line must be
exactly the same and all fields must be included; however only the following fields are
mandatory: 1, 3, 4, 5, 6, 7, 8, 9, 10, 13, 15, 16, 17, and 27.
From: “Whomever” <[email protected]>
To: [email protected]
Subject: DA Form 2028
1. From: Joe Smith
2. Unit: home
3. Address: 4300 Park
4. City: Hometown
5. St: MO
6. Zip: 77777
7. Date Sent: 19--OCT--93
8. Pub no: 55--2840--229--23
9. Pub Title: TM
10. Publication Date: 04--JUL--85
11. Change Number: 7
12. Submitter Rank: MSG
13. Submitter FName: Joe
14. Submitter MName: T
15. Submitter LName: Smith
16. Submitter Phone: 123--123--1234
17. Problem: 1
18. Page: 2
19. Paragraph: 3
20. Line: 4
21. NSN: 5
22. Reference: 6
23. Figure: 7
24. Table: 8
25. Item: 9
26. Total: 123
27. Text:
This is the text for the problem below line 27.
Use Part II (reverse) for Repair Parts and Spe- DATE
RECOMMENDED CHANGES TO PUBLICATIONS AND cial Tool Lists (RPSTL) and Supply Catalogs/
Supply Manuals (SC/SM)
BLANK FORMS
For use of this form, see AR 25--30; the proponent agency is ODISC4. 8/30/02
TO: (Forward to proponent of publication or form)(Include ZIP Code) FROM: (Activity and location)(Include ZIP Code)
Commander, U.S. Army Aviation and Missile Command MSG, Jane Q. Doe
ATTN: AMSAM--MMC--MA--NP 1234 Any Street
Redstone Arsenal, AL 35898 Nowhere Town, AL 34565
PART 1 -- ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS
PUBLICATION/FORM NUMBER DATE TITLE Organizational, Direct Support, And General
Support Maintenance Manual for Machine Gun, .50
TM 9--1005--433--24 16 Sep 2002 Caliber M3P and M3P Machine Gun Electrical Test Set
Used On Avenger Air Defense Weapon System
ITEM PAGE PARA-- LINE FIGURE TABLE
RECOMMENDED CHANGES AND REASON
NO. NO. GRAPH NO. * NO. NO.
1 WP0005 2 Test or Corrective Action column should identify a different WP number.

PG 3
* Reference to line numbers within the paragraph or subparagraph.

TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/ SIGNATURE
AUTOVON, PLUS EXTEN-
SION
MSG, Jane Q. Doe, SFC 788--1234
DA FORM 2028, FEB 74 REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED. USAPA V3.01
TO: (Forward direct to addressee listed in publication) FROM: (Activity and location) (Include ZIP Code) DATE
Commander, U.S. Army Aviation and Missile Command MSG, Jane Q. Doe
ATTN: AMSAM--MMC--MA--NP 1234 Any Street
8/30/02
Redstone Arsenal, AL 35898 Nowhere Town, AL 34565
PART II -- REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS
PUBLICATION NUMBER DATE TITLE
TOTAL NO.
PAGE COLM LINE NATIONAL STOCK REFERENCE FIGURE ITEM OF MAJOR
RECOMMENDED ACTION
NO. NO. NO. NUMBER NO. NO. NO. ITEMS
SUPPORTED
PART III -- REMARKS (Any general remarks or recommendations, or suggestions for improvement of publications and
blank forms. Additional blank sheets may be used if more space is needed.)
TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/AUTOVON, SIGNATURE

PLUS EXTENSION
MSG, Jane Q. Doe, SFC 788--1234

USAPA V3.01
BLANK FORMS
For use of this form, see AR 25--30; the proponent agency is ODISC4.
Commander, U.S. Army Aviation and Missile Command
ATTN: AMSAM-MMC-MA-NP
Redstone Arsenal, AL 35898
PUBLICATION/FORM NUMBER DATE TITLE
Aviation and Intermediate Maintenance
TM 55-1520-210-23-2 30 SEPT 1987
Instructions ARMY Model UH-1H/V/
EH-1H/X Helicopters

SION
PUBLICATION NUMBER DATE TITLE Aviation and Intermediate Maintenance
TM 55-1520-210-23-2 30 SEPT 1987 Instructions ARMY Model UH-1H/V/
EH-1H/X Helicopters
TOTAL NO.
RECOMMENDED ACTION
SUPPORTED

PLUS EXTENSION
USAPA V3.01
BLANK FORMS
TM 55-1520-210-23-2 30 SEPT 1987
EH-1H/X Helicopters

SION
EH-1H/X Helicopters
TOTAL NO.
RECOMMENDED ACTION
SUPPORTED

PLUS EXTENSION
USAPA V3.01
BLANK FORMS
TM 55-1520-210-23-2 30 SEPT 1987
EH-1H/X Helicopters

SION
EH-1H/X Helicopters
TOTAL NO.
RECOMMENDED ACTION
SUPPORTED

PLUS EXTENSION
USAPA V3.01
The Metric System and Equivalents
Linear Measure Liquid Measure
1 centiliter = 10 milliters = .34 fl. ounce

1 centimeter = 10 millimeters = .39 inch 1 deciliter = 10 centiliters = 3.38 fl. ounces
1 decimeter = 10 centimeters = 3.94 inches 1 liter = 10 deciliters = 33.81 fl. ounces
1 meter = 10 decimeters = 39.37 inches 1 dekaliter = 10 liters = 2.64 gallons
1 dekameter = 10 meters = 32.8 feet 1 hectoliter = 10 dekaliters = 26.42 gallons
1 hectometer = 10 dekameters = 328.08 feet 1 kiloliter = 10 hectoliters = 264.18 gallons
1 kilometer = 10 hectometers = 3,280.8 feet
Square Measure
Weights
1 sq. centimeter = 100 sq. millimeters = .155 sq. inch
1 centigram = 10 milligrams = .15 grain 1 sq. decimeter = 100 sq. centimeters = 15.5 sq. inches
1 decigram = 10 centigrams = 1.54 grains 1 sq. meter (centare) = 100 sq. decimeters = 10.76 sq. feet
1 gram = 10 decigram = .035 ounce 1 sq. dekameter (are) = 100 sq. meters = 1,076.4 sq. feet
1 decagram = 10 grams = .35 ounce 1 sq. hectometer (hectare) = 100 sq. dekameters = 2.47 acres
1 hectogram = 10 decagrams = 3.52 ounces 1 sq. kilometer = 100 sq. hectometers = .386 sq. mile
1 kilogram = 10 hectograms = 2.2 pounds
1 quintal = 100 kilograms = 220.46 pounds Cubic Measure
1 metric ton = 10 quintals = 1.1 short tons
1 cu. centimeter = 1000 cu. millimeters = .06 cu. inch
1 cu. decimeter = 1000 cu. centimeters = 61.02 cu. inches
1 cu. meter = 1000 cu. decimeters = 35.31 cu. feet
Approximate Conversion Factors
To change To Multiply by To change To Multiply by
inches centimeters 2.540 ounce-inches Newton-meters .007062

feet meters .305 centimeters inches .394
yards meters .914 meters feet 3.280
miles kilometers 1.609 meters yards 1.094
square inches square centimeters 6.451 kilometers miles .621
square feet square meters .093 square centimeters square inches .155
square yards square meters .836 square meters square feet 10.764
square miles square kilometers 2.590 square meters square yards 1.196
acres square hectometers .405 square kilometers square miles .386
cubic feet cubic meters .028 square hectometers acres 2.471
cubic yards cubic meters .765 cubic meters cubic feet 35.315
fluid ounces milliliters 29,573 cubic meters cubic yards 1.308
pints liters .473 milliliters fluid ounces .034
quarts liters .946 liters pints 2.113
gallons liters 3.785 liters quarts 1.057
ounces grams 28.349 liters gallons .264
pounds kilograms .454 grams ounces .035
short tons metric tons .907 kilograms pounds 2.205
pound-feet Newton-meters 1.356 metric tons short tons 1.102
pound-inches Newton-meters .11296
Temperature (Exact)
°F Fahrenheit 5/9 (after Celsius °C

temperature subtracting 32) temperature
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TM 55-1520-210-23-2

AVIATION UNIT AND INTERMEDIATE

This manual supersedes TM 55-1520-210-23-2, 20 February 1979, including all changes.

HEADQUARTERS, DEPARTMENT OF THE ARMY

Personnel performing operations, procedures,

Warnings, cautions, and notes are used to emphasize

An operating procedure, practice, etc., which,

An operating procedure, practice, etc., which, if not

An operating procedure, condition, etc., which

HANDLING HYDRAULIC FLUID (MIL-H-83282)

FUELING AND DEFUELING

Aviation Unit and Intermediate

ARMY MODEL UH-1H/V/EH-1H/X

DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited.

TM 55-1520-210-23-2, dated 30 September 1987, is changed as follows:

Remove Pages Insert Pages

A through E/(F blank) A through E/(F blank)

2. Retain this sheet in front of manual for reference purposes.

By order of the Secretaries of the Army:

NO. 15 } DEPARTMENT OF THE ARMY

Aviation Unit and Intermediate

ARMY MODEL UH-1H/V/EH-1H/X

DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited.

TM 55-1520-210-23-2, 30 September 1987, is changed as follows:

Remove pages Insert pages

A through E/(F blank) A through E/(F blank)

2. Retain this sheet in front of manual for reference purposes.

By Order of the Secretary of the Army:

NO. 14 } DEPARTMENT OF THE ARMY

Aviation Unit and Intermediate

ARMY MODEL UH-1H/V/EH-1H/X

TM 55-1520-210-23-2, 30 Spetmeber 1987, is changed as follows:

Remove pages Insert pages

Remove pages Insert pages

––––– 9-26.1 / (9-26.2 blank)

2. Retain this sheet in front of manual for reference purposes.

By Order of the Secretary of the Army:

Aviation Unit and Intermediate

ARMY MODEL UH-1H/V/EH-1H/X HELICOPTERS

TM 55-1520-210-23-2, 30 September 1987, is changed as follows:

Remove Pages Insert Pages

2. Retain this sheet in front of manual for reference purposes.

By Order of the Secretary of the Army:

Administrative Assistant to the

Aviation Unit and Intermediate

ARMY MODEL UH-1H/V/EH-1H/X HELICOPTERS

TM 55-1520-210-23-2, 30 September 1987, is changed as follows:

Remove Pages Insert Pages

9-93 and 9-94 9-93 and 9-94

2. Retain this sheet in front of manual for reference purposes.

By Order of the Secretary of the Army:

Administrative Assistant to the

Aviation Unit and Intermediate

ARMY MODEL UH-I1HNIEH-1HIX HELICOPTERS

DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited.

TM 55-1520-210-23-2, 30 September 1987, is changed as follows:

Remove pages Insert pages

By Order of the Secretary of the Army:

Administrative Assistant to the

Aviation Unit and Intermediate