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TECHNICAL MANUAL
AVIATION UNIT AND INTERMEDIATE
MAINTENANCE MANUAL
ARMY MODEL
AH-IP (PROD)
AH-1E (ECAS)
AH-1F (MODERNIZED COBRA)
HELICOPTERS
Approved for public release; distribution is unlimited.
HEADQUARTERS, DEPARTMENT OF THE ARMY
8 MAY 1980
PIN: 032466-016
TM 55-1520-236-23-2
C22
CHANGE HEADQUARTERS
DEPARTMENT OF THE ARMY
NO. 22 WASHINGTON, D.C., 30 April 1996
Aviation Unit and Intermediate
Maintenance Manual
ARMY MODEL
AH-1 P (PROD)
AH-1 E (ECAS)
AH-IF (MODERNIZED COBRA)
HELICOPTERS
DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited.
TM 55-1520-236-23-2, 8 May 1980, 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
i and ii i and ii
v and vi v and vi
xix and xx xix and xx
7-55 through 7-58 7-55 through 7-58
8-7 and 8-8 8-7 and 8-8
8-17 and 8-18 8-17 and 8-18
8-23 and 8-24 8-23 and 8-24
9-23 and 9-24 8-23 and 9-24
9-29 and 9-30 9-29 and 9-30
9-85 and 9-86 9-85 and 9-86
9-86.1/(9-86.2 blank) 9-86.1 and 9-86.2
9-97 and 9-98 9-97 and 9-88
9-101 through 9-104 9-101 through 9-104
9-111 and 9-112 9-111 and 9-112
10-5 through 10-8 0-5 through 10-8
10-11 and 10-12 0-11 and 10-12
10-13 through 10-16 0-13 through 10-16
11-28.1 and 11-28.2 1-28.1 and 11-28.2
11-29 through 11-32 1-29 through 11-32
11-79 and 11-80 1-79 and 11-80
16-7 and 16-8 16-7 and 16-8
TM 55-1520-236-23-2
C 22
Remove pages Insert pages
16-11 and 16-12 16-11 and 16-12
16-19 and 16-20 16-19 and 16-20
16-27 and 16-28 16-27 and 16-28
16-31 and 16-32 16-31 and 16-32
2. Retain this sheet in front of manual for reference purposes.
By Order of the Secretary of the Army:
DENNIS J. REIMER
General, United States Army
Chief of Staff
DISTRIBUTION:
To be distributed in accordance with DA Form 12-31-E, block no. 1149, requirements for
TM 55-1520-236-23-2.
TM 55-1520-236-23-2
C 21
CHANGE HEADQUARTERS
DEPARTMENT OF THE ARMY
NO. 21 WASHINGTON, D. C., 31 October 1995
Aviation Unit and Intermediate
Maintenance Manual
ARMY MODEL
AH-1P (PROD)
AH-1E (ECAS)
AH-1F (MODERNIZED COBRA)
HELlCOPTERS
DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited
TM 55-1520-236-23-2, 8 May 1980, 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
i through vi i through vi
vi.1 /(vi.2 blank) vi.1 and vi.2
viii.1/(viii.2 blank) viii.1/(viii.2 blank)
ix and x ix and x
x.1/(x.2 blank) x.1/(x.2 blank)
xi and xii xi and xii
------ xii.1/(xii.2 blank)
xvii and xviii xvii and xviii
xviii.1/(xviii.2 blank) xviii. 1 and xviii.2
xix through xxi/(xxii blank) xix through xxii
7-59 and 7-60 7-59 and 7-60
8-41 through 8-44 8-41 through 8-44
------ 8-44.1 through 8-44.7/(8-44.8 blank)
2. Retain this sheet in front of manual for reference purposes.
U R G E N T
TM 55-1520-236-23-2
C21
By Order of the Secretary of the Army:
DENNIS J. REIMER
Genera/, United States Army
Chief of Staff
DISTRIBUTION:
To be distributed in accordance with DA Form 12-31-E, block no. 1149, requirements for
TM 55-1520-236-23-2.
TM 55-1520-236-23-2
C 20
CHANGE HEADQUARTERS
DEPARTMENT OF THE ARMY
NO. 20 WASHINGTON, D.C., 15 December 1994
Aviation Unit and Intermediate
Maintenance Manual
ARMY MODEL
AH-1 P (PROD)
AH-1E (ECAS)
AH-1F (MODERNIZED COBRA)
HELlCOPTERS
DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited
TM 55-1520-236-23-2,8 May 1980, 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
V and vi v and vi
vi.1/(vi.2 blank) vi.1/(vi.2 blank)
vii and viii vii and viii
viii.1/(viii.2 blank) viii.1/(viii.2 blank)
ix and x ix and x
x.1/(x.2 blank) x.1/(x.2 blank)
xi and xii xi and xii
xix and xx xix and xx
9-15 through 9-18 9-15 through 9-18
9-83 and 9-84 9-83 and 9-84
9-84.1 /(9-84.2 blank) 9-84.1 /(9-84.2 blank)
9-85 and 9-86 9-85 and 9-86
9-94.1 and 9-94.2 9-94.1 through 9-94.5/(9-94.6 blank)
B-11 and B-12 B-11 and B-12
B-12.1/(B-12.2 blank) B-12.1 and B-12.2
B-19 and B-20 B-19 and B-20
B-25 and B-26 B-25 and B-26
C-3 and C-4 C-3 and C-4
2. Retain this sheet in front of manual for reference purposes.
TM 55-1520-235-23-2
C20
By Order of the Secretary of the Army:
GORDON R. SULLIVAN
Official: General, United States Army
Chief of Stalf
Administrative Assistant to the
Secretary of the Army
07664
DISTRIBUTION:
To be distributed in accordance with DA Form 12-31-E, block no. 1149, requirements for
TM 55-1520-236-23-2.
TM 55-1520-236-23-2
TM 55-1520-236-23
TM 55-1520-236-23-2.
1989
TM 55-1520-236-23-2
TM 55-1520-236-23-2
TM 55-1520-236-23-2
TM 55-1520-236-23-2
1983
1982
1980
TM 55-1520-236-23-2
TECHNICAL MANUAL HEADQUARTERS
DEPARTMENT OF THE ARMY
No. 55-1520-236-23-2 WASHINGTON, D.C., 8 May 1980
Aviation Unit and Intermediate
Maintenance Manual
ARMY MODEL
AH-1P (PROD)
AH-lE (ECAS)
AH-1F (MODERNIZED COBRA)
HELICOPTERS
NOTE
This manual is printed in five volumes, as follows:
TM 55-1520-236-23-1, consisting of Table of Contents, Preface Chap-
ters 1 through 6.
TM 55-1520-236-23-2, consisting of Table of Contents. Chapters 7
through 17. Appendix A through C.
TM 55-1520-236-23-3, consisting of Table of Contents, Appendix D
through G, and Index.
TM 55-1520-236-23-4, consisting of Table of Contents, FO-1 thru
FO-142.
TM 55-1520-236-23-5, consisting of Table of Contents, FO-143 (Sheet
1 of 28 through Sheet 28 of 28) through FO-145.
The Preface, Appendices and Index are applicable to all volumes.
*This manual together with TM 55-1520-236-23-1, 8 May 1980, TM 55-1529-236-2.3-3
8 May 1980, TM 55-1520-236-23-4, 8 May 1980, and TM 55-1520-236235, 31 July
1990, supersedes TM 55-1520-236-23-1, 30 June 1977 and TM 55-1520-236-23-2,
30 June 1977.
Change 16
WARNING PAGE TM 66-1620-236-23
WARNING
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 shall be used for the following conditions:
STARTING ENGINE
Starting and Operation
of the helicopter will be performed only by
authorized personnel in accordance with AR 95-1.
HIGH VOLTAGE
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.
LASER LIGHT
The AIM-1/EXL laser beam is dangerous and can cause blindness if
it enters the eye either directly or reflected from a shiny surface.
Ensure that the laser protective cover is kept over the emitter and
that the AIM power switch is off at all times when the laser is not
in use. The laser shall be used only in controlled areas by qualified
personnel. Night goggles are required during operation and
boresight procedures.
Change 19 a
TM 55-1520-236-23 WARNING PAGE
RADIATION HAZARD
Self-luminous dials contain radioactive materials.
If such an instrument is broken or becomes unsealed, avoid personal contact.
Use forceps or gloves made of rubber or polyethylene to pick up contaminated material.
Place material and gloves in a plastic bag.
Seal bag and dispose of it as radioactive waste
in accordance with AR 755-15 and TM 3-261 (TB 43-0108).
Repair procedures shall conform to requirements in AR 700-52.
DANGEROUS CHEMICALS
Exposure to high concentrations of fire extinguishing agents
can cause severe irritation of eyes and nose.
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.
Use solvents or chemicals in a well ventilated area.
Do not inhale vapors or allow to come in contact with skin or eyes.
Observe proper fire prevention rules.
NOISE LEVEL
Sound pressure levels in the helicopter during some
operating conditions exceed the Surgeon Generals hearing
conservation criteria as defined in TB MED 251.
Hearing, protection devices, such as the aviator helmet or
ear plugs, are required to be worn by all personnel in
and around the helicopter during its operation.
ASBESTOS FIBERS
Avoid creating dust. Breathing asbestos dust
may cause serious bodily harm.
ARMAMENT
When working on, or near an armed helicopter, take all possible
precautions to avoid accidental firing of armament.
Personnel shall not occupy possible firing pattern in front of or up to
20 feet behind rocket pods.
Munitions shall be handled by authorized personnel only.
All weapons shall be dry-fired. Only dummy ammunition with smooth
cases like live ammunition shall be used.
b Change 19
WARNING PAGE TM 55-1520-236-23
JETTISON
All ground safety pins must be removed before flight.
Failure to do so will prevent emergency jettison of stores.
Jettison circuit may be activated with BAT switch OFF
and pilot WING STORES JTSN circuit breaker OPEN. For
positive deactivation of jettison circuit, open both
the PLT JTSN circuit breaker and the GNR JTSN circuit
breaker located in the pilots side console.
Serious injury can result from accidental ground jettison.
SANDING DUST
Sanding on reinforced Iarninated glass produces
fine dust that may cause skin irritations.
Observed necessary protective measures.
TRANSMISSION LEVELING
Do not attempt to level transmission with Jacks Only.
Hoist must be used in conjunction with jacks while lifting transmission.
EXTERNAL STORES
Prior to any helicopter maintenance functions that
require external stores be removed, JETTISON cartridge
shall be removed.
Remove jettison cartridges from pylon stores ejection
device prior to placing helicopter in a hangar, to prevent
injury to personnel and damage to equipment.
Exception: Removal is not necessary when helicopter is
to be placed in hangar for short-term, providing both
PLT JTSN and GNR JETSN circuit breakers in the pilots side
console are OPEN, and warning signs indicate that helicopter
has an armed jettison system.
CANOPY REMOVAL SYSTEM
Ground safety pins must be installed in
pilot and gunner arming firing handles.
of canopy removal system whenever the
helicopter is on the ground. Pins should
be installed by crew.
CLEANING HYDRAULIC COMPONENTS
The use of any alcohol in cleaning components which contact
hydraulic fluids is prohibited. Formation of a
polymeric residue can result, which could impair mechanical
operation of the component.
Change 12 c
TM 55-1520-236-23 WARNING PAGE
HANDLING HYDRAULIC FLUID (MIL-H-83282)
When handling hydraulic fluid (MIL-H-83282), Table 1-3, I t e m
61, observe the following:
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 them immediately with clear water.
If liquid is swallowed, do not induce vomiting; get im-
mediate medical attention.
Wear rubber gloves when handling liquid. If prolonged
contact with mist is likely, wear an appropriate respirator.
When fluid is decomposed by heating, toxic gases are
released.
EPOXY BASED ADHESIVE
Epoxy based adhesive, P/N EA934,
contains an asbestos filler which could
be inhaled or ingested during grinding,
cutting, or sanding operations on
cured epoxy material.
TOOLS
Use only chrome plated steel or unplated
steel tools for disassembly or reassembly
procedures described in this manual.
Use of cadmium or zinc plated tools
is not permitted.
GROUNDING
All aircraft parked outside will be grounded and bonded,
in accordance with FM 1-500, to the aerospace ground
equipment while servicing, i.e., fueling or defueling, arming
(ammunition or explosives), oxygen, hydraulic fluids or any
flammable liquids. Grounding is not necessary for aircraft
parked outside unless one of the above is being
accomplished.
d Change 12
WARNING PAGE
TM 55-1520-236-23
INSPECTION OF REMOVED COMPONENTS
When components are being remove from an aircraft, all
inspections required by the next phase maintenance
inspection must be accomplished prior to either immediate
re-use or storage. Upon installation, the component
will be inspected in accordance with the current
phase (either that phase the receiving aircraft is in or if
in between phase, the last phase performed). This will
ensure that a re-used component will not overfly any PM
inspections, and that it will be properly interfaced with
the receiving aircraft phase sequence.
Change 12 e/(f blank)
TM 55-1520-236-23
TECHNICAL MANUAL HEADQUARTERS
DEPARTMENT OF THE ARMY
NO. 55-1520-236-23 WASHINGTON, D. C., 8 May 1980
AVIATION UNIT AND INTERMEDIATE MAINTENANCE MANUAL
ARMY MODEL
AH-1P (PROD)
AH-1E (ECAS)
AH-1 F (MODERNIZED COBRA)
HELICOPTERS
REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS
You can help improve this manual. If you find any mistakes, or if you know of away to improve these procedures,
please let us know. Mail your letter or DA Form 2028 (Recommended Changes to Publications end Blank
Forms), or DA Form 2028-2 located in the back of this manual directly to: Commander, US Army Aviation and
Troop Command, ATTN: AMSAT-I-MP, 4300 Goodfellow Blvd., St. Louis, MO 63120-1798. A reply will be
furnished directly to you.
DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited.
TABLE OF CONTENTS
PARAGRAPH PAGE
VOLUME 1
CHAPTER 1 AIRCRAFT GENERAL
Section I Servicing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1-1
Section II Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28 1-41
Section Ill Handling, jacking, mooring, hoisting, and sling loading . . . . . . 1-30 1-45
Section IV Inspection requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-55 1-58
Section V Overhaul and retirement schedule . . . . . . . . . . . . . . . . . . . . . 1-58 1-87
Section VI Flight safety critical aircraft parts (FSCAP) program . . . . . . . . 1-59 1-89
CHAPTER 2 AIRFRAME
Section I Structural . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 2-1
Section II Fuselage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41 2-113
Section Ill Tailboom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-281 2-229
Section IV Wing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-335 2-245
Section V Deleted 2-352 2-258
CHAPTER 3 LANDING GEAR
Section 1 Landing Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3-1
Section II Skids/Struts (Not Applicable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
Section Ill Floats (Not Applicable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
Section IV Skis (Not Applicable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
Section V Brakes (Not Applicable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
CHAPTER 4 POWER PLANT
Section I Power plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 4-1
Section II Cooling system (Not Applicable) . . . . . . . . . . . . . . . . . . . . . 4-17
Change 22 i
TM 55-1520-236-23
PARAGRAPH PAGE
Section Ill Air induction system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24 4-18
Section IV Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39 4-36
Section V Oil system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-59 4-50.2
Section VI lgnition system (Not Applicable) . . . . . . . . . . . . . . . . . . . . . . . . . . 4-69
Section VII Power lever controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-98 4-69
Section Vlll Quick change assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-114 4-79
CHAPTER 5 ROTORS
Section I Main rotor system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 5-1
Section II Main rotor hub and blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 5-2.2
Section Ill Main rotor controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47 5-103
Section IV Tail rotor system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-72 5-138
Section V Tail rotor hub and blade assembly. . . . . . . . . . . . . . . . . . . . . . . . 5-79 5-141
Section VI Tail rotor hub and controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-89 5-148
Section VII Tail rotor blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-107 5-170
Section VIII Tracking and balancing procedures . . . . . . . . . . . . . . . . . . . . . . . 5-114 5-181
CHAPTER 6 DRIVE TRAIN SYSTEM
Section I Drive train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 6-1
Section II Main drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 6-7
Section Ill Main transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20 6-24
Section IV Tail rotor drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-75 6-75
Section V Intermediate gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-96 6-86
Section VI Tail rotor gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-113 6-103
section Vll Transmission oil system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-129 6-120.1
VOLUME II
CHAPTER 7 HYDRAULIC AND PNEUMATIC SYSTEMS . . . . . . . . . . . . . . . 7-1
CHAPTER 8 INSTRUMENTS SYSTEM
Section I Instrument maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 8-1
Section II Engine instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10 8-7
Section Ill Flight instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-114 8-25
Section IV Navigation instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-185 8-36
Section V Miillaneous instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-198 8-38
Section VI Instrument panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-285 8-52
CHAPTER 9 ELECTRICALSYSTEMS
Section I Electrical systems maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 9-1
Section II Direct current power distribution system . . . . . . . . . . . . . . . . . . . 8-37 9-27
Section Ill Alternating current power distibution system . . . . . . . . . . . . . . 9-119 9-56
Section IV Starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-238 9-73
Section V Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-246 9-75
Section VI Lighting provisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-254 9-76
Section VII Miscellaneous equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-340 9-102
Section VIII Armament systems arcuitry . . . . . . . . . . . . . . . . . . . . . . . . . 9-412 9-122
ii Change 22
TM 55-1520-236-23
PARAGRAPH PAGE
Section IX Armament systems circuitry . . . . . . . . . . . . . . . . . . . . . . . . 9-442 9-154
Sction X Armament and fire control systems circuitry . . . . . . . . . . . 9-496 9-185
CHAPTER 10 FUELSYSTEMS
Section I Fuel systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 101
Section II Fuel cells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-73 10-17
CHAPTER 11 FLIGHT ONTROLS
Section I Flight controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1 11-1
Section II Flight controls components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-145 11-81
CHAPTER 12 UTILITY SYSTEM
Section I Fire detection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1 12-1
Section II Rain removal system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-9 12-4
Section Ill Defroster system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-10 12-4
section IV Low G Warning System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-11 12-5
CHAPTER 13 ENVIRONMENTAL CONTROL SYSTEM
Section I Heating systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1 13-1
Section II Air cooling systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-125 13-37
CHAPTER 14 HOIST AND WINCHES (Nonapplicable) . . . . . . . . . . . . . . . . . . 14-1 14-1
CHAPTER 15 AUXILIARY POWER PLANT (Not Applicable) . . . . . . . . . . . . . . 15-1 15-1
CHAPTER 16 MISSION EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-1 16-1
CHAPTER 17 EMERGENCY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-1 17-1
APPENDIX A REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
APPENDIX B MAINTENANCE ALLOCATION CHART . . . . . . . . . . . . . . . . . . . B-1
APPENDIX C AIRCRAFT INVENTORY MASTER GUIDE . . . . . . . . . . . . . . . . C-1
VOLUME Ill
APPENDIX D ILLUSTRATED FIELD MANUFACTURE LIST . . . . . . . . . . . . . . D-1
APPENDIX E STORAGE OF AIR CRAFT
Section I General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1 E-1
Section II Flyable storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-6 E-2
Section Ill Short term storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-10 E 4
Section IV lntermediate storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-14 E-11
APPENDIX F WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-1
APPENDIX G WIRE LISTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-1
lNDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index-1
VOLUME IV
FOLDOUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FO-1
VOLUME V
FOLDOUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FO-143
Change 21 iii
TM 55-1520-236-23
LIST OF lLLUSTUSTRATIONS
NUMBER PAGE
1-1 1-2
1-1.1 1-2.3
1-2
1-3
1-4
1-5 1-42
1-6 1-46
1-7 1-48
1-8 1-50
1-9 1-53
1-9.1 1-54.2
1-10 1-55
1-11 1-57
1-12 1-59
2-1 2-2.1
2-2 2-4
2-3 2-8
2-4 2-14
2-5 2-16
2-6 2-23
2-7 2-36
2-8 2-37
2-9 2-38
2-10 2-40
2-11 2-42
2-12 2-43
2-13 2-44
2-14 2-45
2-15 2-46
2-15.1 2-46.1
2-16 2-47
2-17 2-48
2-18 2-49
2-19 2-50
2-20 2-51
2-21 2-52
2-22 2-53
2-23 2-54
2-24 2-55
2-25 2-56
2-26 2-57
2-27 2-58
2-28 2-60
2-29 2-61
2-30 2-62
2-31 2-64
2-31.1 2-66.1
2-31.2 2-66.2
2-32 2-82
2-33 2-85
2-34 2-87
2-35 2-88
2-36 2-89
2-37 2-90
iv Change 16
TM 55-1520-236-23
LIST OF ILLUSTRATIONS (CONT)
NUMBER TITLE PAGE
2-38 2-91
2-39 2-92
2-40 2-96
2-41 2-100
2-42 2-101
2-43 2-102
2-43.1 2-104
2-44 2-104.1
2-45 2-105
2-46 2-106
2-46.1 2-106.1
2-47 2-107
2-48 2-111
2-48.1 2-112.2
2-49 2-115
2-50 2-123
2-51 2-126
2-52 2-132
2-53 2-139
2-54 2-142
2-54.1 2-144.3
2-55 2-146
2-56 2-152
2-57 2-154
2-57.1
2-154.1
2-58 2-155
2-58.1
2-158.1
2-59 2-161
2-60 2-164
2-61 2-167
2-62 2-169
2-63 2-170
2-64 2-176
2-65 2-178
2-66 2-179
2-67 2-180
2-68 2-183
2-69 2-188
2-70 2-190.1
2-70.1 2-190.2
2-70.2 2-191
2-71 2-192
2-72 2-196
2-73 2-199
2-74 2-200
2-75 2-202
2-76 2-204
2-77 2-206
2-77.1 2-206.1
Change 20 v
TM 55-1520-236-23
NUMBER PAGE
2-78 2-209
2-79 2-210
2-76.1 2-212.2
2-79.2 2-212.3
2-79.3 2-212.3
2-79.4 2-212.4
2-79.5 2-212.4
2-80 2-214
2-81 2-215
2-82 2-216
2-83 2-217
2-84 2-218
2-85 2-219
2-86 2-221
2-87 2-223
2-88 2-224
2-89 2-226
2-90 2-230
2-91 2-231
2-92 2-232
2-92.1 2-232.1
2-93 2-234
2-94 2-237
2-95 2-240
2-96 2-242
2-97 2-244
2-98 2-246
2-99 2-250
2-100 2-251
2-101 2-252
2-102 2-253
2-103 2-254
2-104 2-256
2-105
3-1 3-2
3-1.1 3-4.1
3-2 3-5
3-3 3-6
3-9
3-4.1 3-10.2
3-5 3-12
3-6 3-15
vi
TM 55-1520-236-23
LIST OF ILLUSTRATIONS (CONT)
NUMBER TITLE PAGE
3-7 Ground Handling Gear -assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
3-8 Ground Handling Gear Pump, P/N BU0953B-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
3-9 Ground Handling Gear Pump, P/N HP9902-41-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
3-10 Work Aid - Packing Nut Tool Removal/lnstallation - Fabrication Instructions . . . . . . . . . . . . 3-23
3-11 Ground Handling Wheels -Adjustment Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
4-1 Power Plant lnstallation - Right Side... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4-2 Power Plant installation -Left Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2.2
4-3 Engine Vibration Test Equipment Cabling Tiedown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4. - 4
4-3.1 Deleted
4-4 Engine installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4. .- 7
.
4-5 Engine Mount Fittings(Trunnions) installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 .
4-6 Damage Limits Aft - Engine Mount Fittings (Trunnions) and Bearings . . . . . . . . . . . . . . . . . 4-16
4-7 Particle Separator and FOD Screen Installation (Prior to Incorporation of
MW0 55-1520-236-50-12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
4-7.1 Centrisep Particle Separator Installation (After Incorporation of
MW0 55-1520-236-50-12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22.2
4-8 Particle Separator-Air Flow Diagram (Prior to Incorporation of
MWO 55-1520-236-50-12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
4-8.1 Centrisep Particle Separator Air Flow Diagram (After Incorporation of
MWO 55-1520-236-50-12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24.1
4-9 Particle Separator and FOD Screen Assemblies (Prior to incorporation of
MW0 55-1520-236-50-12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
4-10 Inlet Vane Reinforcement Doubler-Fabrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
4-10.1 Centrisep Particle Separator Repair/Replacement (After Incorporation of
MW0 55-1520-236-50-12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-30.1
4-11 FOD (Foreign Object Damage)Screen Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
4-12 Exhaust System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37
..
4-13 Engine Tailpipe Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38
..
4-14 Engine Deck and Firewall Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40
.
4-15 Exhaust System Components with lR Suppression Installation . . . . . . . . . . . . . . 4-41
4-15.1 Hot Metal Plus Plume Suppressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44.10 .
4-15.2 Outer Body Half -Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44.11
.
4-16 Repair Procedures -infrared Suppression System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-45
4-17 Exhaust System Components with lR Suppression -Installation . . . . . . . . . . . . . . . . 4-47
4-17.1 Suppressor Major Structural Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-50
4-18 Engine Oil System installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-50.1 .
4-18.1 ODDS Oil Separator and Oil Filter installation (MWO 1-l520-236-50-30) . . . . . . . . . . . . 4-50.3
4-19 Engine Oil System Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-54.3 ..
4-19.1 Oil Separator (Lubriclone) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-54.4 .
4-19.2 Deleted
4-19.3 Engine External Oil Fitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-54.7
..
4-20 Oil Tank lnstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-57
...
Change 21 vi.1
TM 55-1520-236-23
NUMBER PAGE
4-21 4-60
4-22 4-61
4-23 4-64
4-24 4-66
4-25 4-70
4-26 4-73
4-27 4-75
4-28 4-79
4-29 4-81
4-30 4-83
4-31 4-84
4-32 4-85
4-33
4-86
vi.2 Change 21
TM 55-1520-236-23
LIST OF ILLUSTRATIONS (CONT)
NUMBER TITLE PAGE
4-34 Starter Generator and Gas Producer Tachometer Generator . . . . . . . . . . . . . 487
4-35 Installation Engine Torque Transducer Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-89
4-36 Installation Fuel Drain and Bleed Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-91
4-37 Installation Starter Fuel Filter and Oil Bypass Valve Hose .. . . . . . . . . . . . . . . . .. . . . . . . 4-92
4-38 Installation Bleed Air Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-93
4-39 Installation Oil Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-95
Installation Heat Shield Tailpipe and Ejector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-40 . . . 4-96
4-41 Electrical Cable Installation Engine Left Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-97
4-42 Electrical Cable Installation Engine Right Side 4-100
5-1 Main Rotor System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... 5-2
5-2 Main Rotor Installation . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............... 5-4
5-3 Main Rotor System Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5-4 Tool Application Grip Lock Installation on Pitch Horn 5-7
54.1 Barrel Jack Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
5-4.2 Barrel Jack Work Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ................... 5-8.1
5-5 Tool Application Main Rotor Mast Nut Removal - Installation . . . . . . . . . . . . 5-8.2
5-6 Tool Application Alignment of Main Rotor Hub and Blade . . . . . . . . . . . . 5-9
5-7 Damage Limits Cone Set 5-11
5-8 Pitch Link Assembly Adjustments 5-13
5-9 Pitch Link Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ................... 5-14
5-10 Main Rotor Hub and Blade Assembly 5-16
5-11 Work Aid for Main Rotor Blade Bolt Removal Fabrication Instructions (AVIM) 5-17
5-12 Work Aid Application Main Rotor Blade Retaining Bolt Removal . . . . . . . . . . . . 5-18
5-13 B540 Main Rotor Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ................ 5-23
5-14 B540 Main Rotor Blade Authorized patch Area (AVIM) . . . . . . . . . . . . . . . 5-26
6-15 B540 Main Rotor Blade Trim Tab Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
5-16 K747 Main Rotor Blade (Part Numbers K747-003-205, -209, -303) . . . . . . . 5 - 3 0 . 1
5-16.1 K747 Main Rotor Blade (Part Numbers K747-003-309, -401, -403) 5-31
5-17 External Appearance Changes to K747-003-205/-309, -209/-401, and -303/-403
Blades Resulting from Improved Weight Retention Features . . . . . . . . . . . 5-32
5-18 Internal Modification Incorporated in K747-003-205/-309, -209/-401, and -303/-403
Blades for Improved Weight Retention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
5-19 Damage Limits - Root Fitting (K747 Blade) . . . . . . . . . . . 5 - 3 6 . 2
5-19.1 Damage Limits - Root Fittings - Part Number K747-083-1 (K747 Blade) 5-37
5-20 Damage Limits - Drag Strut (P/N K747-072-1) (K747 Blade) . . . . . . . . . . . . . . . . . . 5-38
5-20.1 Damage Limits - Drag Strut - Part Number K747-082-1 (K747 Blade) . . . . . . . . . 5-38.1
5-21 Inspection of K747-003-205/-309, -209/401, -303/403 Blades for Loss of Blade Weight
Retention Integrity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39
5-22 Proximity Limits for Patches - K747 Main Rotor Blades 5-40
5-23 Balance Adjustment for Patches (K747 Blade) . . . . . . . . . . . . . . . . 5-43
5-24 Root Fitting Assembly (K747-205, -209,-303 Blades) . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-52
5-24.1 Root Fitting Assembly (-309, -401,403 Blades) 5-52.1
5-24.2 Drag Strut Assembly (-309, -401,-403 Blades) . . . . . . . . . . . . . . . . . 5-52.3
5-25 Application of Skin Patch (K747 Blade) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-54
5-26 Curing Patch with Blade Repair Fixture (K747 Blade) . . . . . . . . . . . . . 5-56
5-27 Installation of Plug Patch (K747 Blade) 5-60
Change 20 vii
TM 55-1520-236-23
LIST OF ILLUSTRATIONS (CONT)
NUMBER TITLE PAGE
5-28 Typical Double Plug Patch Repair (K747 Blade) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-67
5-28.1 Application of Trailing Edge Doubler Patch (K747 Blade) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-68
5-28.2 Spline Repair (K747 Blade) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 5-71
5-28.3 Rebonding Delaminated Leading Edge Erosion Guard (K747 Blade) .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-72.1
5-28.4 Typical Repair of Fluorocarbon Erosion Guard Nicks and Cuts Using Kit, P/N 747-207 . . . . . . . . . . . 5-72.3
5-28.5 Application of Leading Edge Erosion Guard Patch (K747 Blade) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-72.5
5-28.6 Placement of Erosion Guard Replacement Part (Kit, P/N K747-206- 1 ) Method for Determining
Current Boot Material and Thickness (K747 Blade Series) . . . . . . . . . . . . . . . 5-72.7
5-28.7 K747 Blade Uralite Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ................5-72.10
5-28.8 Application of Vacuum Bagging Materials and Placement of Erosion Guard . . . . . . . . . 5-72.11
5-28.9 Repair Parts and Specimen Orientation (Kit, P/N K747-206) .. . . .. . . . . . . . . . . . . . . 5-72.15
5-28.10 Vacuum Bagging for Installation of Erosion Guard Repair Kit, P/N K747-206 . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-72.18
5-28.11 Improvised Mold for Casting a Small Section of Leading Edge Filler .. . . . . . . . . . . 5-72.21
5-28.12 Repair Parts Orientation Use for Removal and Installation of Stainless Steel Erosion Guard -
K747-003-303M03 and -303/-403 Field Modified Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-72.23
5-28.13 Preparation of K747-003-303/-403 Blade for Application of Sealant . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-72.24
5-28.14 Application of Sealant to Stainless Steel Guard for K747-003-303/-403 Blade . . . . . . . . . . . 5-72.26
5-28.15 Stainless Steel Erosion Guard Holding Fixture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-72.27
5-28.16 Masking for Paint Touch-Up After Installation of Kit K747-206 .. . . . .. . . .. . . . . . . . . . . . . . . . . 5-72.31
5-29 Main Rotor Hub Yoke Extension and Grip Assembly 5-72.35
5-30 Main Rotor Hub Yoke and Trunnion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............... 5-74
5-31 Main Rotor Bearing Wear Patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ 5-77
5-32 Damage Limits - Main Rotor Hub Yoke Extension . . . . 5-78
5-33 Damage Limits - Main Rotor Hub Bolt Holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-79
5-34 Damage Limits - Main Rotor Hub Yoke . . . . . . . . . . . . . . . . . . . .. . .. . . . . . . . . . . . . . . 5-81
5-35 Damage Limits - Main Rotor Hub Grip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-82
5-36 Damage Limits - Main Rotor Hub Strap Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-83
5-37 Damage Limits - Pitch Horn Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-85
5-38 Damage Limits - Main Rotor Hub Pitch Horn 209-010- 109-5
(Prior to Accomplishment of MWO 55-1520-244-50-6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . 5-86
5-38.1 Damage Limits - Main Rotor Hub Pitch Horn 209-010-109-109
(After Accomplishment of MWO 55-1520-244-50-6 and MWO 55-1520-244-50-9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-86.1
5-39 Damage Limits - Main Rotor Drag Brace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-87
5-40 Damage Limits - Main Rotor Hub Trunnion . . . . 5-88
5-40.1 Damage Limits - Hub Moment Spring Plate . . . . . . . . 5-88.1
5-40.2 Damage Limits - Hub Moment Spring Strap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-88.2
5-41 Damage Limits - Main Rotor Hub Elastomeric Bearing . . . . 5-89
5-42 Main Rotor Hub Yoke Chafing Pad Installation Dimensions . 5-90
5-42.1 Main Rotor Hub Yoke Buffer Installation - Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-90
5-43 Tool Application - Bearing Removal From Housing . . . 5-90.2
5-44 Tool Application - Bearing Removal From Grip . . . 5-92
5-45 Tool Application - Bearing and Seal Installation in Grip . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-93
5-46 Tool Application - Main Rotor Hub Trunnion Centering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-96
5-47 Tool Application - Grip Spacing Adjustment . . . . . . 5-97
5-48 Main Rotor Hub Grip Dust Seal to Radius Ring Dimension . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-99
5-49 Rotor Balancing Kit P/N 7A050 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-101
5-50 Tool Application - Main Rotor Hub Balancing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-102
5-51 Main Rotor Controls Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-104
5-52 Tool Application - Spline Plate Wear Measurement . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-107
5-52.1 Hub Moment Spring Suppon Assembly - Installation (MWO 55-1520-244-50-3 Incorporated) 5-108
viii Change 20
TM 5-1520-236-23
LIST OF ILLUSTRATIONS (CONT)
NUMBER PAGE
5-53 5-108.1
5-53.1 5-108.4
5-53.2 5-108.5
5-54
5-109
5-54.1
5-110.1
5-55 5-110.2
5-56 5-111
5-57 5-112
5-58 5-113
5-59 5-114
5-60 5-115
5-61 5-116
5-62 5-117
5-63 5-118
5-63.1
5-120.2
5-63.2 5-120.3
5-64 5-121
5-65 5-124
5-65.1 5-130.1
5-65.2 5-130.1
5-66 5-132
5-67 5-135
5-68 5-139
5-69 5-144
5-70 5-146
5-71 5-150
5-72 5-151
5-73 5-152
5-74 5-153
5-75 5-155
5-76 5-156
5-77 5-160
5-78 5-161
5-79 5-162
5-80 5-163
5-81 5-164
5-82 5-165
5-83 5-166
5-84 5-167
5-85 5-168
Change 21 viii.1/(viii.2 blank)
TM 55-1520-236-23
LIST OF ILLUSTRATIONS (CONT)
NUMBER PAGE
5-86 5-169
5-87 5-171
5-88 5-172
5-89 5-173
5-90 5-174
5-91 5-176
5-92 5-178
5-93 5-182
5-94 5-183
5-95 5-185
5-96 5-187
5-97 5-188
5-98 5-189
5-99 5-191
5-100 5-194
5-101 5-195
5-102 5-196
5-103 5-198
5-104 5-200
5-105 5-201
5-106 5-202
5-107 5-203
5-108 5-204
Change21 ix
TM 55-1520-236-23
NUMBER PAGE
5-109 5-205
5-110
5-111 5-208
5-112 5-209
5-113 5-210
5-114 5-212
5-115 5-214
5-116 5-215
5-117 5-217
6-1 6-4
6-2 6-5
6-2.1 6-6.3
6-2.2
6-3 6-8
6-4 6-10
6-5 6-11
6-6 6-13
6-7 6-14.1
6-7.1 6-17
6-8 6-18
6-9 6-20
6-9.1 6-20.1
6-9.2 6-20.2
6-9.3 6-20.2
6-9.4 6-20.3
6-10 6-25
6-11 6-27
6-12 6-29
6-13 6-32
6-14 6-34
6-15 6-41
8-15.1 6-44.1
6-16 6-45.1
6-16.1 6-46.1
6-16.2 6-46.2
6-16.3 6-46.3
6-17 6-47
6-18 6-50
6-19 6-53
6-20 6-56
6-21 6-58
6-22 6-59
6-23 6-62
6-24 6-64
6-24.1 6-65
6-24.2 6-66
6-25 6-66.1
6-26 6-68
6-27 6-69
6-28 6-73
6-29 6-76
6-30 6-77
6-31 6-81
x Change 21
TM 55-1520-236-23
LIST OF ILLUSTRATIONS (CONT)
NUMBER PAGE
6-32 6-82
6-33 6-85
6-34 6-87
6-35 6-88
6-35.1 6-90.2
6-36 6-91
6-37 6-99
6-38 6-103
6-39 6-105
6-40 6-106
6-41 6-108
6-42 6-115
6-43 6-116
6-44
6-119
6-45
6-120
6-45.1 6-120.2
6-45.2 6-120.2
6-46 6-126
6-47 6-127
6-48 6-129
6-49 6-131
6-50 6-132
6-50.1 6-132.2
6-51 6-135
6-52 6-137
6-53 6-138
6-54 6-139
6-55 6-140
Change 21 x.1/(x.2 blank)
TM 55-1520-236-23
NUMBER PAGE
6-56 6-141
6-57 6-142
6-58 6-143
6-59 6-144
6-60 6-146
6-61 6-147
6-62 6-148
6-63 6-149
6-64 6-149
6-65 6-150
6-66 6-151
6-67 6-153
6-67.1
6-154.3
6-67.2 6-154.4
6-68 6-155
6-69 6-158
6-70 6-159
7-1 7-3
7-2 7-8
7-3 7-9
7-4 7-28
7-5 7-29
7-6 7-31
7-7 7-37
7-8 7-41
7-9 7-42
7-10 7-43
7-11 7-46
7-12 7-47
7-13
7-49
7-14 7-52
7-15 7-53
7-16 7-55
7-17 7-59
7-18 7-61
7-19 7-62
7-20 7-63
7-21 7-66
7-22 7-67
7-22.1 7-68.4
Change 21 xi
TM 55-1520-236-23
NUMBER PAGE
7-22.2 7-68.6
7-23 7-73
7-24 7-75
7-25
7-80
7-26 7-81
7-27 7-81
7-28 7-84
7-29 7-92
7-30 7-95
7-31 7-98
7-32 7-98
7-33 7-99
7-34 7-102
7-35 7-104
7-36 7-105
7-37 7-107
7-38 7-108
7-39 7-109
7-40 7-111
7-41 7-117
7-42 7-144
7-43 7-149
8-1 8-2
8-2 8-26.3
8-2.1 8-26.4
8-2.2 8-26.5
8-3 8-42
8-4 8-43
8-5
8-44
8-5.1 8-44.4
8-5.2 8-44.5
8-5.3 8-44.6
8-6 8-49
9-1 9-2
9-2 9-3
9-3 9-4
9-4 9-6
xii Change 21
TM 55-1520-236-23
LIST OF ILLUSTRATIONS (CON'T)
NUMBER TITLE PAGE
9-5 9-8
9-6 9-10
9-7 9-13
9-8 9-13
9-9 9-18
9-10 9-20
9-11 9-23
9-12 9-66
9-13 9-80.1
9-14 9-80.1
9-14.1
9-15 9-81
9-15.1
9-16 9-82.1
9-17 9-82.1
9-17.1
9-17.2 9-88.7
9-17.3 9-88.8
9-88.11
9-17.4
9-88.11
9-17.5
9-17.6 9-88.12
9-88.16
9-17.7
9-17.8 9-88.17
9-17.9 9-88.19
Change 21 xii.1/(xii.2 bIank)
TM 55-1520-236-23
LIST OF ILLUSTRATIONS (CONT)
NUMBER TITLE PAGE
9-17.10 Position of Contacts in Latch Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-88 .23
9-17.11 Gunners Caution Panel Schematic Diagram 9-88.25
9-17.12 Gunners Caution Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-88.32
9-17.13 Gunners Caution Panel Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . 9-88.35
9-18 BHC Model RPM Warning Control.. . . . . . . . . . . . . . . . . . . . . . . . . . ...9-18.1
9-18.1 Saturn Model RPM Limit Warning Detector . . . . . . . . . . . . . . . . . . . . . . . . . 9-18.1
9-18.2 Cables for Alignment of RPM Limit Warning Detector . . , . . . . . . . . . . . . . . . . . 9-92.2
9-18.3 Bench Test Set Up for BHT 205-074-033-101 RPM Limit Warning Detector . . . . . . . . 9-93
9-19 Armament Equipment Location . . . . . . . . . . . . . . . . . . . . . . . . . . ...9-128
9-20 TOW Missile Launcher Positions . . . . . . . . . . . . . . . . . . . . . . . . . ...9-131
9-21 Wing Stores Armament Test Panel . . . . . . . . . . . . . . . . . . . . . . . . ...9-139
9-22 Wing Stores Armament Test Panel Schematic . . . . . . . . . . . . . . . . . . . . . 9-140
9-23 Armament Equipment Location . . . . . . . . . . . . . . . . . . . . . . . . . . ...9-155
9-24 TOW Missile Launcher Positions . . . . . . . . . . . . . . . . . . . . . . . . . ...9-164
9-25 DU Digital Display Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...9-173
9-26 LRU Fault Identification and Location Test . . . . . . . . . . . . . . . . . . . . . . .9-173
9-27 XM18 Minigun Circuitry Test Panel . . . . . . . . . . . . . . . . . . . . . . . . . .. 9-175
9-28 Wing Stores Circuitry Test Panel . . . . . . . . . . . . . . . . . . . . . . . . . . .. 9-180
9-29 TOW Missile Launcher Positions . . . . . . . . . . . . . . . . . . . . . . . . . . ..9-195
9-30 DU Digital Display Test, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...9-204
9-31 LRU Fault Identification and Location Test . . . . . . . . . . . . . . . . . . . . . .9-204
9-32 XM18 Minigun Circuitry Test Panel . . . . . . . . . . . . . . . . . . . . . . . . . .. 9-206
9-33 Wing Stores Circuitry Test Panel . . . . . . . . . . . . . . . . . . . . . . . . . . .. 9-211
10-1 Fuel Systems Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...10-3
10-2 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...10-4
10-3 Fuel Shutoff Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...10-9
10-4 Fuel Boost Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...10-12.1
10-4.1 Fuel Boost Pump Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...10-12.2
10-4.2 Work Aid for Fuel Pump Cartridge Removal . . . . . . . . . . . . . . . . . . . . . . . . . 10-12.3
10-5 Collapsing Forward Fuel Cell 10-22
10-6 Installed Forward Fuel Cell . 10-24
10-7 Collapsing Aft Fuel Cell..... . . . . . . . . . . . . . . . . . . . . . . . . . ..10-26
11-1 Collective Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...11-4
11-2 Pilot Collective Stick installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...11-8
11-3 Pilot Collective Stick Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...11-9
11-4 Bearing installation -Pilot Throttle Grip . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-14
11-5 Friction Lining Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...11-16
11-6 ThrottIe Lever Bearing installation . . . . . . . . . . . . . . . . . . . . . . . . . . . ...11-17
11-7 Collective Friction Tube Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...11-18
11-8 Pilot Collective Stick Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-20
11-9 Gunner Collective Stick installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-22
11-10 Gunner Collective Stick-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . ..11-25
11-11 Gunner Collective Stick Adjustment . . . . , . . . . . . . . . . . . . . . . . . . . . . . . 11-27
11-12 Force-And-Aft Cyclic Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...11-30
11-13 Lateral Cyclic Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...11-32
11-14 Work Aid for Rigging Swashplate. . . . . . . . . . . . . . . . . . . . . . . . . . . ...11-34
Change 18 xiii
TM 55-1520-236-23
LIST OF ILLUSTRATIONS (CONT)
NUMBER TITLE PAGE
11-15 Swashplate Rigging Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-35
11-16 Pilot Cyclic Stick Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-36
11-17 Pilot Cyclic Stick Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-40
11-18 Collar and Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-42
11-19 Pilot Cyclic Stick Friction Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-44
11-20 Gunner Cyclic Stick Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-46
11-21 Gunner Cyclic Stick Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-48
11-22 Fore-And-Aft Cyclic Jackshaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 11-51
11-23 Force Gradient Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-56.1
11-24 Tail Rotor Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-57
11-25 Tail Rotor Pedal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-62
11-26 Stability and Control Augmentation System (SCAS) . . . . . . . . . . . . . . . . . . 11-70
11-27 Stability and Control Augmentation System (SCAS) . . . . . . . . . . . . . . . . . 11-71
11-27.1 SCAS Transducer Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-74.2
11-28 Elevator Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-76
11-29 Elevator Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-79
11-30 Damage Limits - Fixed Length Flight Control Tubes and Links (Typical) . . . . . . . . . . 11-82
11-31 Control System Linkage Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-85
11-32 Damage Limits - Anti-Torque System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-95
11-33 Damage Limits - Elevator Control System . . . . . . . . . . . . . . . . . . . . . . . . . . 11-102
11-34 Damage Limits - Collective Control System . . . . . . . . . . . . . . . . . . . . . . . . . 11-104
11-35 Damage Limits - Cyclic Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-110
11-36 Flight Control System Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-118
11-37 Lateral Cyclic and Collective Controls Power Cylinder Support Installation . . . . . . . . . 11-119
11-38 Fore-And-Aft Cyclic Controls Power Cylinder Support Installation . . . . . . . . . . . . . 11-120
11-39 Damage Limits - Power Cylinder Supports . . . . . . . . . . . . . . . . . . . . . . . . . 11-121
12-1 Engine Fire Detection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-3
12-2 Low G Warning System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-5
12-3 Low G Warning Assembly 8A10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-9
12-4 Accelerometer 8A 111 . . . . . . . . . . . . . 12-10
12-5 Low G Warning Light/Switch 8DS25 . . . . . . . . . 12-12
12-6 Converter 8M1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-13
13-1 Environmental Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-3
13-2 Environmental Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-5
13-3 Environmental Control System Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . 13-7
13-4 Temperature Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-8
13-5 Temperature Control Valve Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-9
13-6 ECU Cooling Turbine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-12
13-6.1 ECU Cooling Turbine Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-12.1
13-7 Pressure Regulator and Shutoff Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-14
13-8 Pressure Regulator and Shutoff Valve Schematic . . . . . . . . . . , . . . . . . . . . . . 13-16
13-9 Blower Impeller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-18
13-10 Vent Air Control Valve - Installation . . . . . . . . . . . . . . . . . , . . . . . . . . . . . 13-21
13-11 Vent Air Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-22
13-12 Vent Air Control Valve Test Set-Up . . . . . . . . . . . . . . . . . . , . . . . . . . . . . . 13-24
13-13 Rain Removal Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-28
13-14 Rain Removal Thermal Switch-Installation . . . . . . . . . . . . . . . . . . . . . . . . . 13-30
13-15 Rain Removal Nozzle and Cleared Air Pattern . . . . . . . . . . . . . . . . . . . . . . . 13-31
13-16 Rain Removal Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-34
13-17 Limits Chart -Air Distribution Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-36
13-18 Tool Application - Teflon Lip Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . 13-38
16-1 Turret lnstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-4
16-2 Special Tools for Ejector Racks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-12
xiv Change 16
TM 55-1520-236-23
LIST OF ILLUSTRATIONS (CONT)
NUMBER TITLE PAGE
16-3 Outboard Ejector Rack Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-21
16-4 Ejector Rack Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-24
16-5 Outboard Ejector Rack Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-27
16-6 Inboard Ejector Rack Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-32
16-6.1 Contact Profusion Inside Breech . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-32.1
16-6.2 Wiring Harness Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-32.2
16-7 Inboard Ejector Rack Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-34
16-8 Wing Stores Pylon and Fairings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-35
16-9 AIM-1/EXL Laser Installation.... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-38
17-1 Canopy Removal System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-2
17-2 Damage Limits- Linear Shaped Charge Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-4
C-l Inventory Item List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3
F-l Wiring Identification Chart.... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-5
F-1.1 Symbols Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-6
F-1.2 Altimeter Vibrator System Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-45
F-2 External Power System Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-47
F-3 Starter System Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-49
F-4 Ignition System Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-50
F-5 Anticollision and Position Lights System Wiring Diagram . . . . . . . . . . . . . . . . . . . . F-51
F-6 Searchlight System Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-52
F-7 Engine De-Ice System Wiring Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-53
F-8 Fuel Valve and Oil Valve System Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-54
F-9 Fuel Boost System Wiring Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-55
F-10 Governor Control System Wiring System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-56
F-11 Idle Stop System Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-57
F-12 Force Trim System Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-58
F-13 Environmental Control System Wiring Diagram, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-59
F-14 Pitot Heater System Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-60
F-15 TOW Blower Cooling System Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-6l
F-16 Attitude Indicating System Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-63
F-17 FUEL Quantity Indicating System Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . F-64
F17.1 Turn and SIip Indicating System Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-65
F-18 Radio Blower Cooling System Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-65
F-l8 1 Armament Relay Lucatlon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-66
F-19 AC Electrical Load Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-67
F-20 Altimeter Vibrator System Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-83
F-21 External Power System Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-85
F-22 Starter System Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... F-87
F-23 Searchlight System Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-89
F-24 Engine De. Ice System Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-9O
F-25 Fuel Valve and Engine Oil Valve System Wiring Diagram . . . . . . . . . . . . . . . . . . . . . F-91
F-26 Fuel Boost System Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... F-92
F-27 Governor Control System Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-93
F-28 Idle Stop System Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....... F-94
F-29 Force Trim System Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-95
F-30 Environmental Control System Wiring Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-97
F-31 Pitot Heater System Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-98
F-32 TOWBlower Cooling System Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-99
F-33 Radio Blower Cooling System Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-100
F-34 Attitude Indicating System Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-1OI
F-35 Fuel Quantity Indicating System Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-102
F-36 Tachometer Indicating System Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-103
F-36.1 Centrisep Particle Separator Wiring Diagram (After Incorporation of
MW0 55-1520-236-50-12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-104
Change 19 xv
TM 55-1520-236-23
LIST OF ILLUSTRATIONS (CONT)
NUMBER TITLE PAGE
F-37 Turn and Slip Indicating System Wiring Diagram....................... F-105
F-38 Electrical Equipment Component Replacement Wiring Diagram . . . . . . . . . . . . . . . . F-106
F-38.1 Armament Relay Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-106.1
F-39 AC Electrical Load Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-108
F40 DC Electrical Load Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-109
F-41 Tachometer Indicating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-110
F-42 Pressure Indicating Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-121
F-43 Temperature Indicating Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-131
F-44 Attitude Indicating System (Equipment Location) . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-141
F-45 Turn and Slip Indicating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-147
F-46 Fuel Quantity Indicating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-151
F-47 Altimeter Vibrator System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-160
F-48 DC Generator Power System (Equipment Location) . . . . . . . . . . . . . . . . . . . . . . . . . F-167
F-49 Battery System (Equipment Location) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-177
F-50 External Power Provisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-184
F-51 DC Power Distribution and Interconnect Logic (Equipment Location) . . . . . . . . . F-189
F-52 AC Power System (Equipment Location) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-197
F-53 Stafier System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-207
F-54 IgnitionSystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-213
F-55 Interior Lights System (Equipment Location) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-221
F-56 Caution Lights System (Equipment Location) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-235
F-57 RPM Limit Warning System (Equipment Location) . . . . . . . . . . . . . . . . . . . . . . . . . . . F-259
F-58 Position Lights System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-269
F-59 Anticollision Light System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-276
F-60 Searchlight System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-279
F-61 Engine De-Ice System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-284
F-62 Fuel Valve and Engine Oil Bypass Valve Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-292
F-63 Fuel Boost System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-300
F-64 Governor Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-307
F-65 Idle Stop System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-316
F-66 Force Trim System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-322
F-67 Hydraulic Control System (Equipment Location) . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-331
F-68 Environmental Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-341
F-69 Pitot Heater System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-350
F-70 TOW Blower Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-354
F-71 Radio Blower Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-361
F-71.1 Centrisep Particle Separator Wiring Diagram (After Incorporation
of MWO 55-1520-236-50-12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-366.1
F-72 Universal Turret Subsystem (Equipment Location) . . . . . . . . . . . . . . . . . . . . . . . . . . F-367
F-73 TOW Missile Armament Subsystem (Equipment Location) . . . . . . . . . . . . . . . . . . . F-383
F-74 Fire Control System (Equipment Location) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-399
F-75 Wing Stores Armament Subsystem (Equipment Location) . . . . . . . . . . . . . . . . . . . . F-413
F-76 Electricd Equipment Component Replacment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-425
F-77 Electrical Equipment Component Replacement (After MWO 55-1520-236-50-4) . . . F-466
F-78 C-NITE Subsystem (Equipment Location) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-469
F-79 C-NITE Electrical Equipment Component Replacement . . . . . . . . . . . . . . . . . . . F-471
F-80 FLIR Subsystem Jumper Cable Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-472
FO- 1 Hydraulic System Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FO-1
FO-2 Hydraulic System Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FO-2
FO-3 Balancer and Strobex Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FO-3
FO-4 AC Electricl Load Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FO-4
FO-5 AC Electricd Load Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FO-5
FO-6 ACElecWicd Load Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FO-6
XVI Change 19
TM 55-1520-236-23
LIST OF ILLUSTRATIONS (CONT)
TITLE PAGE
NUMBER
FO-7 AC Electrical Load Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FO-7
FO-8 DC Electrical Load Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FO-8
FO-9 DC Electrical Load Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FO-9
FO-10 DC Electrical Load Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FO-10
FO-11 DC Electrical Load Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FO-11
FO-12 DC Electrical Load Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FO-12
FO-13 DC Electrical Load Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FO-13
FO-14 DC Electrical Load Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FO-14
FO-15 DC Electrical Load Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FO-15
FO-16 DC Electrical Load Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FO-16
FO-17 Battery System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FO-17
Change 16 xvi.1/(xvi.2 blank)
TM 55-1520-236-23
LIST OF ILLUSTRATIONS (CONT)
NUMBER TITLE PAGE
FO-18 Generator and DC Bus System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FO-18
FO-19 AC Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FO-19
FO-20 Interior Lights System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FO-20
FO-21
FO-21 Interior Lights System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FO.21.l Interior Lights System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FO.21.1
FO-22 Interior Lights System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FO-22
FO-22.1 Interior Lights System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FO-22.1
FO-23 Caution Lights System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FO-23
FO-24 Caution Lights System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FO-24
FO-25 RPM Limit Warning System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FO-25
FO-26 Hydraulic Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FO-26
FO-27 Armament Turret System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FO-27
FO-28 Armament Turret System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FO-28
FO-29 Armament Turret System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FO-29
FO-30 Armament Wing Stores System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FO-30
FO-31 Armament Wing Stores System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FO-31
FO-32 Armament Wing Stores System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FO-32
FO-33 Armament TOW Missile Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FO-33
FO-34 Armament TOW Missile Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FO-34
FO-35 Armament TOW Missile Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FO-35
FO-36 Armament TOW Missile Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FO-36
FO-37 Pressure Indicating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FO-37
FO-38 Tachometer Indicating Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FO-38
FO-39 Temperature Indicating Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FO-39
FO-40 RPM Limit Warning Test Set Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FO-40
FO-41 AC Electrical Load Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FO-41
FO-42 DC Electrical Load Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FO-42
FO-43 DC Electrical Load Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FO-43
FO-44 attery System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FO-44
FO-45 DC Generator Power System.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FO-45
FO-46 DCPower Distribution and Interconnect Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FO-46
FO-47 DC Power Distribution and Interconnect Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FO-47
FO-48 AC Power System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F O - 4 8
FO-49 Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F O - 4 9
FO-50 Interior Lights System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FO-50
FO.50.1 Interior Lights System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FO-50.1
FO-51 Interior Lights System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FO-51
FO-51.1 Interior Lights System . . . . . . . . . . . . . . . . . . . . . . FO-51.1
FO-52 Interior Lights System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FO-52
FO-53 Caution Lights System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FO-53
FO-54 Caution Lights System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FO-54
FO-55 RPM Limit Warning System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FO-55
FO-56 Anticollision and Position Lights System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FO-56
FO-57 Hydraulic Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FO-57
FO-58 Turret System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FO-58
FO-59 Turret System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FO-59
FO-60 Turret System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FO-60
FO-61 Turret System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. FO-61
FO-62 Turret System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... FO-62
FO-63 Turret System . . FO-63
FO-64 Turret System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FO-64
Change ll xvii
TM 55-1520-236-23
LIST OF ILLUSTRATIONS (CONT)
TITLE PAGE
NUMBER
FO-50 Interior Lights System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FO-50
FO-50.1 Interior Lights System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FO-50.1
FO-51 Interior Lights System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FO-51
FO-51 .1 Interior Lights System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FO-51.1
FO-52 Interior Lights System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FO-52
FO-53 Caution Lights System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FO-53
FO-54 Caution Lights System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FO-54
FO-54.1 Caution Lights System (After Incorporation of MWO 1-1520-236-50-30) . . . . . . . . .FO-54.1
FO-54.2 Caution Lights System (After Incorporation of MWO 1-1520-236-50-30) . . . . . . . . . FO-54.2
FO-54.3 Caution Lights System (After Incorporation of MWO 1-1520-236-50-30) . . . . . . . . . FO-54.3
FO-54.4 Caution Lights System (After Incorporation of MWO 1-1520-236-50-30) . . . . . . . . . FO-54.4
FO-55 RPM Limit Warning System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FO-55
FO-56 Anticollision and Position Lights System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FO-56
FO-57 Hydraulic Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FO-57
FO-58 Turret System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FO-58
FO-59 Turret System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FO-59
FO-60 Turret System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FO-60
FO-61 Turret System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FO-61
FO-62 Turret System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FO-62
FO-63 Turret System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . .FO-63
FO-64 Turret System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FO-64
FO-65 Wing Stores System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FO-65
FO-66 Wing Stores System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FO-66
FO-67 Wing Stores System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FO-67
FO-68 TOW Missile System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FO-68
FO-69 TOW Missile System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FO-69
FO-70 TOW Missile System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FO-70
FO-71 TOW Missile System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FO-71
FO-72 TOW Missile System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FO-72
FO-73 TOW Missile System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FO-73
FO-74 TOW Missile System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FO-74
FO-75 TOW Missile System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FO-75
FO-76 TOW Missile System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FO-76
FO-77 TOW Missile System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FO-77
xviii Change 21
TM 55-1520-236-23
LIST OF lLLUSTRATlONS (CONT)
NUMBER TITLE PAGE
FO-78 Pressure Indicationg Sytem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FO-78
FO-79 Temperature Indicating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FO-79
FO-80 Electrical Equipment Component Repalcement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FO-80
FO-81 Electrical Equipment Component Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FO-81
FO- 81.1 Electrical Equipment Component Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FO-81.1
FO-82 Electrical Equipment Component Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FO-82
FO-83 Electrical Equipment Component Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FO-83
FO-84 Electrical Equipment Component Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FO-84
FO-85 Electrical Equipment Component Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FO-85
FO-86 EIectrical Equipment Component Replacement. . . . . . . . . . . . . . . . . . . . .FO-86
FO-87 Electrical Equipment Component Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FO-87
FO-88 Electrical Equipment Component Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FO-88
FO-89 Electrical Equipment Component Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FO-89
FO-80 Electrical Equipment Component Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FO-80
FO-91 Pressure Indicating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FO-91
FO-92 Temperature Indicating Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FO-92
FO-93 Attitude Indicating Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FO-93
FO-94 DC Generator Power System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FO-94
FO-95 Battery System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FO-95
FO-96 DC Power Distrubution and Interconnect Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FO-96
FO-97 DC Power Distrubution and Interconnect Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FO-97
FO-98 AC Power System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FO-98
FO-99 Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FO-99
FO-100 Interior Lights Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FO-100
FO-100.1 lnterior Lights Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FO-100.1
FO-101 lnterior Lights Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FO-101
FO-101.1 Interior Lights Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FO-102
FO-102 Interior Lights System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FO-102.1
FO-102.1 Interior Lights System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FO-102.1
FO-103 Interior Lights System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FO-103
FO-104 Caution Lights System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FO-104
FO-105 Caution Lights System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FO-105
FO-106 RPM Limit Warning System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FO-106
FO-107 RPM Limit Warning System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FO-107
FO-108 Hydraulic Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FO-108
FO-109 Universal Turret Subsystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FO-109
FO-110 Universal Turret Subsystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FO-110
Change 21 xviii.1
TM 55-1520-236-23
LIST OF ILLUSTRATIONS (CONT)
NUMBER TITLE PAGE
FO-111 Universal Turret Subsystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FO-111
FO-112 Universal Turret Subsystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FO-112
FO-113 UniversalTurret Subsystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FO-113
FO-114 Universal Turret Subsystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FO-114
FO-115 Universal Turret Subsystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FO-115
FO-116 Universal Turret Subsytem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FO-116
FO-117 Universal Turret Subsystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FO-117
FO-118 Universal Turret Subsystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FO-118
FO-119 TOW Missile Armament Subsystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FO-119
FO-120 TOW Missile Armament Subsytem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FO-120
FO-121 TOW Missile Armament Subsystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FO-121
FO-122 TOW Missile Armament Subsystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FO-122
FO-123 TOW Missile Armament System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FO-123
FO-124 TOW Missile Armament Subsystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FO-124
FO-125 TOW Missile Armament . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FO-125
FO-126 FO-126
FO-127 FO-127
FO-128 FO-128
FO-129 FO-129
FO-130 FO-130
FO-131 FO-131
FO-132 FO-132
FO-133 FO-133
FO-134 FO-134
FO-135 FO-135
FO-136 FO-136
FO-137 FO-137
FO-138 FO-138
FO-139 FO-139
FO-140 FO-140
FO-141 FO-141
FO-142 FO-142
FO-143 FO-143
FO-144 FO-199
FO-145 FO-211
FO-146 FO-213
FO-147 FO-215
xviii.2 Change 21
TM 55-1520-236-23
LIST OF TABLES
NUMBER PAGE
1-1 1-3
1-2 1-4
1-3 1-10.1
1-4 1-19
1-5 1-24.1
1-6 1-24.1
1-7
1-8
1-9
1-10
1-11 1-24.2
1-11.1 1-54.1
1-12 1-89
2-1 2-13
2-2 2-17
2-3 2-26
2-4 2-69
2-5 2-248
4-1 4-43
4-1.1 4-44.4
4-1.2 4-44.8
4-2 4-51
4-2.1 4-54.5
4-3 4-67
5-1 5-34
5-1.1 5-45
5-1.2 5-49
5-2 5-58
5-3 5-140
5-4 5-218
6-1 6-2
6-1.1 6-6.2
6-1.2 6-6.4
6-2 6-80.1
6-3 6-122
7-1 7-11
7-2 7-15
7-3 7-20
7-4 7-34
7-4.1 7-68.3
7-4.2 7-68.6
7-4.3 7-68.7
7-5
7-71
Change 22 xix
TM 55-1520-236-23
LIST OF TABLES (CONT)
NUMBER PAGE
7-6
7-76
7-7
7-77
7-8
7-79
7-9 7-94
7-10 7-95
7-11 7-97
7-12 7-122
7-13 7-125
7-14
7-142
8-1 8-8
8-2
8-14
8-3 8-20
8-4 8-22
8-4.1 8-26
8-4.2 8-26.1
8-4.3 8-26.1
8-5 8-29
8-6 8-30
8-7 8-32
8-8 8-34
8-9 8-38
8-10 8-39
8-11 8-43
8-12 8-48
8-13 8-51
9-1 9-29
9-2 9-34
9-3 9-37
9-4 9-41
9-4.1 9-44.2
9-5 9-46
9-6 9-49
9-7 9-50
9-8 9-58
9-9 9-62
9-10 9-74
xx Change 21
TM 55-1520-236-23
NUMBER TITLE PAGE
9-11 Troubleshooting - Ignition System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-75
9-12 . 9-77
9-12.1 9-78.1
9-13 Troubleshooting - Console, Engine, Flight, and Tactical Instrument Lights . . . . . . . . . . . . . . . . 9-79
9-14 Pilot Caution Panel Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-83
8-15 Gunners Caution Panel Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-83
8-15.1 Troubleshooting Pilots Caution Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-88.2
9-15.2 Pilots Caution Panel Wiring Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-88.21
9-15.3 Gunners Caution Panel Fault Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-88.27
9-15.4 Troubleshooting - Gunners Caution Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-88.28
9-15.5 Gunners Caution Panel Waring Craft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-88.36
9-16 Troubleshooting -RPM Limit Warning System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-91
6-16.1 Troubleshooting -Skid Landing Light System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-94.1
9-16.2 Troublesgooting - ODDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-94.3
9-17 Troubleshooting -Position Lights System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-95
9-18 Troubleshooting - Anticollision light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-98
9-19 Troubleshooting - Searchligt System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-100
9-20 Troubleshooting - Transmission Oil Level Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-102
9-21 Troubleshooting - Engine De-Icing Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-103
9-22 Troubleshooting - Engine Oil Bypass valve Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-105
9-23 Troubleshooting - .Fuel Valve Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-106
9-24 Troubleshooting - Fuel Boost Pumps Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-107
9-25 Troubkshooting - Governor Control Circiutry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-108
9-26 Troubleshooting - Odle Stop Solenoild System Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-110
9-26.1
of MWO 55-1520-236-50-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-110.1
9-27 Troubleshooting -Force Trim System Circuity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-111
9-28 Troubleshooting -Hydraulic Control System Circuity . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-113
9-29 Troubleshooting -Environmental Control System Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-115
9-30 Troubleshooting -Pitot Heating System Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-117
9-31 Troubleshooting -TOW Blower Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-118
9-32 Troubleshooting -Radio Blower Wing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-121
9-32.1 Relay Matrix, Pilot in Control Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-122-1
9-32.2 Relay Matrix, Pilot in Fixed Forward Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-122.3
9-32.3 Relay Matrix, Gunner in Control Mode - HSS controlling Turret . . . . . . . . . . . . . . . . . . 9-122-5
9-32.4 Relay Matrix, Gunner in Control Mode- TSU Controlling Turret . . . . . . . . . . . . . . . . . . 9-122.7
9-32.5 Relay Matrix, Gunner Controlling TOW and Pilot Controlling Turret and Wing Stores
Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-122.9
9-32.6 Relay Matrix, TSU Acquisition of Target with Gunner or Pilot HSS Mode 9-122.11
9-32.7 Relay Matrix TSU Acquisition of Target with Gunner or Pilot HSS Mode 9-122.13
9-32.8 Relay Matrix, Gunner Jettison Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-122-15
Change 21 xxi
TM 55-1520-236-23
LIST OF TABLES (CONT)
NUMBER PAGE
9-32.9 9-122.16
9-33 9-143
9-34 9-145
9-35 9-150
9-36 9-152
9-36.1 9-156.1
8-36.2 9-156.3
8-36.3
9-156.5
9-36.4 9.156.7
9-36.5
9-36.6 9-156.11
9-36.7 9-156.13
9-36.8 9-156.14
9-37 9-176
9-38 9-177
9-39 9-181
9-40 9-183
9-41 9-207
9-42 9-208
9-43 9-212
8-44 9-214
10-1 Troubleshooting - Fuel System 10-1
11-1 11-1
12-1 Troubleshooting - Engine fire Detection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1
12-2 12-6
13-1 Troubleshooting-ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..13-1
13-2 Troubleshooting -Rain Removal Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-32
16-1 16-13
16-2 16-16
16-3 16-39
F-1 F-9
F-2 F-15
F-3 F-19
F-4 F-26
F-5 F-32
F-6 F-39
xxii Change 21
TM 55-1520-236-23
CHAPTER 7
HYDRAULIC AND PNEUMATIC SYSTEM
7-1. HYDRAULIC SYSTEM. controls by engaging the mechanical stops on the
servo-actuators and moving the cylinders through
NOTE direct mechanical coupling and internal irreversible
valving. When the pilot moves the servo-actuator
with no hydraulic pressure available, the fluid is
Refer to paragraph 7-145 for description
moved from one side of the actuator to the other
of hydraulic system for helicopters coded
and helicopters coded through flow passages in the actuator head. When
the feed-back forces exceed the pressure setting of
the differential relief valve, the valve will open,
7-2. DESCRIPTION HYDRAULIC
allowing a slight amount of fluid bypass through the
SYSTEM.
actuator pressure to actuator return passages. This
will warn the pilot of an overloading condition.
a. Two similar but separate hydraulic systems are
used to operate flight control power cylinders,
c. An emergency system is provided to furnish
stability and control augmentation system (SCAS)
hydraulic power to the collective hydraulic cylinder
servoactuators, the armament turret, and the TOW
when pressure is lost in System No. 1 and System No.
missile launcher actuator. A schematic diagram of
2. The emergency system consists basically of an
the hydraulic system for helicopters coded is electric driven pump, reservoir, solenoid valves, filter,
shown on figure FO-1 (foldout page FO-1 ). System
check valves, and pressure switch. The system is also
No. 1 and No. 2 are exactly alike as to their reservoirs,
used to power turret and wing, pylon armament
transmission driven pumps, and module assemblies
systems for boresight capability without hydraulic
which contain system filters, solenoid valves, relief
test stand. The description of the emergency system
valves and pressure switches for the caution panels.
in paragraph b is applicable to the cyclic control
Although both systems operate three dual servo
hydraulic cylinders and to the collective control
hydraulic cylinders in main rotor controls there is no
hydraulic cylinder except that when the emergency
connection between systems because they separate electric hydraulic pump switch is positioned to
passages and piston chambers inside each dual emergency hydraulic fluid under pressure will be
cylinder and valve assembly. Both systems and the
supplied to the collective cylinder. The remainder of
emergency system also have other hydraulic circuits
System No. 2 will be closed off by solenoid valves. The
and functions different and separate from each other.
primary purpose of the emergency systems is to
ensure that hydraulic power is furnished to the
b. An emergency system is provided to enable the collective hydraulic cylinder. The pilot cannot
pilot to execute a landing in the event that pressure is maintain collective c o n t r o l w i t h o u t h y d r a u l i c
lost in both System No. 1 and System No. 2. The pressure at the collective hydraulic cylinder.
emergency systems consists basically of a
pressurized lockout valve, a pressure operated d. In the event of a dual hydraulic system and
shutoff valve, solenoid operated shutoff valve, and starter/generator failure, the emergency electrical
check valves. See schematic diagram, figure FO-1 system, with a fully charged battery, is capable of
(foldout page FO-1). If the pressure in hydraulic supplying the essential bus loads for at least 17.8
System No. 1 should fall to 650 psig for any reason, minutes, with the emergency hydraulic pump being
the pressurized lockout valve and the pressure used during low speed flight prior to landing, and,
operated shutoff valve will close, locking 650 psig during landing operations not to exceed 5 minutes.
on both pressure and return sides of the servo-
actuators. This is done to ensure that the actuators 7-3. OPERATIONAL CHECK AND
remain full of oil and free of air. A small accumulator, TESTING HYDRAULIC SYSTEM.
1.0 cubic inch, is connected to the pressurized
lockout valve to make up normal leakage of the cyclic The following principles of operation of System No. 1,
actuators and to help maintain the 650 psig trapped System No. 2, and emergency system inform the
in the actuators. The pilot can then move the flight mechanic how each system functions prior to
7-1
TM 55-1520-236-23
performing testing and operational checks of (3) Both hydraulic modular units are equipped
hydraulic systems after maintenance requirements with quick disconnect couplings to allow ground
have been accomplished. operation with a portable hydraulic test stand (S2).
System operation with such a unit is the same as
a. Principles of Operation (typical for both described for normal operation, except that the
systems). reservoir and transmission-driven pump are not
being used. External dc power will also be required for
In normal operation of each system, hydraulic fluid is electrically operated valves, caution panels, and
supplied from its nonpressurized reservoir by gravity electric driven hydraulic pump when engine is not
feed and suction to a transmission-driven pump. The operating.
pump is a variable-displacement type with internal
pressure compensation, preset to provide 1500 (plus
b. Special Functions of System No. 1.
or minus 25) psi output pressure and 6.1 gpm flow
rate at operating rpm, according to system demands.
In addition to typical operation described in preceding
Fluid bypassed in pump, to regulate pressure and
paragraphs for both systems, hydraulic System No. 1
flow, is released through a line to the return side of
has the following special functions:
the hydraulic modular unit. Pump output is delivered
to the module and passes through the pressure filter.
(1) Tail rotor controls hydraulic cylinder. This is
A relief valve in the module guards the system against
a single hydraulic cylinder and servo valve assembly,
excessive pressure, relief valve is set to open at 1626
mechanically connected into control linkage to the
TO 2140 psi. The system solenoid valve is normally
tail rotor.
de-energized and open to the SYS PRESS outlet of the
modular unit but can be electrically energized to
(2) Yaw stability and control augmentation
bypass position by placing the HYD TEST switch to
system (SCAS) servo actuator. This circuit includes a
position marked for opposite system. A pressure
pressure line filter, a three-way, two-position
switch will cause the caution panel to light if modular
solenoid valve, and an electro-hydraulic servo
unit outlet pressure decreases (at 600 TO 400 psi).
actuator connected in the tail rotor control linkage.
(1) B e y o n d t h e m o d u l a r u n i t , f l u i d u n d e r
c. Special Functions of System No. 2.
pressure is delivered through tubes and hoses to
three dual hydraulic servo cylinders in main rotor
In addition to typical operation described for both
cyclic and collective control systems. Fluid flows into
systems in paragraph 7-2, hydraulic System No. 2 has
and out of one functional half of each dual cylinder
the following special functions:
when its servo control valve is moved mechanically by
linkage from a control stick, causing the cylinder
(1) A r m a m e n t s y s t e m h y d r a u l i c p o w e r
piston rod to make corresponding movements of
provisions (figures 7-1, 7-2, and FO1). This circuit
linkages to the main rotor. The cylinder valves also
provides pressure and return hydraulic lines to
have internal functions which tend to prevent
couplings where the M28A1E2 armament turret
feedback of motion from the rotor to the control stick.
hydraulic system is connected. The pressure line
Either system alone can operate the cylinders, but the
includes a two-way, two-position solenoid shutoff
dual (or tandem) arrangement is used for added safety
valve, controlled by the armament panel MASTER
of operation.
ARM switch, a directional flow check valve, and a
bypass with a check valve to relieve pressure when
(2) Fluid is returned from power cylinders and solenoid is off. The return line has a directional flow
other units through external lines to the SYS RET inlet check valve. A bypass line with a relief valve is
of the module, to pass through the return filter. installed around the flow check valve in the pressure
Normal return flow from module to reservoir is line.
through a hose connected on the quick-disconnect
coupling which is at other times used to connect (2) P i t c h a n d r o l l s t a b i l i t y a n d c o n t r o l
ground test equipment, However, if this hose has not augmentation system (SCAS) actuators. Circuits are
been connected, a low pressure (45 psi) will open a provided for pitch and roll functions of stability
relief valve and allow flow through another line from augmentation system. Each of the two circuits
the module RES RET outlet to the reservoir BYPASS includes a pressure line filter, a three-way two-
inlet. position solenoid valve, and an electro-hydraulic
7-2
TM 55-1520-236-23
Figure 7-1. Hydraulic System (Sheet 1 of 5)
7-3
TM 55-1520-236-23
Figure 7-1.
7-4
TM 55-1520-236-23
Figure 7-1. Hydraulic System (Sheet 3 of 5)
7-5
TM 55-1520-236-23
Figure 7-1.
TM 55-1520-236-23
1. Module assembly 15. Module assembly
2. Relief valve 16. Check valve
3. Pump (system No. 2) 17. Pump (system No. 1 )
4. Lockout valve 18. Check valve
5. Check valve 19. Solenoid valve (directional SCAS actuator)
6. Flow regulator P/N 209-076-023-1 FSCM 16780 P/N 15355
7. Solenoid valve (lateral cyclic SCAS actuator) 20. Filter
P/N 209-076-023-1 FSCM 16780 P/N 15353 21. Accumulator assembly
8. Filter 22. Lockout valve
9. Solenoid valve (fore and aft SCAS actuator) 23. Solenoid valve (wing armament pylon)
P/N 209-076 -023-1 FSCM 16780 P/N 15353 P/N 7U7464
10. Filter 24. Solenoid valve (nose gun turret)
11. Reservoir assembly P/N 7U7464
12. Test connectors 25. Check valve
13. Relief valve 26. Servo actuator
14. Reservoir assembly 27. Servo actuator
209076-47-5B
Figure 7-1. Hydraulic System (Sheet 5 of 5)
servo actuator connected into the fore-and-aft or (b) E q u i p p e d w i t h 1 0 micron filter in
lateral cyclic control linkage. pressure and return lines through which all fluid
passes before leaving and returning to unit.
(3) Hydraulic provisions for left and right XM65
TOW missile launchers ejector racks are installed. (c) Capable of 2300 psig pressure and at
This circuit provides pressure and return hydraulic least 6 gpm flow rate.
lines to a hydraulic servo actuator mounted on each of
the TOW missile launcher racks. The master (d) Having a calibrated pressure gage of
armament switch controls the XM65 TOW missile 2500 psi minimum capacity.
launcher rack hydraulic servo actuator ON-OFF
solenoid valve. The two-way, two-position solenoid (e) Pressure and return lines equipped to
valve can be de-energized (turned off) by the gunner connect to both hydraulic systems for simultaneous
pilot override switch. operation.
d. Ground Testing of Hydraulic Systems with (2) Visually inspect entire hydraulic system of
Hydraulic Test Stand (S2). helicopter to make sure all lines and components are
secure and appear capable of operation. Obtain
The following ground operational check of the three access as follows:
hydraulic systems is to aid in troubleshooting or test
for proper functioning of system after maintenance. (a) Open left and right doors (8, figure 2-3).
Whenever possible hydraulic systems should be
pressurized simultaneously to avoid introducing air (b) Open left and right transmission cowls
into the unpressurized system. When this is not (11).
possible, avoid rapid control movement when
operating with a single pressurized system. (c) Remove left and right panels (l 7) attached
with cowl fasteners directly below wings at both
(1) Use hydraulic test stand (S2) or provide a sides.
similar hydraulic test stand conforming to the
following requirements:
(d) Remove panel door, from aft battery
compartment on right side of fuselage below tailpipe
fairing, for access to tail rotor contro power cylinder.
Ensure that fluid in hydraulic test stand is
the same type fluid as in the helicopter. (e) R e m o v e s c r e w - m o u n t e d p a n e l s f r o m
sides of fuselage for access to lines leading to
(a) T h o r o u g h l y c l e a n , a n d s e r v i c e w i t h armament hydraulic connections and stability
prescribed hydraulic fluid (C62) or (C61). augmentation system actuators.
7-7
TM 55-1520-236-23
1. Filler cap 6. Filter
2. Reservoir assembly 7. Pressure relief valve
3. Solenoid valve (system return) P/N 204-076 -504-3 8. Sight gage
FSCM 94641 P/N 1-U-1025-63 or 9. Emergency hydraulic pump package
FSCM 16780 P/N 130027-5 10. Pressure switch
4. Lockout valve (system No. 2)
5. Solenoid valve (system pressure) P/N 204-076 -504-3
FSCM 94641 P/N 1-U-1025-63 or
FSCM 16780 P/N 130027-5 209076-47-3C
Figure 7-2. Emergency (Electric Motor Drive) Hydraulic System
7-8 Change 3
TM 55-1520-236-23
21. Control valve lever
1. Nut and lock 11. Spring 22. Control tube (fore and aft cyclic)
2. Rod end bearing 12. Spring retaining nut 23. Swivel joint flange
3. Swashplate 13. Nut 24. Bolt
4. Collective lever 14. Boot 25. Special steel washer
5. Cylinder (collective) 15. Tube 26. Special steel washer
6. Control tube 16. Boot (bonded)
7. Control tube (lateral cyclic) 17. Cylinder (fore and aft cyclic) 27. Washer
8. Support 18. Support 28. Nut
9. Cylinder (Iataral cyclic) 19. Valve 29. Bearing housing nut
10. Base 20. Nut and bolt 30. 8earing housing
209001-8H
Figure 7-3. Dual Hydraulic Servo Cylinders Installation
7-9
(f) Remove cowling from right and left TOW flexible connections, to make sure hoses are not
pylons for access to hydraulic cylinders. pinched and that vibration does not tend to loosen
fittings.
(3) Prepare hydraulic test stand unit (S2) for
operation. Pressure relief valve set for 2100 psig (c) Work out air from systems by actuating
cracking pressure; pump set to provide at least 6 gpm cyclic stick, collective stick, and tail rotor control pedals
flow; pressure compensation set at 1475 TO 1525 psig. through at least ten full strokes. Some chatter in tail rotor
controls is normal with hydraulic test stand (S2). If air is
(4) On each of two hydraulic modular units eliminated satisfactorily, proceed to step e. If air is not
located above reservoirs, prepare ground test couplings eliminated, accomplish step (d).
by removing cap from pressure coupling and
disconnecting reservoir return hose from return (d) When air is not removed by accomplishing
coupling. Connect hydraulic test stand (S2) hoses to procedures in step (c), perform the following:
both modules.
1 . Disconnect collective cylinder (5, figure
WARING 7-3) from collective lever (4).
Verify that turret gun is unloaded. 2. Disconnect fore and aft cyclic cylinder (17)
from swashplate (3).
CAUTION
3. Disconnect lateral cyclic cylinder (9) from
swashplate (3).
Ensure main rotor tiedown is removed to
minimize possible contact of main rotor
4 . Disconnect control tube (22) from
hub components with each other in
bellcrank at lower end.
extreme positions during ground
operation with external power.
5. Disconnect control tube (7) from bellcrank
at lower end.
NOTE
6. Disconnect control tube (6) from bellcrank
The following procedure must be
at lower end.
followed whenever air is in the system. It
is the only way SCAS lines can be
CAUTION
purged.
(5) Remove main rotor tie-down. Apply 28 Volt Ensure that upper ends of cylinders (5,17
DC electrical auxiliary power (S12) unit to external power and 19) will not strike any object when
receptacle at left side of fuselage. On pilot console, set moved through full throw during
electrical control to INV main (to provide AC PWR). Set accomplishment of following steps.
switches to activate both hydraulic systems. On SCAS
control panel switch, PWR to on. After Go/No Go lights 7. Check hydraulic test stand (S2) to ensure
go out, engage pitch, roll and yaw the channels on (up). it is operating as described in step (6).
(6) Operate hydraulic test stand (S2), applying 8. Pushup on fore and aft cyclic control tube
pressure (1475 TO 1525 psig) to hydraulic systems for (22) and hold until cylinder (17) moves through full
at least 15 minutes. During this time, perform the throw. Pull down on tube (22) until cylinder (17) moves
following: through full throw. Repeat through ten full strokes.
(a) Observe all parts of systems for evidence 9. Move cylinder (5) and cylinder (9) through
of leakage, taking corrective action as necessary. See ten full strokes by same procedure outlined in step 8.
table 7-1 for maximum acceptable leakage.
10. Connect control tube (22) to bellcrank at
(b) Slowly cycle all controls to limits of stroke, lower end.
observing movement of hydraulic power cylinders.
Check that all moving parts have clearance so that there 1 1 . Connect control tube (7) to bellcrank at
is no fouling or binding. Give particular attention to lower end.
7-10 Change 18
TM 55-1520-236-23
1 2 . Connect control tube (6) to bellcrank at (a) Energize electrical system.
.Iower end
(b) Close CAUTION LTS circuit breakers.
1 3 . Connect collective cylinder (5) to
collective lever (4).
(c) With test unit pressure reduced to 0 psig,
cycle controls to lose residual pressure. Pilot NO. 1
1 4 . Connect fore and aft cyclic cylinder (l7)
HYDR PRESS, gunner HYDR PRESS #1, Pilot NO. 2
to swashplate (3).
HYDR PRESS, and gunner HYDR PRESS #2 caution
panel worded segments should be illuminated.
1 5 . Connect lateral cyclic cylinder (9) to
swashplate (3).
(d) With external hydraulic power applied,
(e) Reduce pressure in both systems to O slowly increase test unit pressure. Pilot No. 1 HYDR
psig. PRESS, gunner HYDR PRESS #1, Pilot NO. 2 HYDR
PRESS and gunner HYDR PRESS #2 caution panel
(7) Check operation of caution panel circuits as worded segments should extinguish at 700 TO 900
follows: psig.
Table 7-1. Maximum Allowable Leakage for Hydraulic System
Definitions:
D Dynamic Seal leakage
S Static Seal Leakage
S D Static leakage through dynamic seal
Drop 20 drops equal approximately one cubic centimeter
COMPONENT FUNCTION TYPE LEAKAGE RATE
SERVO Tandem piston D 2 drops/20 cycles
ACTUATORS
(Weep hole or S-D 4 drops/15 min.
Intersystem vent)
Rod Seal D 1 drop/20 full stroke cycles
Rod Seal S-D 1 drop/20 min.
End cap S 1 drop/20 cycles or 2 drops/day
Valve input D 1 drop/5 cycles
Valve input S-D 1 drop/5 min.
7-11
TM 55-1520-236-23
Table 7-1. Maximum Allowable Leakage for Hydraulic System (Cont)
Definitions:
D Dynamic Seal leakage
S Static Seal Leakage
S D Static leakage through dynamic seal
Drop 20 drops equaI approximately one cubic centimeter
COMPONENT FUNCTION TYPE LEAKAGE RATE
Servo ram D 1 drop/5 cycles
(Transducer)
Pressure switch S-D 1 drop/5 min.
Valve body S-D 1 drop/5 min.
(Weep holes)
PUMPS Output shaft D 8 drops/rein.
Output shaft S-D 1 drop/rein.
Housing (mating S 2 drops/day
surfaces
VALVES Body (weep hole) S 1 drop/5 cycles or 2 drops/day
Manual stem D 1 drop/20 cycles
Manual stem S-D 1 drop/15 min.
FITTINGS Flared or flareless S None
Compression seals S 1 drop/30 min. - lower rate if fitting is
readily accessible
7-12
TM 55-1520-236-23
Table 7-1. Maximum Allowable Leakage for Hydraulic System (Cont)
NOTES:
1. Components in a static condition, as in a parked helicopter, are allowed a maximum leakage of two drops per
seal or packing per day.
2. When the fluid escaping is of an insignificant quantity and will have no detrimental effect on helicopter
operation, and when correction of this slight leakage does not warrant the maintenance time involved, the
leakage is then termed allowable.
3. If fluid leakage is such that the hydraulic reservoir may be depleted or dangerously lowered
during normal operation, a fire hazard created, or the airworthiness of the helicopter otherwise compromised,
the leakage is termed excessive. Under certain circumstances, it may be possible to have enough components
with allowable leakages such that their combined leakage will come under the classification of excessive.
4. Leakage checks should not be immediately performed on helicopter hydraulic systems and cornponents that
have remained in a static unpressurized condition for an appreciable period of time. The systems should be
activated first and the components operated a nurnber of times, after which any hydraulic fluid should be wiped off
before marking leakage checks.
5. Where fluid dropping from a component may be directly observed, do not wipe surfaces but pressurize and
cycle the component until a drop falls free. Continue operating the component until another drop falls and
compare results with leakage criteria.
6. For tests requiring long period of time, and where fluid can drop, wipe the surface clean and dry but do not
use a solvent. Check for leakage after the system has operated or has been idle the required period of time.
7. Within one hour after helicopter shutdown, approximately 1 cubic inch of hydraulic fluid (volume of 204-076-012-
5 accumulator) will be added to system 2 reservoir. On start up, approximately 1 cubic inch of hydraulic fluid
(volume of 204-076-012-5 accumulator) will be removed from system 1 reservoir.
Change 12 7-13
TM 55-1520-236-23
(e) Slowly reduce pressure. Pilot NO. 1 HYDR System No. 2 cylinders. This fluid will be
PRESS, gunner HYDR PRESS #l, pilot NO. 2 HYDR displaced to the System No, 2 reservoir
PRESS, and gunner HYDR PRESS #2 caution panel which could overflow. Refer to table 7-3,
worded segments should illuminate at 600 TO 400 step 13.
psig.
(i) D e c r e a s e h y d r a u l i c t e s t s t a n d ( S 2 )
(8) Check operation of single systems as pressure to 0 psig.
follows:
(j) S h u t d o w n a n d d i s c o n n e c t e l e c t r i c a l
(a) Close HYDR CONT and CAUTION LTS auxiliary power unit (S12) from helicopter.
circuit breakers.
(9) Check emergency hydraulic system as
(b) Apply external hydraulic test stand (S2) follows:
pressure to System No. 1 and System No. 2 test
connectors. (a) C h e c k e m e r g e n c y h y d r a u l i c s y s t e m
reservoir, located in right side of fuselage, underwing
(c) Energize electrical system. for proper fluid level.
(d) While operating hydraulic test stand (S2) (b) Using electrical auxiliary power unit
at 1475 TO 1525 psig pressure, place HYD TEST (S12), engage EMERG HYDR PUMP circuit breaker.
switch (located on console) to SYS 1. Pilot NO. 2
HYDR PRESS and gunner HYDR PRESS #2 caution (c) Position pilot or gunner EMER HYDR
panel worded segments should illuminate. Pilot NO. 1 pump switch to boresight. Pilot and gunner green
HYDR PRESS and gunner HYDR PRESS #1 caution EMER HYD PUMP ON caution panel worded
panel worded segments should be extinguished. segments should illuminate.
(e) Operate cyclic, collective, and tail rotor (d) Check that collective cylinder is powered.
controls, checking for smooth and positive response.
(e) Engage LCHR Boresight switch and check
(f) On console, place HYD TEST switch to that the wing pylon actuators are powered.
SYS 2. Pilot NO. 1 HYDR PRESS and gunner HYDR
PRESS #1 caution panel worded segments should be (f) Place TOW ACQ/TRK/STOW switch to
illuminated. Pilot NO. 2 HYDR PRESS and gunner STOW position.
HYDR PRESS #2 caution panel worded segments
should be extinguished. Operate cyclic and collective (9) P l a c e M A S T E R A R M s w i t c h t o A R M
controls, checking for smooth and positive response. position.
NOTE (h) Position TURRET SELECT switch to BOTH
and check that the nose turret is powered.
System No. 2 does not provide boost
power for tail rotor controls. (i) Turn all switches to the OFF position and
check that the collective actuator is not powered. Pilot
and gunner green EMER HYDR PUMP ON caution
(g) Operate tail rotor controls. Tail rotor
panel worded segments should extinguish.
controls will lack hydraulic power and should require
more force than in normal operation.
NOTE
(h) Release HYD TEST switch. Refer to table 7-2 for emergency
hydraulic system operational switching
NOTE sequence.
Continued operation of the cyclic (j) Position pilot or gunner EMER HYDR
actuator on System No. 1 (with System PUMP switch to EMER. Pilot and gunner green EMER
No. 2 unpressurized), could result in the HYDR PUMP ON caution panel worded segments
hydraulic fluid being evacuated from the should illuminate. The collective actuator should be
7-14
TM 55-1520-236-23
TABLE 7-2.
7-15
TM 55-1520-236-23
powered. The turret and wing pylons should not be DC power from helicopter. Shutdown hydraulic test unit
powered. and disconnect hoses from couplings. Connect hoses
from reservoirs to return test coupling on modules.
(k) Remove filter bowls, drain fluid and check
filters for contamination and replace filter if required. (15) Install fuselage panels removed for access.
Torque filter bowls 100 TO 140 inch-pounds and secure Close cowling and compartment doors.
with Iockwire (Cl 37).
e. Operational Check of Hydraulic Systems
(l) Apply 1000 psig to both systems and bleed Utilizing Helicopter Power.
air from the systems by cycling all controls through full
travel a minimum of ten cycles. Perform ground runup operational check of hydraulic
Systems No. 1 and No. 2 and emergency hydraulic
(m) Reduce pressure in both systems to 0 psig. system as follows:
Shut down hydraulic test stand (S2).
(1) Pretest Procedure.
(I0) Test hydraulic relief valves as follows:
(a) Check hydraulic reservoir for proper fluid
(a) Disconnect System No. 2 from test unit. level. If required, using hydraulic fluid dispenser, (S1) fill
reservoir with hydraulic fluid (paragraph 7-6) (C61 or
(b) Slowly increase System No. 1 pressure C62).
until relief valve (located on module unit) opens. Check
that relief valve opens between 1626 and 2149 psig. (b) Check all ground test connections for
replacement of dust caps.
(c) Reconnect System No. 2 and disconnect
System No. 1 from the hydraulic test stand (S2). (c) Connect a 0 TO 3000 psig calibrated gage
(S13) to each system at the pressure ground test fittings.
(d) Repeat test procedures outlined in
preceding sub-step (b) for System No. 2. (2) Test. Utilizing helicopter power (TM
55-1526-236-10), perform the following:
(e) Reduce pressure in both System No. 1 and
No. 2 to 0 psig. Shut down hydraulic test stand (S2). (a) With the cyclic, collective, and directional
controls stationary, run-up helicopter power and main
(11) Using hydraulic fluid dispenser (S1), fill rotor is turning at 88 TO 98 percent.
reservoirs with clean hydraulic fluid (C61 or C62).
(b) Check pressure in both hydraulic Systems
(12) Perform operational checks of armament No. 1 and No. 2. Pressure should be 1475 T0 1525 psig.
hydraulic system in accordance with applicable
instructions outlined in the following step e and (c) Shut down engine. (TM 55-1520-236-10).
paragraph 9-500.
(13) Check filter bypass indicators on each NOTE
hydraulic modular unit. Replace filters as required. After
replacing any filters, operate hydraulic test stand (S2) See note 7, table 7-1.
to check for leaks (table 7-1) and replenish fluid in
system.
(d) Remove hydraulic pressure gage (S13).
NOTE
Before shut-down of operation on NOTE
hydraulic test stand, (S2) center cyclic
and place collective stick full down. Refer to note 7, table 7-1.
(14) On pilots SCAS control panel, switch (3) Wing Pylons and Gun Turret. Functional
power to OFF. Set lNV/OFF/STBY to OFF. Disconnect check wing pylon actuators and gun turret in
7-16 Change 18
TM 55-1520-236-23
accordance with procedures outlined in T M Premaintenance Requirements for
55-1520-236-10. Flushing Hydraulic System
(4) Operational Check of Emergency Condition Requirements
Hydraulic System. Perform operational check of
emergency hydraulic system as follows: Model AH-1S
(a) Run up helicopter. (TM 55-1 520-236-10). Part No. or Serial No. All
Special Tools None
(b) With the engine running at flight IDLE,
position HYD TEST switch to SYS 1. Pilot No. 2 HYDR Test Equipment None
PRESS and gunner HYDR PRESS #2 caution panel
worded segments should illuminate. Position pilot or Support Equipment (S1) (S2)
gunner EMER HYDR PUMP switch to EMER. Pilot and (S10)(S12)
gunner green EMER HYDR PUMP caution panel
worded segments should illuminate. Minimum Personnel Two
Required
(c) Position pilot and gunner EMER HYDR Consumable Materials (C62) (C112)
PUMP switches to OFF. (C137) (C61)
(d) Release HYD TEST switch. Special Environmental Dust free
Conditions well ventilated
(e) Shut down engine (TM 55-1 520-236-10). area
a. Test Equipment Requirements.
NOTE
Test equipment shall consists of a thoroughly clean
Refer to note 7, table 7-1. (S2) hydraulic test stand serviced with hydraulic fluid
(C61 or C62) and as follows:
(1) Be capable of producing pressures of 2300
7 - 4 . F L U S H I N G H Y D R A U L I C
psig with minimum flow rate of 6 g p m .
SYSTEM.
(2) Include a calibrated pressure gage with a
Prior to flushing the hydraulic system, functionally
minimum capacity of 2500 psig.
check the hydraulic test stand (S2) to ensure that it is
operating properly. Install new hydraulic filter
(3) Include a 10-micron absolute metal filter on
elements in the test stand for maximum fluid
the pressure line and a 10-micron absolute metal
filtration. Using hydraulic fluid dispenser (S1) fill the
filter on the return line.
hydraulic reservoir to capacity with clean, hydraulic
fluid (C61 or C62). Inspect pressure and return hoses
(4) Include provisions in the pressure and
on hydraulic test stand (S2) for cleanliness. Clean the return lines for connecting both System No. 1 and
hoses if required. Clean and flush the hydraulic
System No. 2 for simultaneous operation.
system as follows:
b. Prepare and test hydraulic systems as follows:
NOTE
NOTE
Systems must be flushed individually at
1000 psi. Flushing is required only if Immediately after disconnecting hoses.
system is rebuilt due to major damage or cap cylinder ports to prevent
if fluid has become contaminated. contamination of system.
7-17
TM 55-1520-236-23
(1) Disconnect hoses from cyclic and collective (10) Energize HYDR CONT circuit breaker.
cylinders. Connect hose ends together with
MS21902D4 and MS21902D6 unions. (11) Turn hydraulic test stand (S2) ON. Adjust
hydraulic test stand (S2) to sufficient pressure to
(2) Disconnect hoses from tail rotor control maintain 6 gpm minimum flow rate. Energize the
cylinder and (SCAS) servo actuators in the lateral, directional SCAS system solenoid valve. Flush
fore and aft, and directional control systems. Connect system for 5 minutes. Reduce pressure and shut
hose ends together with MS21916D5-4 reducers. hydraulic test stand (S2) OFF. De-energize the
directional SCAS system solenoid valve. Reconnect
(3) Disconnect hoses from left and right wing all System 1 hoses except those on the two cyclic
pylon servo actuators. Connect hose ends together actuators.
with MS21902D6 unions.
NOTE
(4) Deleted.
With all actuators bypassed, the lockout
valve isolates the cyclic actuators (650 to
850 psi is required to open the lockout
valve),
(12) Turn hydraulic test stand (S2) ON; adjust
outlet pressure to 800 TO 1000 psig and flush for a
Use extreme caution in handling filter minimum of 3 minutes. Reduce pressure and shut
element to prevent contamination hydraulic test stand (S2) off. Reconnect System 1
damage. hoses on the cyclic actuators.
(5) Remove filters and discard elements from (13) Disconnect hydraulic test stand (S2) from
four filter element bowls of hydraulic modular System No. 1 and connect to System No. 2 through
units (paragraph 7-46). Do not remove packings. ground test fitting in module assembly.
Immediately after removing filter elements,
reinstall bowls. Torque bowls 100 TO 140 inch- (14) Turn hydraulic test stand (S2) and
pounds. electrical auxiliary power unit (S12) ON. Adjust
hydraulic test stand (S2) pressure to maintain a flow
rate of 6 gpm. Energize the pitch and roll SCAS
Hydraulic Systems No. 1, No. 2 and system solenoid valves. Flush system for 5 minutes.
emergency system cannot be flushed at the Reduce pressure and shutoff hydraulic test stand
some time. (S2). De-energize pitch and roll SCAS system
solenoid valve. Reconnect pitch, roll and cyclic
(6) Connect hydraulic test stand (S2) to System actuator hoses.
No. 1 through ground test fittings (12, figure 7-1)
(located on service deck on right side of helicopter (15) Perform flushing operation as follows:
inside access door).
(a) Energize the following circuit breakers:
(7) Make a thorough visual inspection of
complete hydraulic system to ensure that all HYDR CONT
components and lines are securely attached and TURRET CONT
appear, capable of satisfactory operation before WPN CONT
continuing flushing. WPN FIRE
(8) When performing steps (9) thru (11), (b) Turn main inverter ON. MASTER ARM
observe all system lines and components for external switch to ARM position. TOW system TCP MODE
leakage. Take appropriate action to correct any SELECT switch ON (STBY/TOW or any of the four
leakage before proceeding. ARMED MODE positions. Turn LAUNCHER
ACTIVATE SWITCH in the ammo bay to either L/H or
(9) Connect external 28 Vdc electrical auxiliary R/H. This will open the hydraulic solenoid valve for
power unit (S12) to helicopter. the articulated pylons.
7-18 Change 5
TM 55-1520-236-23
(c) Turn electrical auxiliary power unit (S12) (c) With electrical auxiliary power unit (S16)
ON. connected, engage EMER HYDR PUMP circuit
breaker. Energize electrical auxiliary power unit (Sl2)
(d) T u r n h y d r a u l i c t e s t s t a n d ( S 2 ) O N . and move pilot or gunner EMER HYDR PUMP switch
Increase pressure to 800 TO 1000 psig and flush for to BORESIGHT position. Flush system for f i v e
a minimum of 5 minutes. minutes.
(e) Turn hydraulic test stand (S2) OFF. (d) Continue filling reservoir until all air is
purged and reservoir is full.
(f) Turn electrical auxiliary power unit (S12)
OFF. (e) Position pilot and gunner EMER HYDR
PUMP switches from BORESIGHT to OFF position.
(g) Move MASTER ARM switch to OFF
position. (f) Turn electrical auxiliary power unit (S12)
OFF.
(g) De-energize all circuit breakers.
Ensure that fluid in hydraulic test stand is (17) Provide a small container to catch oil when
the same type fluid as in the helicopter. disconnecting hoses after a flushing operation.
Remove dust caps from dual hydraulic cylinder ports.
(16) F i l l i n g a n d f l u s h i n g of emergency Reconnect hoses to collective dual hydraulic
hydraulic system. Fill and flush emergency hydraulic cylinders, wing pylon servo actuators, and turret.
system as follows:
NOTE
(a) Drain fluid from reservoir (2, figure 7-2)
Cyclic dual hydraulic cylinder lines may
(paragraph 7-9).
have residual pressure caused by lockout
valve and accumulator assembly.
(b) R e m o v e f i l l e r c a p f r o m t h e r e s e r v o i r
(figure 7-5) mounted on bulkhead at station 213.94 in
(18) Replace filter elements previously
the hydraulic compartment under right wing. Using removed. Torque filter bowls 100 TO 140 i n c h -
hydraulic fluid dispenser (S1), fill reservoir with clean
pounds and secure with Iockwire (Cl37).
hydraulic fluid (C61 or C62). Refer to paragraph 7-6
for servicing of reservoir.
(19) Using hydraulic fluid dispenser (S1), fill
System No. 1 and No. 2 reservoirs with clean
hydraulic fluid (C61 or C62) until all air is purged and
reservoirs are full. Refer to paragraph 7-6 for
servicing of reservoirs.
To prevent pump damage (running dry), (20) Bleed hydraulic system in accordance
engage pilot or gunner EMER HYDR with procedures outlined in paragraph 7-3.
PUMP switch to BORESIGHT position
with a momentary ON-OFF action until (21) Disconnect hydraulic test stand (S2) and
the pump is filled. electrical auxiliary power unit (S12) from helicopter.
7-19
TM 55-1520-236-23
7 - 5 . T R O U B L E S H O O T I N G
HYDRAULIC SYSTEM.
NOTE
The following list of conditions, tests or
inspections and corrective actions is
intended to aid in hydraulic system
troubleshooting. This guide should be
used with other sources of information
such as; (1) Hydraulic System Schematic
Illustration; (2) Electrical diagrams; and
(3) Operational Ground Test and other
detailed procedures in this section
Ensure that all normal operational checks
have been performed prior to using the
following table 7-3. Any malfunction not
listed requires assistance of next higher
maintenance level.
Table 7-3. Troubleshooting of Hydraulic System
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. Pilot No. 1 HYDR PRESS, pilot NO. 2 HYDR PRESS, gunner HYDR PRESS #1, and/or gunner HYDR PRESS
#2, caution panel worded segments reported being illuminated during normal operation.
STEP 1. Loss of fluid and pressure by leakage.
Locate and repair leaks; replace faulty lines, hoses, seals, or other parts. Service system as
required (paragraph 7-6).
STEP 2. Total loss of fluid in system.
Replace pump (paragraphs 7-25 and 7-29).
STEP 3. Other malfunction in system.
Perform operational check with hydraulic test stand (S2) (paragraph 7-3).
STEP 4. If pilot NO. 1 HYDR PRESS, pilot No. 2 HYDR PRESS, gunner HYDR PRESS #1, or gunner HYDR
PRESS #2 caution panel worded segments do not illuminate and system operates normally with hydraulic
test stand (S2), trouble may be in the pump circuit or defective pump.
Replace pump (paragraphs 7-25 and 7-29).
STEP 5. Pump pressure line restricted or check valve reversed.
Replace or correct installation of parts (paragraph 7-18).
7-20
TM 55-1520-236-23
Table 7-3. Troubleshooting of Hydraulic System (Cont)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
STEP 6. System actuators operate normally on hydraulic test stand (S2), but caution segment is
illuminated, caution circuit may be faulty or pressure switch faulty.
Replace pressure switch (figure 7-4) in hydraulic modular unit (paragraph 7-39).
STEP 7. Electric circuit malfunction.
Check and repair electrical circuit (paragraphs 9-8 through 9-13 and paragraph 9-374).
STEP 8. Caution panel light is illuminated and system actuators do not operate normally with hydraulic test
stand (S2), trouble may be in the hydraulic modular unit or beyond the hydraulic modular unit.
STEP 9. System solenoid valve staying at OFF position or faulty HYDR TEST switch.
Replace hydraulic modular unit (paragraphs 7-39 and 7-43). Repair electrical circuit (paragraphs
9-8 through 9-1 3) or replace switch (paragraphs 9-20 and 9-22).
STEP 10. System relief valve staying open or relieving at too low pressure.
Replace relief valve in hydraulic modular unit.
STEP 11. Internal leakage through a unit.
Isolate and replace defective unit.
2. (SCAS) actuator will not unlock from its center position.
STEP 1. Faulty wiring, switches or connections.
Refer to chapter 11 and TM 11-1520-236-20 or TM 11-1520-236-34, Troubleshooting Stability
and Control Augmentation System (SCAS).
STEP 2. Filter clogged.
Replace in line hydraulic filter (paragraph 7-79).
STEP 3. Restricted flow in pump suction line.
Inspect reservoir and lines; replace faulty parts (paragraphs 7-7 and 7-20).
3. Pilot NO. 1 HYDR PRESS, Pilot NO. 2 HYDR PRESS, gunner HYDR PRESS #1, or gunner HYDR PRESS #2
caution panel worded segments fail to illuminate when HYD TEST switch is at other system position.
STEP 1. Caution panel lamp or light indicating panel (caution panel) failed.
Replace lamp (paragraph 9-282) or light indicating panel (caution panel) (paragraphs 9-281 and
9-283).
7-21
TM 55-1520-236-23
Table 7-3. Troubleshooting of Hydraulic System (Cont)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
STEP 2. Pressure switch in hydraulic modular unit or wiring faulty.
Replace pressure switch (figure 7-4). Repair electrical circuit (paragraphs 9-8 through 9-13 and
paragraph 9-284).
STEP 3. System solenoid or electrical circuit faulty.
Repair electrical circuit (paragraph 9-284) or replace hydraulic modular unit (paragraphs 7-39
and 7-43).
STEP 4. Faulty HYD TEST switch.
Replace switch.
4. Filter element differential pressure indicators tripped.
STEP 1. Fluid temperature below 20 degrees F (-7 degrees C).
Operate until fluid temperature is normal, then reset indicators by pushing buttons in. If not again
tripped, no further action needed (figure 7-4) (paragraph 7-45).
STEP 2. Indicators tripped by unusual vibration or hydraulic modular unit being struck.
Check hydraulic modular unit for damage, reset indicators. If not again tripped, no further action
needed (figure 7-4).
STEP 3. Clogged filter elements.
Inspect and replace filter elements (paragraphs 7-46 and 7-50). Reset indicators (paragraph
7-45).
STEP 4. Defective indicator assembly.
Replace hydraulic modular unit (paragraphs 7-39 and 7-43).
5. Servo cylinders chatter when controls are moved. (Some chatter in tail rotor control cylinder is normal when
using hydraulic test stand (S2).
STEP 1. Air in system.
Cycle controls at least ten full strokes at normal operating pressure to work out air (paragraph
7-3).
STEP 2. Loose mounting bearing (9, figure 7-12) on dual hydraulic cylinder. Replace dual hydraulic cylinder
assembly (paragraphs 7-60 and 7-66).
7-22
TM 55-1520-236-23
Table 7-3. Troubleshooting of Hydraulic System (Cont)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
STEP 3. Any internal looseness in dual hydraulic cylinder assembly.
Replace dual hydraulic cylinder assembly (paragraphs 7-60 and 7-66).
6. Controls do not operate smoothly,
STEP 1. Servo valve on dual hydraulic cylinder is binding (requires more than 12 oz. force to operate valve).
Check to ensure all bolts at servo head linkage are free to rotate by finger pressure. Replace dual
hydraulic cylinder assembly (paragraph 7-60 and 7-66).
STEP 2. Incorrect bolts inserted.
Check the valve linkage bolts. Install correct bolts.
7. Excessive feedback in operation of controls.
STEP 1. Air in servo cylinders.
Cycle controls at least ten times to work out air (paragraph 7-3).
STEP 2. Loose or worn bearing housing mounting studs.
Tighten or replace mounting studs.
8. Hydraulic power inadequate or lacking at couplings for armament turret or TMS Iaunchers (other indications
normal).
STEP 1. Faulty circuit to armament couplings, or System No. 2 pressure is marginally low.
Check operation with hydraulic test stand (S2) (paragraph 7-3).
STEP 2. No improvement when using hydraulic test stand (S2) for normal system pressure, or armament,
or TMS solenoid valve inoperative.
Replace solenoid valve (paragraphs 7-117 and 7-1 25) or repair electrical circuit (paragraphs 9-8
through 9-13 and paragraph 9-374),
STEP 3. Restriction in test connectors (12, figure 7-1) or lines.
Replace defective parts (paragraphs 7-18 and 7-22).
STEP 4. Operation becomes normal on hydraulic test stand (S2), or System No. 2 pump or lines defective.
Replace faulty lines (paragraphs 7-18 and 7-22) or replace pump (paragraphs 7-25 and 7-29).
7-23
TM 55-1520-236-23
Table 7-3. Troubleshooting of Hydraulic System (Cont)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
9. System No. 2 reservoir overflows.
NOTE
Within one hous after helicopter shut down approximately 1 cubic inch of hydraulic
fluid from accumulator, P/N: 204-076 -012-5 will be added to system 2. On start up
approximately 1 cubic inch of hydraulic fluid will be removed from system 1 reservoir
to fill accumulator P/N 204-076-012-5.
STEP 1. Repeated cyclic inputs with hydraulic system test switch in System No. 1 position.
Release hydraulic system test switch. Actuate cyclic stick, approximately ten full cycles, to
remove air from actuators (paragraph 7-3), Replenish fluid in reservoir (paragraph 7-6).
10. Either left or right TOW pylons inoperative or sluggish. (System No. 2 operation otherwise normal.)
STEP 1. Electrical wiring faulty.
Repair electrical circuit (paragraphs 9-8 through 9-13 and paragraph 9-374).
STEP 2. Faulty electrical circuit to actuator.
Repair electrical circuit (paragraphs 9-8 through 9-13 and paragraph 9-374).
STEP 3. TOW solenoid valve stuck closed.
Replace solenoid valve (paragraphs 7-117 and 7-125).
STEP 4. Check SECU and TOW system.
11. Only one TOW pylon inoperative or operates sluggish. (Other TOW pylon operates normal.)
STEP 1. Restricted hydraulic fluid in circuit of affected wing pylon servo actuator.
Inspect hoses and tubes; replace faulty parts (paragraph 7-16).
STEP 2. Faulty electrical circuit to affected wing pylon servo actuator.
Repair electrical circuit (paragraphs 9-8 through 9-13 and paragraph 9-374).
STEP 3. Defective armament wing pylon servo actuator.
Replace armament wing pylon servo actuator (paragraphs 7-128 and 7-142).
STEP 4. Check SECU and TOW system.
7-24
TM 55-1520-236-23
Table 7-3. Troubleshooting of Hydraulic System (Cont)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
12 Pylons do not remain in stowed position with TOW system OFF and hydraulic system operational.
STEP 1. Fault in electrical wiring.
Repair electrical circuit (paragraphs 9-8 through 9-13 and paragraph 9-374).
STEP 2. Faulty electrical circuit to pylon servo actuators.
Repair electrical circuit (paragraphs 9-8 through 9-13 and paragraph 9-374).
STEP 3. TOW solenoid valve stuck open.
Replace solenoid valve (paragraphs 7-117 and 7-125).
STEP 4. Check valve installed backwards or stuck open.
Reverse or replace check valve (figure FO-1).
STEP 5. Check SECU.
13 With hydraulic test stand (S2) and electrical power unit (S12) connected to helicopter and operating, and
with pilot and/or gunner EMER HYDR PUMP switch in BORESIGHT or EMER position, pilot and/or gunner
green EMER HYDR PUMP caution panel worded segments do not illuminate.
STEP 1. If collective controls are powered, check for a faulty panel lamp or light indicating panel (caution
panel).
Replace panel lamp (paragraph 2-282) or replace light indicating panel (caution panel)
(paragraphs 9-281 and 9-283).
STEP 2. If collective controls are powered, check for faulty electrical wiring.
Repair wiring (paragraphs 9-8 through 9-13 and paragraph 9-284).
STEP 3. If collective controls are powered, check for faulty pressure switch.
Replace pressure switch in hydraulic modular unit (figure 7-4).
STEP 4. If collective controls are unpowered and emergency electric motor driven pump package failed,
check for faulty wiring or switch.
Repair wiring (paragraphs 9-8 through 9-13), or replace switch (paragraphs 9-20 and 9-22), or
replace emergency electric motor driven pump package (paragraphs 7-32 and 7-36).
7-25
TM 55-1520-236-23
Table 7-3. Troubleshooting of Hydraulic System (Cont)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
14. With electrical power unit (S12) connected to helicopter and operating, and with pilot and/or gunner EMER
HYDR PUMP switch in BORESIGHT or EMER position, and pilot and gunner green EMER HYDR PUMP
caution panel worded segments illuminated, System No. 2 is non-operative and collective controls are
unpowered.
STEP 1. Faulty electrical wiring.
Repair wiring (paragraphs 9-8 and 9-13 and paragraph 9-374).
STEP 2. Pressure or return solenoid valve failed.
Replace pressure or return solenoid valve (paragraphs 7-97 and 7-107).
15. With electrical auxiliary power unit (S12) connected to helicopter and turned ON, pilot and/or gunner EMER
HYDR PUMP switch in EMER position, System No. 2 non-operative, wing pylons and/or nose turret are
powered when switches are engaged.
STEP 1. Faulty electrical wiring to armament wing pylon and/or nose turret solenoid valve.
Repair wiring (paragraphs 9-8 through 9-13 and paragraph 9-374).
16. With electrical auxiliary power unit (S12) connected to helicopter and turned ON, pilot and/or gunner
EMER HYDR PUMP switch in BORESIGHT position, System No. 2 non-operative, armament wing pylons and/or
turret are not powered when switches are engaged.
STEP 1. Faulty electrical wiring to armament wing pylon and/or turret solenoid valve.
Repair wiring (paragraphs 9-8 through 9-13 and paragraph 9-374), or replace pylon solenoid
valve (paragraphs 7-117 and 7-125), or replace armament wing pylon servo actuator (paragraphs
7-128 and 7-142).
7-6. SERVICING HYDRAULIC Conditions Requirements
SYSTEM.
Premaintenance Requirements for Support Equipment (S1)(S10)
Servicing Hydraulic System
Minimum Personnel One
Condition Requirements Required
Model AH-lS
Consumable Materials (C61) (C62) (Cl 37)
(C88)(C91)(Cl12)
Part No. or Serial No. All
(C1 20) (C102) (C31)
Special Tools None
Special Environmental Clean/dust
Conditions free area
Test Equipment None
7-26
TM 55-1520-236-23
a. Provide suitable maintenance work stand and Conditions Requirements
open left and right access doors (8, figure 2-3) and
right access panel (17).
Support Equipment (S1 (S10)
b. Remove cap from System No. 1 reservoir
Minimum Personnel One
(figure 7-4). Using hydraulic fluid dispenser (S1) and
Required
clean hydraulic fluid (C61 or C62) fill reservoir to
overflow until all excess air bubbles have been
Consumable Materials (C21) (C22) (C31)
expended. Service System No. 2 reservoir and
emergency system reservoir (figure 7-5) in the same (C61) (C88) (C102)
manner. (C120) (C122) (C127)
(C128)(C137)
c. Install cap to reservoir.
Special Environmental Clean/dust
Conditions free area
d. Install right access panel (17).
e. Close left and right access doors (8).
7-7. HYDRAULIC RESERVOIR. 7-9. REMOVAL HYDRAULIC
RESERVOIR.
7-8. DESCRIPTION HYDRAULIC
RESERVOIR.
a. Systems No. 1 and No. 2.
Two separate hydraulic reservoirs are located in a
(1) Open right transmission cowling (11, figure
compartment directly aft of the pilots canopy. Both
2-3) for access to hydraulic pumps. Using a suitable
are mounted on Station 186.25 bulkhead, with
container to catch fluid, disconnect reservoir
System No. 1 reservoir near left side and System No.
SUCTION hose from pump INLET fitting and allow
2 reservoir near right side (figure 7-4). An additional
fluid to drain from reservoir and connecting lines.
reservoir has been added to the hydraulic system to
Reconnect hose to pump,
accommodate the electrically operated hydraulic
emergency system, located below and inboard of
(2) Open hinged door for access to reservoir
right pylon wing and is mounted on the aft bulkhead
(figure 7-5). Each is a non-pressurized reservoir of compartment. Provide a suitable container and drain
fluid from reservoir. Disconnect all lines and hoses
3.1 pints capacity, equipped with a filler cap and
from reservoir fittings. Cap or cover all open fittings
screened adapter, and overflow scupper, a screened
and lines.
vent, a fluid vent, a fluid level sight glass and marked
ports for system connections. Hinged left and right
(3) Remove three bolts, with nuts and washers,
doors (8, figure 2-3) provide access to both side of
compartment, and fluid level sight glass are placed for to detach reservoir from bulkhead. Lift reservoir from
view from the left door. compartment.
(4) I f r e s e r v o i r i s b e i n g r e p l a c e d , r e m o v e
Premaintenance Requirements for fittings from ports marked SUCTION, BYPASS, and
Hydraulic Reservoir DRAIN (scupper) for use in new reservoir, (figure 7-6).
Condition Requirements b. Emergency Hydraulic System.
Model AH-lS
(1) Remove right access panel (19, figure 2-3).
Part No. or Serial No. All
Special Tools None (2) P r o v i d e a s u i t a b l e c o n t a i n e r . R e m o v e
Iockwire from plug (7, figure 7-6). Remove plug and
Test Equipment None drain hydraulic fluid from reservoir (5).
7-27
TM 55-1520-236-23
(3) D i s c o n n e c t a l l l i n e s a n d h o s e s f r o m 7-10. DISASSEMBLY - HYDRAULIC
reservoir. Cap or cover all open fittings and lines. RESERVOIR.
(4) Remove three bolts, with nuts and washers,
to detach reservoir from bulkhead. Lift reservoir from Disassemble hydraulic reservoir as follows:
compartment.
a. Remove cap (1) from adapter (2, figure 7-6).
(5) I f r e s e r v o i r i s b e i n g r e p l a c e d , r e m o v e
fittings from ports marked SUCTION, BYPASS, and b. Remove adapter (2) and screen (3) from
DRAIN (scupper) for use in new reservoir. reservoir.
Figure 7-4.
Figure 7-4. Hydraulic Reservoirs
7-28 Change 5
TM 55-1520-236-23
Figure 7-5.
Figure 7-5. Hydraulic Reservoir - Emergency System (Sheet 1 of 2).
Change 19 7-29
TM 55-1520-236-23
Figure 7-5.
Figure 7-5. Hydraulic Reservoir Emergency System (Sheet 2 of 2)
7-30
TM 55-1520-236-23
1. Cap 6. Packing 11. Nut
2. Adapter 7. Plug 12. Ring (backup)
3. Screen 8. Sight gage 13. Packing
4. Vent screen 9. Packing 14. Bolt
5. Reservoir 10. Baffle 15. Washer
Figure 7-6. Hydraulic Reservoir Assembly
c. Break torque on nut (11) and remove baffle 7-11. CLEANING HYDRAULIC
(10). Remove packing (13), ring (12) and nut (11) from RESERVOIR.
baffle (10).
WARNING
d. Remove Iockwire from sight gage (8). Remove
sight gage from reservoir (5). Cleaning solvent is flammable and toxic.
Provide adequate ventilation. Avoid
e. Remove packing (9) from sight gage (8). prolonged breathing of solvent vapors
and contact with skin or eyes. Eye
f. When requirements are necessary for replacing protection is required when using com-
of vent screen (4), three point staked areas must be pressed air.
removed (by grinding or sanding) in order to remove
screen.
Change 16 7-31
TM 55-1520-236-23
a. Thoroughly wash and clean inside and outside b. Replace all packings.
of reservoir and fittings with solvent (C112). Drain
completely and dry with filtered compressed air, with c. Polish all nicks and scratches to original finish
care to avoid pressurizing the reservoir. and touchup with primer (C88 or C91).
7-14. ASSEMBLY HYDRAULIC
RESERVOIR.
Ensure that fluid in hydraulic test stand is
the same type fluid as in the helicopter. a. Ensure that all parts are thoroughly clean prior
to performing the following assembly procedures
b. Flush inside of reservoir with hydraulic fluid (paragraph 7-11).
(C61 or C62).
b. Install nut (11, figure 7-6), ring (12) and
7-12. INSPECTION HYDRAULIC packing (13) on baffle (10). Install baffle (10) on
RESERVOIR. reservoir (5).
a. Visually inspect filler cap adapter and strainer c. Install packing (9) on sight gage (8) and install
screen for rust, cleanliness, damage, and corrosion sight gage on reservoir (5). Secure sight gage to
and security. reservoir with Iockwire (C137).
b. Inspect fluid level sight gage (8, figure 7-6) for d. Position vent screen (4) into port of reservoir (5)
scratches, cracks, checks, internal staining, and other and point stake (three places). Ensure security of vent
defects of transparency which could prevent proper screen.
sight of fluid level.
e. Place screen (3) into port of reservoir (5).
c. Inspect sight gage (8) for leaks and security.
f. Apply a light coat of primer (C88 or C91) to
d. I n s p e c t v e n t s c r e e n ( 4 ) f o r c l e a n l i n e s s , threads of adapter (2) and install adapter on reservoir
damage, and corrosion. (5).
e. Inspect screen (31) for damage and corrosion. g. Install cap (1) on adapter (2).
f. Inspect screen on inner end of RETURN port h. If reservoir is not to be immediately installed,
fitting for cleanliness and damage. cap or plug all fittings and port openings.
g. Inspect bosses of reservoir for damaged 7-15. INSTALLATION HYDRAULIC
threads, corrosion, and damage to packing contact RESERVOIR.
surfaces.
a. Systems No. 1 and No. 2.
h. Inspect reservoir for security and leaks.
(1) Check reservoir assembly to ensure all
i. Inspect attaching tubes and hoses for damage. fittings are properly installed. If replacing a reservoir
assembly, install the following parts which are not
j. I n s p e c t r e s e r v o i r f o r c r a c k s , n i c k s , a n d included on spares:
scratches. No cracks are acceptable.
(a) For SUCTION boss, assemble and install
k. Inspect fittings for damaged threads. an elbow, nut, packing and ring. Position elbow to
point forward and inboard when reservoir is in place.
7-13. REPAIR OR REPLACEMENT
HYDRAULIC RESERVOIR. (b) For BY-PASS boss, assemble and install
ring, packing, tee fitting and nut.
a. Replace parts that fail to meet inspection
requirements of paragraph 7-12. Refer to paragraph (c) For scupper DRAIN boss, assemble and
7-14 for assembly instructions. install an elbow, nut, packing, and ring. On System
7-32
TM 55-1520-236-23
No. 1 reservoir, elbow should point down between maintenance functions to the hydraulic
RETURN and BY-PASS fittings. On System No. 2 system (figure 7-1).
reservoir, elbow should point slightly down but above
sight plug. 7-19. CLEANING HOSES, TUBING
AND FITTINGS.
(2) Install dissimilar metal separation tape
(C120) to three mounting pads of reservoir (5, figure
7-6).
Cleaning solvent is flammable and toxic.
P / N Provide adequate ventilation. Avoid
Aluminum washers
prolonged breathing of solvent vapors
NAS1197-416, only, must be installed
and contact with skin or eyes. Eye
under bolt head.
protection is required when using
compressed air.
(3) Place three aluminum washers (15) on three
bolts (14) and apply a light film of primer (C88 or C91) to
I bolt shanks. Position reservoir on threaded insert in
a. Wash hoses, tubing, and fittings with solvent
bulkhead and install bolts.
(C112) and dry with clean filtered compressed air.
(4) Connect lines and hose to reservoir fittings b. Clear hoses, tubing, and fittings with clean
(figure 7-1). filtered compressed air.
(5) S e r v i c e a n d t e s t hydraulic system
(paragraphs 7-3 and 7-6). 7-20. INSPECTION HOSES,
TUBING, AND FITTINGS.
b. Emergency Hydraulic System.
a. Inspect tubing for nicks, cuts, cracks, and
(1) Install hydraulic reservoir (5, figure 7-6) to
deformed condition (TM 55-1500-204-25/1). Minor
electric emergency system in accordance with
nicks, scratches, and dents on fittings are acceptable
procedural steps outlined in preceding step a.
provided they are sanded smooth with 600 grit
sandpaper (C102), treated with chemical film
(2) S e r v i c e a n d t e s t hydraulic system
material (C31) and touched up with primer (C88 or
(paragraphs 7-3 and 7-6).
C91).
7-16. HOSES, TUBING, AND b. Inspect threaded parts for corrosion and
FITTINGS. mechanical damage. Damaged threads are not
acceptable.
7-17. DESCRIPTION HOSES,
TUBING, AND FlTTINGS. c. Inspect hoses for fraying, cuts, and
deterioration. Damage more severe than superficial
Throughout No. 1, No. 2, and emergency hydraulic is not acceptable.
systems are hoses, tubing, and fittings that
interconnect reservoirs, check valves, relief valves,
solenoid valves, pumps, etc, and are attached to
fuselage structure with clamps, spacers, screws, and 7-21. REPAIR OR REPLACEMENT
nuts. HOSES, TUBING, AND FITTINGS,
7-18. REMOVAL HOSES, TUBING, a. Replace parts that fail to meet inspection
AND FITTINGS. requirements of paragraph 7-20.
NOTE
b. Refer to appendix D and to TM
Removal of hoses, tubing, and fittings 55-1500-204-25/1 for instructions to fabricate
will apply only as necessary to perform tubing and hoses.
Change 16 7-33
TM 55-1520-236-23
7.22. INSTALLATION-HOSES, TUBING, AND kinked. Do not try to straighten bends in
FITTINGS. used hoses.
a. Prior to and after installation of part, observe the (5) Ensure hoses do not become twisted during
following: tightening of end connectors or nuts.
(1) Part is clear of obstructions and clean. (6) Ensure hose is free to allow movement of
components. Ensure hose does not have bends that
(2) Threads are not corroded, stripped, or will restrict fluid flow.
blurred.
(7) Spiral wrap all areas on hoses where chafing
(3) All seals, packings, and threads are coated may occur. Use teflon tape (C128).
with clean hydraulic fluid (C61 or C62).
(8) Ensure hoses are properly anchored to
(4) All fittings and hose or tubing are properly prevent chafing.
aligned prior to tightening end connectors.
(9) Torque hose end connectors (table 7-4) by
CAUTION using the dash number from the fittings that the hose
will be connected to obtain the dash number from the
Straightening bends in a used hose can part number stamped on the fittings or go to the parts
result in hose becoming flattened and manual. The last number is the dash number.
Table 7-4. Torque Values for Fluid Connections
*AN 818 NUT (inch/pounds)
Dash Tubing Al. Aly. Tubing Hose End Fittings and
Number OD (Flare AND 10061 Steel Tubing Hose Assemblies
Reference (Inches) or AND 10078) (Flare AND 10061) (MS 28740) (AN 6292)
Min. Max. Min. Max. Min. Max.
0.125
- 3 0.187 90 100 70 100
- 4 0.25 40 65 135 150 70 120
- 5 0.312 60 80 180 200 85 180
- 6 0.375 75 125 270 300 100 250
- 8 0.50 150 250 450 500 210 420
-10 0.625 200 350 650 700 300 480
-12 0.75 300 500 900 1000 500 850
-16 1.0 500 700 1200 1400 700 1150
-20 1.25 600 900
-24 1.50 600 900
-28 1.75
-32 2.0
*Flareless tubing connections shall be tightened as follows: Tighten the MS2192 nut one-sixth to one-third turns
(one-half HEX flats) past the point of sharp torque rise on all sides and materials for all types of fittings or tubes.
NOTE: The one-sixth to one-third turns (performed after the presetting operation) is the final installation
torque.
7-34 Change 18
TM 55-1520-236-23
(10) Plug all open ends if hoses will not be forward side. Allow fluid to drain into container.
connected immediately. Disconnect both hoses. Cap hoses and fittings.
(11) Do not try to pull tubes into position by c. Disconnect hose from CASE DRAIN port fitting
tightening nuts. Position tubes properly between at top inboard on pump. Cap hose and fitting.
connecting points to avoid stressing.
d. Disconnect hose from SEAL DRAIN port fitting
(12) Do not bend installed tubes. Remove tubes at bottom inboard on pump. Cap hose and fitting.
and bend to proper configuration, using proper tools.
e. Remove washers and nuts from four mounting
(13) Spiral wrap all areas on tubes where they studs at flange of pump. Pull pump and gasket from
contact supports. Tape should extend a minimum of drive pad. Cover drive pad to protect from dirt.
0.375 inch from each end of support. Tape thickness
to be 0.006 inch. Use insulation tape (C122). f. If pump is being replaced, remove fittings from
ports for use on replacement pump. Cover open pump
(14) Ensure tubes are properly anchored to ports. Protect driveshaft from dirt and damage.
prevent chafing.
7-26. CLEANING HYDRAULIC
(15) Plug all open ends if tubes will not be PUMPS (TRANSMISSION DRIVEN).
connected immediately.
(16) Torque connectors of tubes. (Refer to table
7-4.) If leaks occur, back off connector and examine
parts for damage, replace parts if necessary, and
Cleaning solvent is flammable and toxic.
torque.
Provide adequate ventilation. Avoid
prolonged breathing of solvent vapors
b. Installation of hoses, tubing or fittings applies
and contact with skin or eyes. Eye
only to damaged parts that were required to be
protection is r e q u i r e d w h e n u s i n g
removed from system, or attaching components,
compressed air.
necessary to perform maintenance functions.
a. Clean external surface of pump with solvent
7 - 2 3 . H Y D R A U L I C PUMPS
(C112). A soft bristle brush maybe required to loosen
TRANSMISSION DRIVEN).
caked dirt/grease deposit. Do not submerge pump in
solvent.
7-24. DESCRIPTION HYDRAULIC
PUMPS (TRANSMISSION DRIVEN). b. Dry pump using clean filtered compressed air.
Dual hydraulic pumps are mounted on a drive quill
7-27. INSPECTION HYDRAULIC
located on the transmission lower case, and is
. PUMPS (TRANSMISSION DRIVEN).
accessible by opening right transmission cowling
door (11, figure 2-3). System No. 1 pump is on aft pad
a. Inspect pump for leaks (table 7-1).
of drive quill, and System No. 2 pump is on forward
pad (figure 7-1 ).
b. I n s p e c t p u m p f o r c r a c k s . N o c r a c k s a r e
acceptable.
7-25. REMOVAL HYDRAULIC
PUMPS (TRANSMISSION DRIVEN). c. Inspect pump for security.
Either pump can be removed in the same manner.
d. Inspect drive pad on transmission for leaks.
a. Open right transmission cowling (11, figure 2-
3). Place a suitable container under pump to catch e. Inspect attaching hose connection for leaks.
spilled fluid.
f. I n s p e c t p u m p f o r c o r r o s i o n . S u p e r f i c i a l
b. Loosen hose nuts on SUCTION port fitting on corrosion is acceptable on external surfaces if
outboard end of pump and pressure port fitting at polished out and treated for corrosion protection.
7-35
TM 55-1520-236-23
Corrosion on threads or internal parts is not accept- e. Connect hoses to suction, pressure, case drain
able. and seal drain on port fittings.
7-28. REPAIR OR REPLACEMENT f. Refill reservoir (paragraph 7-6). Bleed system.
HYDRAULIC PUMPS (TRANSMISSION D R I Check operation of system at next ground run-up of
VEN). helicopter (paragraph 7-3).
a. Replace pump if damage in excess of limits 7-30.HYDRAULIC PUMP (EMERGENCY
(paragraph 7-27). ELECTRIC MOTOR DRIVEN).
b. Polish out corrosion damage that is within 7-31. DESCRIPTION - HYDRAULIC PUMP
repairable limits, use 600 grit sandpaper (C 102) and (EMERGENCY ELECTRIC MOTOR DRIVEN).
polish to original finish. Ensure that all traces of corro-
sion are removed, and that depth of repair does not The emergency hydraulic system is powered by an
exceed limits (paragraph 7-27). electric motor driven, pressure compensated, variable
delivery, hydraulic pump. The leading particulars for
c. Treat with chemical film (C31). both the hydraulic pump and the electric motor are as
follows:
d. Touch up with primer (C88 or C91).
Pump:
7-29. INSTALLATION HYDRAULIC PUMP Rated discharge pressure
(TRANSMISSION DRIVEN). Full flow 1100 psig minimum
Zero flow 1250 psig maximum
Either pump can be installed in the same manner. Rated inlet pressure 10 psig
Rated full flow 1.0 gpm minimum
Electric Motor
Rated voltage 28 volt dc nominal
Install P/N 212-076-364-3 or vendor P/N Rated current 40 amperes maximum
2514-6 check valve in pump case drain at full flow
port. 180 amperes maximum
at zero flow
Speed 5400 rpm maximum
a. Before installing fittings on new pump, remove at zero flow
case drain plug and drain preservative fluid from pump.
Fill pump with clean hydraulic fluid (C61 or C62) and 7-32.REMOVAL HYDRAULIC PUMP
install check valve. (EMERGENCY ELECTRIC MOTOR DRIVEN).
b. If pump is being replaced, install fittings from old a. Gain access to emergency hydraulic pump by
pump at suction port on outboard end, pressure port on removing access panel (17, figure 2-3).
forward side, case drain port at top inboard end, and
seal drain port at bottom inboard end. Use new pack- b. Remove Iockwire and disconnect electrical plug
ings. from pump assembly (4, figure 7-7).
c. Apply a thin film of antisieze compound (C21) to c. Remove four bolts (5) and four washers (6)
pump splines and to mating splines in transmission. attaching pump assembly (4) to shelf.
d. Position new gasket and pump to transmission d. Provide a suitable one gallon container. Place
drive pad. Engage pump shaft to splines of pad, and container under pump assembly directly below SUC-
pump flange over four studs. Install washers and nuts TION hose connection. Break torque on connector of
on studs. Seal area around hydraulic pump and quill tube (10) and allow fluid to drain from system slowly. It
assembly mating flanges (paragraph 6-54.f.) may be necessary to remove filler
7-36 Change 19
TM 55-1520-236-23
Figure 7-7. Emergency Electric Motor Driven Hydraulic Pump Installation
7-37
TM 55-1520-236-23
caps from all three reservoirs to allow better drainage. CAUTION
Remove tube (10) from fitting (11) and install protective
dust cap to tube. Do not submerge pump assembly (4,
figure 7-7) in dry cleaning solvent as it will
e. Remove tube (13) from fitting (14). Install damage internal components.
protective dust cover to tube connector.
f. Remove tube (3) from fitting (2). Install protective a. Wash pump assembly with a clean rag saturated
dust cover to tube connector. with solvent (C112). A soft bristle brush maybe required
to remove stubborn deposits of caked dirt and oil.
g. Remove hose assembly (9) from fitting (8) and
remove pump assembly (4) from helicopter. Install b. Dry pump assembly with clean filtered
protective dust cover to hose connector. Remove fitting compressed air.
(8) from pump assembly and discard packing (7).
7-34. INSPECTIONHYDRAULIC PUMP
h. Drain remainder of fluid from pump assembly. (EMERGENCYELECTRIC MOTOR DRIVEN).
i. Remove fitting (11) and discard packing (12) from
pump assembly (4). NOTE
j. Remove fitting (2) from pump assembly (4). The following inspection procedures are
Remove packing (1) from fitting (2). Discard packing. applicable to external surfaces and
threaded bosses only. No internal
k. Remove fitting (14) from pump assembly (4). inspections of the pump are authorized at
Remove packing (15) from fitting (14). Discard packing. this level of maintenance.
l. Clean pump assembly (paragraph 7-33).
a. Inspect hydraulic pump assembly (4, figure 7-7)
m. Fill pump assembly (4) with hydraulic fluid (C61 for leaks (table 7-1).
or C62) and plug or cap all open port holes and electrical
connector. b. Inspect pump/motor package for corrosion and
mechanical damage. Damage within limits noted below
n. Wrap pump assembly in barrier material (C22) is acceptable if polished out.
and secure with tape (C127). Send pump to next higher
level of maintenance. (1) Corrosion damagemaximum depth:
Hydraulic pump0.015 inch (0.030 inch after cleanup).
7-33. CLEANING HYDRAULIC PUMP Electric motor0.030 inch (0.060 inch after cleanup).
(EMERGENCYELECTRIC MOTOR DRIVEN).
(2) Nicks and scratches-maximum depth:
Hydraulic pump0.030 inch (0.030 inch after cleanup).
Electric motor0.060 inch (0.060 inch after cleanup).
Cleaning solvent is flammable and toxic. (3) Dent or deformationmaximum depth:
Provide adequate ventilation. Avoid
prolonged breathing of solvent vapors Hydraulic pump0.010 inch (0.030 inch after cleanup).
and contact with skin or eyes. Eye
protection is required when using
compressed air.
7-38 Change 18
TM 55-1520-236-23
Electric motor 0.050 inch (0.060 inch after f. Remove protective dust covers from connectors
cleanup). of tubes (3, 10, and 13) and hose assembly (9). Check
tube and hose connectors for thread damage.
(4) Cracks: No cracks are acceptable.
g. Position pump assembly (4) on shelf and under
c. Inspect electrical connection to pump bonding strap. Install four bolts (5), and four washers
assembly (4) for corrosion, damaged threads, and (6).
bent or broken pins.
h. Install tubes (3, 10, and 13) to fittings (2, 11,
d. Inspect threaded ports in pump for damage. and 14).
Maximum acceptable thread damage is one-third of
thread depth 0.250 inch in length, and one damage
per port.
Do not allow hose to chafe, twist or kink
during installation. Ensure that hose is
7-35. REPAIR OR REPLACEMENT clear and clean.
HYDRAULIC PUMP (EMERGENCY
ELECTRIC MOTOR DRIVEN). NOTE
Hose connector shall be torqued in
a. Replace pumps which fail to meet inspection. accordance with torque requirements
requirements of paragraph 7-34. outlined in table 7-4.
b. Polish out mechanical and corrosion damage i. Install hose (9) to fitting (8).
that is within repairable limits noted in paragraph
7-34. Use 600 grit sandpaper (C102) and polish to j. Connect electrical plug to pump assembly,
original finish. Iockwire (C137).
c. Touch up with primer (C88 or C91). k. Perform operational check (paragraph 7-3).
7-36. INSTALLATION HYDRAULIC
PUMP (EMERGENCY ELECTRIC MOTOR 7 - 3 7 HYDRAULIC MODULAR
DRIVEN). UNITS.
a. Remove case drain plug from top of pump 7-38. D E S C R I P T I O N HYDRAULIC
assembly and drain preservative fluid. Using MODULAR UNITS.
hydraulic fluid dispenser (S1), fill pump with clean
hydraulic fluid (C61 or C62) and install case drain Two hydraulic system modular units are located in a
plug. Secure case drain plug with Iockwire (C137). compartment at top of the fuselage between pilot
canopy and the transmission pylon, on front of
b. Install packing (1, figure 7-7) on fitting (2) and bulkhead at Station 186.25 (figure 7-4). Hinged doors
install fitting into CASE DRAIN port, located top (8, figure 2-3) at each side give access to the
center of pump. compartment. Each modular unit consists of a
housing equipped with the system solenoid valve,
c. Install packing (7) on fitting (8) and install fitting relief valve, pressure switch for caution panel light,
into SEAL DRAIN port located on lower end of pump. pressure and return filters, filter indicators (popout
button), marked ports for system connections. Two
d. Install packing (12) on fitting (11) and install quick-disconnect couplings are located on right
fitting into SUCTION port, located on forward face of modular unit for connection of hydraulic test stand
pump (outboard). (S2). One coupling is also used in normal operation
for the return hose to the reservoir System No. 1
e. Install packing (15) on fitting (14) and install hydraulic modular unit is at left, and System No. 2
fitting into PRESSURE port, located on forward face of hydraulic modular unit at right on bulkhead.
pump (inboard).
Change 5 7-39
TM 55-1520-236-23
7 - 3 9 . REMOVAL HYDRAULIC 7-41. INSPECTION HYDRAULIC
MODULAR UNITS. MODULAR UNITS.
Either module can be removed in the same manner. a. Inspect module unit for cleanliness.
a. Open left and right door (8, figure 2-3). Place a b. Inspect modular unit for leaks and malfunction
suitable container below module (figure 7-4) to catch during operational checks (paragraph 7-3).
spilled fluid.
c. Inspect modular unit for security.
b. Disconnect electrical connectors from solenoid
and pressure switch at top of module.
d. Inspect modular unit for nicks, scratches,
c. Disconnect return line hose from quick- dents, cracks and corrosion.
disconnect coupling on front of module, and four
tubes from fittings at side ports. Cap fittings and open 7-42. REPAIR OR REPLACEMENT
ends of tubes. HYDRAULIC MODULAR UNITS. (AVIM)
d. Remove three bolts, with washers and nuts, to a. Replace modular units that fail to meet
detach module from bulkhead. Remove module from inspection requirements of paragraph 7-41.
compartment.
b. Touch up external finish with primer (C88 or
e. If module is being replace, remove fittings as C91).
necessary for use on replacement module.
7-43. INSTALLATION HYDRAULIC
7-40. CLEANING HYDRAULIC MODULAR UNITS.
MODULAR UNITS.
Either module can be installed in the same manner.
a. Clean electrical components with dry, filtered
compressed air. a. If module is being replaced, install serviceable
fittings, and assemblies from old module as needed.
Use new packings and gaskets.
b. Position module to bulkhead, with pressure
ports at outboard side. Align mounting holes. Insert
Cleaning solvent is flammable and toxic.
Provide adequate ventilation, Avoid three bolts through module housing and bulkhead,
and install washers and nuts at back of bulkhead.
prolonged breathing of solvent vapors
and contact with skin or eyes. Eye
c. Connect hydraulic system tubes to fittings at
protection is required when using
marked ports. Connect hose from reservoir RETURN
compressed air.
port to quick-disconnect coupling.
d. Connect electrical wiring connectors to
solenoid valve and pressure switch.
Do not submerge hydraulic modular unit e. Perform operational check (paragraph 7-3).
in dry cleaning solvent.
b. Wash modular unit externally with solvent 7-44. FILTER ELEMENTS.
(C112).
7-40 Change 16
TM 55-1520-236-23
7-45. . DESCRIPTION FILTER Two filter elements (figure 7-8) are installed in each
ELEMENTS. of the two hydraulic modular units. The filter
elements are enclosed in filter bowls. Filter elements
are inspected at intervals specified in Preventive
Maintenance Checklists. The filter elements are also
NOTE inspected when indicator buttons on pressure
indicator assemblies pop out, except when indicators
The functions of the No. 3 Hydraulic are reset (pushed in) and do not pop out a second time.
System, Filter Element Assembly ln- Also, the filter elements do not require inspection
dicator button, is identical to that of the when indicator buttons pop out and the condition is
Nos. 1 and 2 Systems. known to be caused by fluid temperature below 20
degrees F (-7 degrees C).
Change 16 7-40.1/(7-40.2 blank)
TM 55-1520-236-23
1. Pressure indicator assembly 5. Packing
2. Module housing 6. Filter element
3. Packing 7. Filter bowl
4. Element retainer
Figure 7-8. Filter Element Installation
Premaintenance Requirements for
Conditions Requirements
Filter Element
Minimum Personnel One
Condition Requirements
Required
Model AH-1S
Consumable Materials (C31) (C61) (C62)
Part No. or Serial No. All (C88) (C91) (C102)
(C112) (C137)
Special Tools None
Special Environmental Clean, dust-free
Test Equipment None Conditions area
Support Equipment (S1)(S10)
7-41
TM 55-1520-236-23
7-46. REMOVALFILTER ELEMENTS.
a. Open left compartment door (8, figure 2-3).
Place a suitable container below module to catch fluid.
b. Remove Iockwire and remove filter bowl (7,
figure 7-8).
c. Remove packing (3).
d. Remove element retainer (4).
NOTE
Filter elements must be replaced when
spectrometic analysis fluid sample
shows signs of contamination.
e. Examine filter element and all fluid in filter bowl
for unusual contamination which might indicate need for
corrective action beyond replacement of filter element.
f. Remove packing (5).
g. Remove remaining filter elements in the same
manner outlined in steps a. through f.
NON-CLEANABLE
747. q CLEANINGFILTER ELEMENT.
PIN 205-076-034-3
Do not clean paper-type filter elements.
748. q INSPECTIONFILTER ELEMENTS.
Figure 7-9. Non-Cleanable Filter Element
Refer to paragraph 7-46, step e.
e. Install filter bowl (7) and filter element on module
749. q REPAIR OR REPLACEMENTFILTER housing (1). Torque filter bowl 100 TO 140 inch-pounds.
ELEMENTS. Secure filter bowl to housing with Iockwire (C-137).
Install new paper-type filter elements P/N NOTE
205-076-034-3.
Torque emergency system filter bowl 20
7-50. q INSTALLATIONFILTER ELEMENTS. to 60 inch-pounds.
a. Wipe filter bowl (7, figure 7-8) and mating f. Install other filter elements in the same manner.
surfaces of module housing (2) clean with a clean cloth.
g. Perform ground runup and inspect for hydraulic
b. Install new packing (3) into groove in housing fluid leaks.
(2).
7-51. q ACCUMULATOR AND LOCKOUT VALVE.
c. Install new packing (5) in filter element (6).
7-52. ~ DESCRIPTIONACCUMULATOR AND
c.1 Fill filter bowl 3/4 full of clean hydraulic fluid LOCKOUT VALVE.
(C61 or C62).
The hydraulic accumulator and lockout valve
d. Insert new filter element (6) in filter bowl (7) and assembly (figure 7-10), in System No. 1 pressure line
install filter retainer (4). to cyclic control hydraulic cylinders, is located on a
7-42 Change 18
TM 55-1520-236-23
bracket beneath the pylon lift beam. The accumulator 7-53. ~ REMOVAL ACCUMULATOR
and lockout valve are automatic in operation, with no AND LOCKOUT VALVE.
electrical or manual controls, and do not require any
charging procedure. The lockout valve is a. Remove left access panel (17, figure 2-3).
interchangeable with the valve used in the collective
controls hydraulic circuit. System No. 2 has a lockout b. Place a suitable container below accumulator
valve only. and valve assembly to catch trapped fluid.
Figure 7-10. ~ Accumulator and Lockout Valve Installation
7-43
TM 55-1520-236-23
c. Using care to avoid spraying of fluid, if any 7-54. q CLEANING ACCUMULATOR
pressure is still trapped, remove tubes (1, 2, 7, 13, 22 AND LOCKOUT VALVE.
and 35, figure 7-10). Cap all tube connectors.
d. Remove three nuts (19), six washers (25), three
spacers (26) and three bolts (27) attaching lockout
valve (28) to bracket and remove lockout valve (with Cleaning solvent is flammable and toxic.
accumulator (21), from helicopter. Drain fluid from Provide adequate ventilation. Avoid
lockout vaIve. prolonged breathing of solvent vapors
and contact with skin or eyes. Eye
e. Place lockout valve (28) (with accumulator (21) protection is required when using
on clean work bench and remove attaching compressed air.
components from lockout valve as follows:
a. Clean external surfaces of accumulator and
f. When replacing accumulator assembly (21) lockout valve by wiping with a clean cloth moistened
proceed as follows: with solvent (C112), but do not allow solvent to enter
units.
(1) Remove accumulator assembly (21) from
lockout valve assembly (28). b. Dry accumulator and lockout valve with filtered
compressed air.
(2) Remove packing (20) from accumulator
assembly (21) and discard packing.
7-55. q INSPECTION ACCUMULATOR
AND LOCKOUT VALVE.
(3) R e m o v e c o n t a i n e r l o c a t e d b e l o w
accumulator.
a. Inspect accumulator (21) and lockout valve (28)
for nicks, scratches, corrosion and cracks.
g. Remove accumulator (21) from lockout valve
(28) and remove packing (20) from accumulator. b. Inspect fittings, tube connectors, ports of
lockout valve and accumulator, and nuts for thread
(1) Remove fitting (23) and packing (24) from damage.
lockout valve (28).
c. Inspect accumulator (21) and lockout valve (28)
(2) Break torque on nut (16) and remove tee for cleanliness and security.
(15) from lockout valve (28). Break torque on nut (10)
and remove elbow (9) from tee (15). Remove packing 7-56. ~ REPAIR OR REPLACEMENT
(12), ring (11) and nut (10) from elbow (9). Remove ACCUMULATOR AND LOCKOUT VALVE.
packing (18), ring (17) and nut (16) from tee (15). (AVIM)
(3) Remove fitting (3) from tee (5). Remove a. Any cracks to fittings, nuts, accumulator or
packing (4) from fitting. lockout valve requires replacement of part. No repairs
allowed.
(4) Break torque on nut (6) and remove tee (5)
from lockout valve (28). Remove packing (14), ring (8) b. Replace all packings and rings (backup).
and nut (6) from tee (5).
c. Replace accumulator or lockout valve or both if
(5) Remove fitting (34) from tee (32). Remove malfunction or damage occurs. No repairs allowed.
packing (33) from fitting.
d. Minor nicks, scratches, and corrosion to
(6) Break torque on nut (31) and remove tee exterior surface of lockout valve of accumulator is
(32) from lockout valve (28). Remove packing (29), acceptable, provided the damaged area is polished
ring (30) and nut (31) from tee (32). out with 600 grit sandpaper (C102) to the original
finish and treated with chemical film (C31). Touchup
h. Remove container from helicopter. repair area with primer (C88 or C91).
7-44
TM 55-1520-236-23
e. Any corrosion to internal area of lockout valve
or accumulator, requires replacement of part. No
repairs aIlowed. Do not mix hydraulic fluids (C62) and
(C63).
e. Using hydraulic fluid dispenser (S1), service all
7-57. q INSTALLATION three hydraulic reservoirs with clean hydraulic fluid
ACCUMULATOR AND LOCKOUT VALVE. (C61 or C62) to proper fluid level.
f. B l e e d hydraulic System and perform
a. R e m o v e p r o t e c t i v e d u s t c o v e r s f r o m operational check (paragraphs 7-3 and 7-6).
replacement lockout valve (28, figure 7-10).
7-58. ~ D U A L HYDRAULIC
b. Install attaching components to replacement CYLINDERS.
lockout valve (28) as follows:
7-59. ~ DESCRIPTION DUAL
(1) Provide a clean work area. Place packing (4) HYDRAULIC CYLINDERS.
on fitting (3) and install fitting into tee (5). Three dual hydraulic actuating cylinders are used in
collective, lateral cyclic, and fore-and-aft cyclic
(2) Place packing (33) on fitting (34) and install controls (figure 7-3). Each cylinder assembly consists
fitting into tee (32). of a dual cylinder and valve combination, a bearing
and housing, and an extension tube on the cylinder
(3) Install nut (31), ring (30) and packing (29) on piston rod. All three have the same cylinder and valve
tee (32). Thread tee (32) into SYS RET port; position group, but use different extension tubes. Valves and
tee as shown and tighten nut (31). rod end bearings are aligned in each assembly by
locks in slots provided.
(4) Install nut (6), ring (8) and packing (14) on
tee (5). Thread tee (5) into SYS PRESS port; position Premaintenance Requirements for
tee as shown and tighten nut (6). Dual Hydraulic Cylinders
(5) Install nut (16), ring (17) and packing (18) on Condition Requirements
tee (15). Thread tee (15) into PRESS port (located on Model AH-1S
opposite end from valve spring housing); position tee
as shown and tighten nut (16). Part No. or Serial No. 209-076-362-1, -3, and -5
Special Tools (T22) (T23)
(6) Install nut (10), ring (11) and packing (12) on
elbow (9). Thread elbow (9) into tee (15); position
elbow (9) shown and tighten nut (10). Test Equipment None
(7) Place packing (24) on fitting (23) and install Support Equipment (S1) (S10)
fitting into RES RET port.
Minimum personnel Two
Required
(8) Place packing (20) on accumulator (21) and
install accumulator into open port adjacent to RES
RET port. Consumable Materials (C43) (C61 ) (C62)
(C88) (C91) (C112)
(C137)
c. Position accumulator/lockout valve to bracket
and install three bolts (27), six washers (25), three Special Environmental Clean, dust
spacers (26) and three nuts (19). Conditions free area
d. Remove protective dust covers from end 7-60. ~ REMOVAL DUAL HYDRAULIC
connectors of tubes (1, 2, 7, 13, 22 and 35) and CYLINDERS.
connect tubes to lockout valve. Torque tube end
connector in accordance with torque requirements a. Any of three cylinder assemblies can be
outlined in table 7-4. removed by the same typical procedure.
Change 3 7-45
TM 55-1520-236-23
(7) Turn valve (19) as necessary to pass
through hole in support (8 or 18). Remove cylinder
assembly (5, 9, or 17).
7-61. q DISASSEMBLY DUAL
Before loosening any connections in
HYDRAULIC CYLINDERS. (AVIM)
accumulator circuit, ensure trapped
hydraulic pressure is released.
a. Cyclic (lateral) Dual Hydraulic Cylinder.
Disassemble cyclic: dual, lateral hydraulic cylinder
(1) Open left and right transmission cowl assembly.
assemblies (11, figure 2-3). Remove left and right
access panels (17) on side of fuselage below wing. (1) Remove sealant from threads of rod end
Install maintenance platform (S10) on helicopter. bearing (1, figure 7-12), lock (2), and nut (3).
(2) Disconnect control tube (22, figure 7-3) (2) Cut Iockwire, loosen nut (3) and remove rod
from control valve lever (21) by removing cotter pin, end bearing (1) from end of tube (4). Remove nut (3)
nut, bolt, and washers. Disconnect control tubes (6 and lock (2). Remove sealant from threads of nut, rod
and 7) in the same manner. end bearing and lock.
(3) Place a container to catch spilled fluid. (3) Remove clamps (5) from dust protective
Disconnect hydraulic hoses from lower end of valve boot and flange assembly (6). Slide boot up and
(19). Cap open hoses and fittings. remove boot from cylinder assembly (23).
(4) Remove Iockwire from nuts (11 and 12).
(4) Open left and right pylon access doors
and disconnect rod end bearing (2, figure 7-3) (5) Place torque fixture (T22 or T23) in suitable
at top of cylinder tube from swashplate horn (3) or vise and install cylinder assembly in fixture (figure
collective lever (4) by removing cotter pin, nut, bolt, 7-13). While holding cylinder piston rod from rotating,
and washers. Remove control tubes (6, 7, and 22). loosen nut (11, figure 7-12). Remove nut (11) and
spring (13) from cylinder assembly (View B-B, figure
7-12).
(5) Hold bolts (24) with work aid shown on
figure 7-11. Remove nuts (28, figure 7-3), (6) Remove Iockwire from lock (15 and nut (12).
washers (27), washers (25), and bolts (24).
(7) While holding cylinder piston rod to prevent
rotation, loosen nut (12) and back nut off from tube
(4). Remove tube (4), nut (12), lock (15), and base (14)
(6) L o o s e n h y d r a u l i c c o n n e c t i o n s as from piston rod of cylinder assembly (view B-B, figure
necessary to provide clearance for removal. 7-12).
Figure 7-11. Work Aid for Dual Hydraulic Cylinder Removal and Installation
7-46 Change 3
TM 55-1520-236-23
Figure 7-12. Dual Hydraulic Cylinder (Sheet 1 of 2)
Change 2 7-47
TM 55-1520-236-23
Figure 7-12. Dual Hydraulic Cylinder (Sheet 2 of 2)
7-48 Change 10
TM 55-1520-236-23
Figure 7-13. Tool Application Cylinder Assembly Torque Fixture
Part Numbers T41000310-1 and T100619-2
(8) Remove pressure and return fittings. (1) Remove sealant from threads of rod end
bearing (1, figure 7-12), lock (2) and nut (3).
(9) Remove cylinder assembly from torque (2) Remove Iockwire from lock (2) and nut (3)
fixture (T22 or T23). and remove rod end bearing (1) from tube (4). Clean
sealant from threads of nut, rod end bearing and from
lock.
b. Cyclic (Fore and Aft) and Collective Dual
Hydraulic Cylinders. Disassemble cyclic (fore and aft) (3) Remove clamp (5) from upper and lower end
and collective dual hydraulic cylinder assemblies as of boot/flange assembly (6). Slide boot up and remove
follows: boot/flange assembly from tube (4).
7-49
TM 55-1520-236-23
(4) Remove Iockwire from lock (24) and nut friction drag of approximately 2.5 pounds is con-
(25). sidered normal.
(5) Place torque fixture (T22 or T23) in suitable c. Check bearing installation for looseness or
vise and install cylinder assembly in fixture (figure binding. To check the bearing installation, perform
7-13). While holding cylinder piston rod from rotating, the following:
loosen nut (25, figure 7-12) and back off nut from tube
(4). Remove tube (4), nut (25), and lock (24) from
cylinder piston rod. NOTE
(6) Remove cylinder assembly from torque When the part number of the cylinder
fixture (T22 or T23). assembly is 209-001-362, the bearing
part number will be KSP 6099-1. The
(7) Remove pressure and return fittings from required friction has been built into this
bottom of servo valve. bearing during manufacture and it
requires no additional adjustment. The
(8) Remove springs (16 and 17) from collective bearing is designed to gimbal freely, thus
servo valve by removing nut (20), washers (19), and does not have the characteristic
bolt (18). tightness of the uniball bearing which
requires the spring scale torque test. The
7-62. ~ CLEANING DUAL HYDRAULIC rotational freedom of the KSP 6099-1
CYLINDERS. bearing should not be interpreted as wear
and the axial movement should not be
considered as excessive unless feedback
is felt in the controls. The bearing
requires no lubrication and plugs should
be installed in grease fitting holes.
Cleaning solvent is flammable and toxic. Installation of KSP 6099-1 bearing
Provide adequate ventilation. Avoid requires that the bearing housing
prolonged breathing of solvent vapors retaining nut be torqued 1100 to 1180
and contact with skin or eyes. Eye inch-pounds to secure it to the servo
protection is required when using cylinder. This torque does not affect the
compressed air. friction on the bearing. When the KSP
6099-1 bearing is installed, the KSP
a. Clean external surfaces, except polished 9059 shield and KSP 9056 seal must
surfaces of piston rod and control valve by wiping also be installed. Do not use the rubber
with a clean cloth moistened with solvent (C112). boot assembly used on other servo
cylinder assemblies. Only one positive
b. Carefully clean exposed polished surfaces of safety is required for this installation.
piston rod and control valve with a soft cloth
moistened with hydraulic fluid (C61 or C62).
7-63. ~ INSPECTION DUAL
HYDRAULIC CYLINDERS. (1) Disconnect the cyclic and collective servo
actuator upper control tubes from the swashplate.
a. Inspect all parts for damage, corrosion or
(2) Disconnect the push-pull tubes from the
pitting, and exposed threads for distortion:
bottom of all three servo actuators.
(1) No elongation in holes is acceptable.
(3) Bottom servos in full up position. Inspect
(2) Black residue around the piston rod is not a servo valve for serviceability. Check selector set for
reason for replacement of the servo cylinder. sticking or binding. Inspect lever stop for distortion.
Inspect bolts through arm lever for wear and
b. Inspect piston rod for nicks, scratches; or distortion; bolts (20, figure 7-3) to be finger tight only.
scoring, and for smooth operation in cylinder. A Check cotter pins for security. Inspect bearing
7-50 Change 5
TM 55-1520-236-23
housing (8, figure 7-12) for damage and flange for NOTE
cracks and elongation of holes; holes not to exceed
0.001 inch beyond dimensions shown in view A, It is permissible for the main rotor
figure 7-15. cylinder barrel to rotate within the hous-
(4) Attach a pound reading spring scale to the ing assembly providing there is no ver-
clevis or rod end at the top of the control tube. tical barrel movement. When vertical
Working with each servo independently, move the movement is apparent, retorque the
actuators laterally until they bottom out. A force lower retaining nut (21, figure 7-12).
of 1 to 2.5 pounds should be required to move bear- Recheck force required to move the
ing through its full travel with the servo fully ex- cylinder. Refer to step (8) above.
tended.
NOTE
(5) If the force required to move the bearing
is above or below the requirements established in Ensure support mounts are lubricated
step (4) above, lubricate bearing. (Refer to Chapter every 150 hours of operation. To proper-
1.) Recheck force as outlined in step (4). If force is ly grease, detach the rod end from the
not within limits, torque bearing housing nut (29, pitch control lever or swashplate horn.
figure 7-3) 400 to 450 inch-pounds. Recheck force. Rotate the cylinder assembly in the
If force is not within limits, correct as follows: bearing housing while applying grease.
Rotating the cylinder will assure com-
plete lubrication of the bearing. Assem-
ble rod end to the pitch control lever or
(6) Torque lower retaining nut (21, figure 7-12) 900
to 1000 inch-pounds. Make sure nut is safetied properly to swashplate horn.
with tab washer (22).
(10) Reinstall and safety all control tubes
NOTE
previously removed in steps (1) and (2) above.
To properly assembIe tab washer on cylinder
assembly, fit the tab on the inside of washer d. Inspect cylinder assembly for leaks at all con-
into machined slot of cylinder barrel before nections and fittings. Seepage around piston rod
retainer nut is tightened. seals during operation is acceptable, but not to ex-
ceed one drop every 20 cycles. The maximum
leakage allowed at the cylinder bleed hole is 3
(7) Torque the bearing housing nut (29, figure 7-3) drops in 25 cycles. Accumulation of the equivalent
400 to 450 inch-pounds to ensure proper seating of the
bearing surfaces. of one drop of static leakage at the valve and
sleeve assembly in 24 hours is acceptable.
(8) Loosen nut (29) and retorque until a force of 1 e. Inspect shield for security.
to 2.5 pounds is required to move cylinder laterally. f. Inspect nuts and locks for proper safetying.
in accordance with TM 55-1500-204-25/1.
g. Collective flight control cylinder (AVIM).
(9) Double Iockwire retaining nut 180 degrees
apart. One Iockwire shall be a positive lock and (1) Inspect rod end bearing for roughness and
one negative. Paint slip marks on bearing retain- freedom of movement.
ing nut and bearing housing.
Change 16 7-50.1/(7-50.2 blank)
TM 55-1520-236-23
(2) Inspect lock (2, figure 7-12) for cracks and extension tubes are different lengths for use in
deformity. collective, lateral, and fore-and-aft controls.
(3) Inspect tube (4) and rod end bearing (1) for d. During reassembly, set rod end dimensions first,
mechanical, corrosion and thread damage. Refer to then adjust assembly length by screwing tube on cyl-
paragraph 11-150 for damage limits on flight control inder piston rod (figure 7-15). Use locks in slots to
tubes. obtain correct alignment, torque nuts as shown, and
secure nuts and locks with Iockwire (C137).
(4) Inspect nut (25) for cracks and for damaged
threads.
(5) Inspect lock (24) for cracks and deformity. NOTE
(6) Remove and visually inspect servo springs Assembly dimensions shown on figures
(16 and 17) and bolt (18) for excessive wear. 7-12 and 7-15 are nominal and are
subject to change during rigging
h. Fore and aft and lateral control cylinders (AVIM). (chapter 11).
(1) Inspect rod end (1) for roughness and for e. When replacing servo cylinder in an assembly,
freedom of movement. perform the following:
(2) Inspect nut (3) for cracks and for damaged (1) After removing rod end and tube, inspect
threads. fittings in upper and lower ends of tube for corrosion
in internal areas.
(3) Inspect locks (2, 15 or 24) for cracks and
deformity. (2) If corrosion is present, replace the tube. If
replacement is not available, tube maybe temporarily
(4) Inspect tube (4) for cracks and for damaged kept in service by applying preventive compound (C43)
threads. to retard corrosion until tube can be replaced at next
scheduled maintenance inspection.
(5) Inspect nut (25) for cracks and for damaged
threads. (3) Before installing a new tube, flush internal
surfaces with primer (C88 or C91). Stop one end of
(6) Inspect spring (13) for cracks and for free tube, pour primer into other end, rotate tube to obtain
length of spring, which must be 8.9 TO 9.2 inches in full coverage of primer in both end fittings, and drain
length. Compress the spring 6 inches and release. for 10 TO 20 minutes before installation.
Remeasure spring length. If spring is shorter, replace
the spring.
(7) Inspect spring base (14) and nut (11) for NOTE
cracks, excessive wear and bonded washers for
adhesion. On a new complete cylinder assembly,
tube can be left in place and treated as in
step (3) above by removing rod end to
7-64. ~ REPAIR OR REPLACEMENT apply primer.
DUAL HYDRAULIC CYLINDERS.
Assembly directions shown on figures
a. Replace protective boot or attaching parts if 7-12 and 7-15 are nominal and are
damaged or unserviceable. subject to change during rigging
(chapter 11).
b. Replace cylinders that fail to meet inspection
requirements. e. Any damage to nut (7) requires replacement of
cylinder assembly. Damage to bearing housing (8) in
c. When replacing cylinder assembly, check that excess of limits shown on figure 7-14 requires
overall length is correct for control system location (fig- replacement of cylinder assembly. Send cylinder
ure 7-15). Servo cylinders are interchangeable, but assembly to next higher maintenance level.
Change 8 7-51
TM 55-1520-236-23
TYPE OF DAMAGE MAXIMUM DEPTHS AND REPAIR AREAS ALLOWED
CRACKS ALLOWED None None
NICKS, SCRATCHES, 0.020 0.040
AND SHARP DENTS
CORROSION 0.010 0.020
MAXIMUM AREA PER 0.10 Sq. In. Not critical
FULL DEPTH REPAIR
NUMBER OF REPAIRS Not critical Not critical
EDGE CHAMFER 0.040 0.060
BORE DAMAGE 0.002 for 1/2 circumference
THREAD DAMAGE:
DEPTH: One-third of thread
LENGTH: cumulative
NUMBER:
ALL DIMENSIONS ARE IN INCHES UNLESS OTHERWISE NOTED
209076-28E
Figure 7-14. Damage Limits For Hydraulic Cylinder Bearing Housing
f. On lateral system cylinder, instaIl base (14, (1) Redate rod end, nuts, and locks if they fail
figure 7-12), spring (13), lock (15), nut (11), and nut inspection.
(12). Install nut (11), and nut (12). Install nut (11) flush
with nut (12). See view B-B. (2) Repair minor surface damage on tube (4),
that is within allowable limits. Refer to paragraph
g. On collective system cylinder, check that two 11-150 for repair procedure on flight control tubes.
springs (16 and 17) are installed on valve as shown. Replace rod end bearing (1) if damaged. Replace tube
(4) if mechanical damage is in excess of acceptable
h. Collective Flight Control Cylinder (AVIM). limits.
7-52 Change 5
TM 55-1520-236-23
Figure 7-15. Dual Hydraulic Cylinder Assembly (Typical)
Change 2 7-53
TM 55-1520-236-23
(3) Deleted. (a) Remove bleed pluq (12) from pilot
valve (13).
(4) Replace excessively worn servo springs
(16 and 17) and bolts (18). (b) Remove packing (11) from body of
bleed plug (12) and replace with new packing.
i. Fore and aft lateral control cylinders (AVIM).
(c) Replace bleed plug (12) in pilot valve
(1) Repair leaking servo cylinder as follows: and tighten.
(a) Cut and remove Iockwire securing (4) Clean filters (14 and 15) with clean, dry fil-
cylinder lock nut (1, figure 7-16) to lock (2) and loosen tered compressed air. Remove packings (16 and 17)
lock and locknut from upper end of cylinder. and replace with new packing.
(b) Unscrew cap (3) from cylinder.
7-65. ~ ASSEMBLY DUAL HYDRAULIC
(c) Remove packing retainers (4) and CYLINDERS (AVIM).
packing (5) from inside cap (3) and replace with like
serviceable items.
Premaintenance Requirements for
(d) Remove internal retainer ring (10) Dual Hydraulic Cylinder Assembly
from cap (3).
(e) Remove two scraper rings (8), scraper Condition Requirements
ring retainer (9) from cap (3), and replace with like ser-
viceable items. Model AH-1S
(f) Remove packing (6) and packing Part No. or Serial No. 209-001-362-1, -3, -5
retainer (7) from cap (3) and replace with like service-
able items. Special Tools (T22) (T23)
(g) Install retainer ring (10) in cap (3). Test Equipment None
(h) Screw cap (3) on upper end of cylinder Support Equipment (S2) (S10)
and tighten until it bottoms out then loosen sufficiently
to allow alignment of lock (2). Minimum Personnel One
Required
(i) Position locknut (1) against cap (3)
and torque locknut 250-300 inch-pounds. Install lock Consumable Materials (C22) (C61) (C62) (C69)
(2) and secure to locknut with Iockwire (C137). (C105) (C112) (C127) (C137)
(C138)
(2) Replace lock (2) if damaged or broken as Special Environmental None
follows: Conditions
(a) Remove cap (3).
(b) Remove locknut (1) and lock (2) from a. Fore and Aft Cyclic and Collective Dual
cylinder. Hydraulic Cylinders. Assemble fore and aft cyclic and
collective dual hydraulic cylinder assemblies as fol-
(c) Install lock (2) in keyway of cylinder lows:
and screw locknut (1) and lock (2) on cylinder.
(1) Place torque fixture (T22 or T23) in suitable
(3) Repair leaking bleed plug in pilot valve as vise and install cylinder assembly in fixture (figure 7-
follows: 13).
7-54 Change 19
TM 55-1520-236-23
Figure 7-16. Flight Control Hydraulic Cylinder and Servo Actuator Valve
Change 19 7-55
TM 55-1520-236-23
NOTE NOTE
Ensure aping of larger diameter wire
Assembly dimensions shown on
(17, figure 7-12, view C-C) is Installation
figures 7-12 and 7-15 we nominal and
bottom as illustrated
are subject to change during rigging
(Chapter 11).
(7) Install springs (16 and 17) on collective
servo cylinder (view C-C) with bolt (18), four washers
(2) Install rod end (1) into tube (4) until the (19) and nut (20). Thread nut (20) onto bolt (18) until
distance from tube end and hole center of rod distance from top of nut (20) is 0.12 inch from top of bolt
end is 2.19 inches. Maintain 2.19 inches distance, (18, view C-C, figure 7-12).
torque nut (3) 450 TO 600 inch lbs. Safety nut to safety
lock (2) with Iochwire (C138). Apply sealant (C105) to (8) On the fore and aft cyclic cylinder, keep
exposed threads of rod end bearing (1), jamnut (3), the 2.19 inch dimension set in step(3) and set rod end
and upper end of control tube. bearing to angle shown on figure 7-12, view A-A (FOR
FORE AND AFT CYL ASSY). Torque nut (3) 450 TO
(3) Install shield assembly (figure 7-15, view 600 inch-pounds. Secure nut with Iockwire (C138).
B) on housing.
(9) On the collective cyclic cylinder, keep the
2.19 inch dimension set in step (3) and set rod end
(4) Position lock (24, figure 7-12) into nut (25) bearing to angle shown in figure 7-12, view A-A (FOR
and thread nut onto shaft of servo cylinder (23) with COLLECTIVE CYLASSY). Torque nut (3)450 TO 600
lock positioned in keyway on shaft of servo cylinder inch-pounds.
(23).
(10) Install new packings on fittings and install
on servo as shown on figure 7-17, cap or plug open
ports to avoid entry of foreign matter.
(11) Remove dual hydraulic cylinder assembly
from torque tire (T22 or T23).
b. Lateral Cyclic Dual Hydraulic Cylinder.
Assemble lateral cyclic hydraulic cylinder assem-
bly as follows
(1) Place torque fixture (T22 or T23) in suit-
able vise and install cylinder assembly in fixture (figure
7-13).
NOTE
NOTE
Assembly dimensions shown on
figures 7-12 and 7-15 are nominal and
Assembly dimensions shown on are subject to change during rigging
figures 7-12 and 7-15 are nominal and (chapter 11).
are subject to change during rigging
(chapter 11).
7-56 Change 22
TM 551520-236-23
(3) Install spring base (14) at top of cyilnder (15) Install new packings on fittings and install
housing. fittings in servo as shown on figure 7-17. Cap or plug
open to prevent entry of foreign matter.
(4) Place lock (15) into nut (12). Align lock
with slot in cylinder piston rod and thread nut (12) on (16) Remove dual hydraulic cylinder assembly
cylinder piston rod. from torque fixture (T22 or T23).
(5) Position nut (11) and spring (13) on base 7-66. INSTALLATION DUAL
(14). HYDRAULIC CYLINDERS.
(6) Thread lube (4) on cylinder assembly. a. Any of three dual hydraulic cylinder assem-
blies can be installed using the following procedures
NOTE (figure 7-3). Ensure that dual hydraulic cylinder
assembly is correct for control system in which itis to
Assembly dimensions shown on be installed.
figures 7-12 and 7-15 are nominal and
are subject to change during rigging NOTE
(chapter 11).
Self-locking nuts will be used one time
(7) Adjust tube (4) to 55.16 inch dimension as only In this application.
shown in figure 7-12.
Rod end bearing (1, figure 7-12) must be
(8) Maintain 55.16 inch dimension and torque positiones in rellation to larger hole In
nut (12) 8001111000 inch-pounds. Lockwire nut (12) housing (8) as shown on view A-A,
to lock (15) with Iockwire (C138). figures 7-12.
(9) Position spring (13) and base (14) on Ensure that four washers (26 figure 7-3)
cylinder assembly. Threads nut (11) on nut (12). Install are bonded to supports (8 and 18)at
nut (11 ) flush with top of nut (12), as illustrated on figure each dual hydraulic cylinder installa-
7-12, view BB. tion position.
(10) Lockwire nut (11) to nut (12) with Iockwire Bond the washers to the support with
(C138). adhesive (C8).
b. Carefully Iower dual hydraulic cylinder (5, 9, or
17, figure 7-3) down through support (8 or 18). Align
"larger" hole in dual hydraulic cylinder housing with
(12) Position boot (6) at 15.16 inch dimension "larger" hole in support (8 or 18). Position special
as illustrated (figure 7-12). washer (25) on MS2006-48, bolt (24) with chamfered
side of washer next to bolt head. Install this bolt in
(13) Install damp (5) to secure upper end of larger hale. Hold bolt (24) with work aid shown on
boot (6) to tube (4). figure 7-11. Install washer (27) and nut (28). Install
three MS2005-48 bolts (24) in the three "smaller" hales
with special washer (25) positioned on bolts in the
NOTE
same manner. Hold bolts with aid shown cm figure
7-11. Install washer (27) and nut (28). Torque nuts (28,
Assembly dimensions shown on figure 7-3) evenly to values shown below.
figures 7-12 and 7-15 are nominal and
are subject to change during rigging
(Chapter 11).
Change 22 7-57
TM 55-1520-236-23
Install lower end of control tube assemblies 7-67. INTERSYSTEM LEAKAGE
(13, 52, and 83, figure 11-31) to bellcranks (11, 53, D U A L HYDRAULIC CYLINDERS.
and 85).
Ensure that check valves are installed
with flow arrows toward valve in
pressure ports P1 and P2. Be sure flow
regulators on collective servo cylinder
are installed with flow regulator arrow
pointing away from servo valve (figure
7-17).
d. Connect hydraulic hoses to fittings in
ports at bottom of cylinder valve (19, figure 7-3).
a. Bleed all residual pressure from system
(paragraph 7-3).
b. Trace return lines from the overflowing
reservoir to each dual hydraulic cylinder. Mark lines
Check that all four bolts through the for subsequent removal.
control valve Iever (21, figure 7-3) have a
self - locking caste hated nut safetied with c. Connect hydraulic test stand (S2) hoses to
a cotter pin. Check that nuts and bolts as system which shows low fluid level.
an assembly can be turned by hand after
cotter pin installation (four places).
d. Disconnect control tube (6, 7, or 22, figure 7-3)
from control valve lever (21) of dual hydraulic
cylinder being tested. Disconnect rod end of bearing
a. Connect upper rod end bearing of control tube
assembly (6, 7, or 22) to control valve lever (21) with of dual hydraulic cylinder from swashplate horn or
collective lever. Disconnect previously located return
bolts, two thin washers, self-locking castellated nut
line from dual hydraulic cylinder (step b above).
and cotter pin. Hold nut on the blind side with wrench
and turn the head of the bolt with wrench until nut
slot is in alignment with bolt shank hole for cotter pin
installation. Make sure nut and bolt as an assembly
can be turned by hand. Install cotter pin.
NOTE
Cotter pin is to be installed after final
rigging is checked.
e. Set hydraulic test stand (S2) for approximately
f. Position and connect rod end bearing of dual 6 gpm flow at 850 TO 900 psig pressure.
hydraulic cylinder to swashplate horn or collective
f. Extend cylinder to full travel. Leakage from
lever, using attaching parts as shown (figure 7-18).
cylinder return port after the cylinder is bottomed
Check rigging of collective and cyclic control system
indicates intersystem leakage Increase pressure to
(paragraphs 11-7 and 11-29).
1475 TO 1525 psig and check both open ports.
9. Reconnect any hydraulic connections g. Repeat steps e. and f. with cylinder in full
loosened for removal. retract position.
7-58 Change 5
TM 55-1520-236-23-2
k Refill and bleed hydraulic system (paragraphs 7-68. SERVO VALVE REPLACEMENT - DUAL
7-6 and 7-3). HVDRAULIC CYLINDERS (AVIM).
L Remove maintenance platform (S10) from heli-
copter. With cylinder assembly removed and in a dean, shel-
tered work area replace servo valve on a dual hydraulic
m. Disconnect hydraulic test stand (S2) from heli- cyilnder assembly.
copter.
Figure 7-17. Dual Hydraulic Cylinder Valve Connections (Sheet 1 of 2).
Change 11 7-59
TM 55-1520-236-23
Figure 7-17. Dual Hydraulic Cylinder Valve Connections (Sheet 2 of 2).
7-69. REMOVAL - SERVO VALVE - DUAL 7-70. INSTALLATION - SERVO VALVE -
HYDRAULIC CYLINDERS. DUAL HYDRAULIC CYLINDERS.
a. Loosen nut (2, figure 7-19) enough to release tab a. With nut (2, figure 7-19) and tab washer (3) in
Iockwasher (3) from slot in top of servo valve (5) hous- place, install six new packings (4) on piston rod (1).
ing. Unscrew servo valve from piston rod (1). Apply a heavy coat of hydraulic fluid (C61 or C62) to
packings (4) and lower end of piston rod (1). Screw
b. Remove six packings (4) from piston rod (1). servo valve (5) onto threaded end of piston rod (1) until
7-60 Change 21
TM 55-1520-236-23
Figure 7-18. Dual Hydraulic Cylinders to Swashplate and Collective Lever Installation
Change 5 7-61
TM 55-1520-236-23
Figure 7-19. Dual Hydraulic Cylinder Servo Valve Installation
bottomed. Back off servo valve (5) one-half to one and
one-half turns to align and insert tab Iockwasher (3) d. q q Install check valves, relief valves;
into slot at top of servo valve housing. Turn nut (2) and/or flow regulators and fittings into parts in lower
down to hold tab Iockwasher (3) in slot. end of servo valve (5), see figure 7-17 (Sheet 2).
b. Torque nut (2) 500 TO 600 inch-pounds and
secure with Iockwire (C137). 7-71. m (SCAS) S E R V O
ACTUATORS.
Ensure that check valves are installed
with flow arrows toward valve in 7-72. ~ D E S C R IPTION (SCAS) SERVO
pressure ports P1 and P2 (figure 7-17). ACTUATORS.
Cm Install check valves, and/or flow regulators, Hydraulic components of stability and control
and fittings into ports in lower end of servo valve (5). augmentation system (SCAS) are the pitch, roll, and
See figure 7-17. yaw servo actuators (figure 7-1 and 7-20) and
7-62 Change 16
TM 55-1520-236-23
associated pressure Iine filters, solenoid valves, and
connecting lines. Each actuator assembly consists of
an electro-hydraulic servo actuator, fitted with a tube
assembly at one end and a clevis at the other for
connection into cyclic and tail rotor control linkages
ahead of hydraulic power cylinders. Filters, rated 1 0
micron, are in pressure Iines to protect each actuator.
Solenoid valves have two positions, pressure-to-
cylinder when electrically energized, or cylinder-to-
reaturn when de-energized.
Premaintenance Requirements for
(SCAS) Servo Actuators
Condition Requirements
Model AH-1S
Part No. or Serial No. 209-076-020-3, -5
Special Tools None
Test Equipment None
Support Equipment None
Minimum Personnel Two
Required
Consumable Materials (C22) (C61) (C62)
(C112) (C127) (C137)
Special Environmental None
Conditions
7-73. q R E M O V A L ( S C A S ) S E R V O
ACTUATORS.
a. Remove doors on underside of fuselage for
access.
b. Disconnect electrical connectors and hydraulic
hoses from servo actuator. Cap hose and cover ports
on actuator.
c. Remove bolts to disconnect actuator tube and
clevis from control system bellcranks. Remove
Figure 7-20. (SCAS) Servo Actuator Assembly actuator assembly.
7-63
TM 55-1520-236-23
7-74. ~ CLEANING (SCAS) SERVO b. Replace tube assembly or clevis if damaged
ACTUATORS. beyond specified limits (paragraph 11-150).
Do not cross hoses.
Cleaning solvent is flammable and toxic. c. Replace servo actuator if malfunction occurs. If
Provide adequate ventilation. Avoid both the roll and the pitch actuators must be replaced,
prolonged breathing of solvent vapors remove and install one at a time to avoid possibility of
and contact with skin or eyes. crossing hoses.
a. C l e a n e x t e r n a l s u r f a c e s , e x c e p t p o l i s h e d d. W h e n r e p l a c i n g ( S C A S ) s e r v o a c t u a t o r
surfaces of piston rod and valve, by wiping with cloth assembly, remove hydraulic fittings for use on new
moistened with solvent (C112). assembly.
b. Carefully clean polished surfaces of piston rod e. When replacing tube assembly, ensure that
and valve with a soft cloth moistened with hydraulic tube is correct part for control system in which it is to
fluid (C61 or C62). be used. Decals are provided on tubes for this
purpose.
7-75. ~ I N S P E C T I O N (SCAS) SERVO
ACTUATORS. (1) Tubes for lateral cyclic and fore-and-aft
cyclic systems are identical, and have an internal rod
a. Inspect tube assembly and clevis for surface in riveted joint at inboard end.
damage and corrosion according to limits for flight
control tubes (paragraph 11-150). (2) T u b e f o r d i r e c t i o n a l ( t a i l r o t o r ) c o n t r o l
system omits the internal rod because of vibration
b. Inspect (SCAS) servo actuator for leakage and conditions at its location and is marked by orange
corrosion damage. yellow paint on outer end.
c. Inspect (SCAS) servo actuator for binding or f. When replacing tube on (SCAS) servo actuator,
malfunction. torque spanner nut 200 TO 300 inch-pounds and
secure with Iockwire (C137).
d. Inspect (SCAS) servo actuator assembly for
security. g. When replacing clevis on threaded end of
(SCAS) servo actuator piston rod, adjust clevis 42.72
e. Inspect electrical connector for security. inches as shown. Torque nut against clevis and
secure nut to lock with Iockwire (C137).
7-76. q R E P A I R O R R E P L A C E M E N T
(SCAS) SERVO ACTUATORS. (AVIM) 7-77. ~ I N S T A L L A T I O N (SCAS)
SERVO ACTUATORS.
NOTE
a. Connect (SCAS) servo actuator into control
Repair of (SCAS) servo actuator (other linkage according to instructions for flight control
than tube replacement) is not permitted. system.
Excessive leakage, damage or
malfunction to component requires
replacement of part. Damaged part shall
be cleaned, wrapped in barrier material Ensure that hydraulic hoses do not chafe
(C22) and secured with tape (C127). when flight control system is operated
through full travel.
a. Repair surface damage on tube assembly o r
clevis according to instructions for flight control tubes b. Connect hydraulic hoses to fittings on (SCAS)
(paragraph 11-151). servo actuator (figure 7-1).
7-64 Change 3
TM 55-1520-236-23
c. Connect electrical connectors to (SCAS) servo 7-81. q D E S C R I P T I O N C Y L I N D E R
actuator. AND SUPPORT ASSEMBLY TAIL ROTOR
CONTROL.
d. Perform operational check (paragraph 7-3).
The hydraulic cylinder and support assembly used in
tail rotor control system is mounted horizontally in the
7-78. q (SCAS) FILTER fuselage compartment just ahead of the tailboom.
REPLACEMENT. Access is by a door attached with cowling fasteners
on right side, aft end, of the fuselage. The assembly
7-79. ~ DESCRIPTION (SCAS) FILTER includes a power cylinder and a walking beam
REPLACEMENT. mounted together in a support (figures 7-21 and
7-22). The cylinder is connected by hoses into
hydraulic System No. 1.
One in-line (SCAS) filter is located in the pressure line
to the directional (anti-torque) (SCAS) servo actuator,
and one in line (SCAS) filter is located in the pressure
line to each of the two cyclic (SCAS) servo actuators Premaintenance Requirements for
(figures 7-1, 7-2, and FO-1). Cylinder and Support Assembly
Tail Rotor Control
NOTE Condition Requirements
Model AH-1S
Change filter(s) ONLY if (SCAS) servo
actuators malfunctions because of Part No. or Serial No. 209-001-700-5
restricted hydraulic flow.
Special Tools None
a. Identify the in line filter which is to be replaced.
The two in line filters for the cyclic (SCAS) servo Test Equipment None
actuators are located in the compartment below the
transmission. Remove panels on both sides of the Support Equipment None
fuselage below wings to gain access to the
compartment. The in line filter for the directional Minimum Personnel Two
(anti-torque) (SCAS) servo actuator is located in a Required
compartment in the lower part of the fuselage below
the engine. Remove access panel aft of the aft landing Consumable Materials (C112) (C120) (C88)
gear cross tube to gain entry to the compartment. (C91) (C61) (C62)
(C23) (C127)
b. Before removal of in line filter, note flow
direction arrow on filter and decal on adjacent Special Environmental Clean, dust
structure. Use standard precautions to prevent Conditions Free Area
spillage of hydraulic fluid and remove filter. If new
filter is not to be installed immediately, cap or plug
open lines.
c. Install new filter with flow arrow properly 7-82. q R E M O V A L C Y L I N D E R A N D
oriented. Use new packings. SUPPORT ASSEMBLY TAIL ROTOR
CONTROL.
d. Perform functional check to ensure (SCAS)
servo actuator operates properly, and that there are a. Remove access panel (12, figure 2-2) and FM
no hydraulic leaks (paragraph 7-3). Install access sense antenna (35, figure 2-3).
panels.
b. Provide a small suitable container to catch
7-80. ~ C Y L I N D E R A N D S U P P O R T spilled fluid when removing hose assemblies (2 and
A S S E M B L Y TAIL ROTOR CONTROL. 21, figure 7-21) and tube assembly (16).
Change 5 7-65
TM 55-1520-236-23
Figure 7-21. Tail Rotor Control Cylinder and Support Installation
7-66
TM 55-1520-236-23
Figure 7-22. Tail Rotor Control Cylinder and Support Assembly
7-67
TM 55-1520-236-23
c. Remove hose assembly (2) from elbow (6).
Install protective dust cover to connector of hose
assembly.
d. Remove hose assembly (21) from elbow (8).
Cleaning solvent is flammable and toxic.
InstaII protective dust cover to connector of hose
Provide adequate ventilation. Avoid
assembly.
prolonged breathing of solvent vapors
and contact with skin or eyes. Eye
e. Remove tube assembly (16). Install protective
protection is required when using
dust covers to open fittings and tube assembly
compressed air.
connectors.
f. Remove cotter pin (11), nut (10), two washers
(9), and bolt (13) from clevis of cylinder and support
assembly (7) and remove control tube (12) from clevis. To prevent damaging internal
components, do not submerge cylinder
g. Remove cotter pin (3), nut (5), two washers (4) assembly (5, figure 7-22) or walking
and bolt (20) from control tube (1) and remove control beam (19) in solvent. Ensure that
tube from walking beam (22). PRESSURE and RETURN ports in
cylinder assembly (5) are capped prior to
h. Remove two nuts (19), four washers (18) and cleaning.
two bolts (17) attaching cylinder and support
assembly (7) to floor panel of fuselage. a. Wash external surfaces of cylinder and support
assembly with clean cloth saturated with solvent
i. Remove two bolts (14) and two washers (15) (C112). A soft bristle brush may be necessary to
attaching cylinder and support assembly (7) to floor loosen hardened deposits.
panel of fuselage and remove cylinder and support
assembly. Cap open ports of elbows (6 and 8). b. Allow to air dry or blow dry with clean, filtered,
compressed air.
7-83. ~ D I S A S S E M B L Y C Y L I N D E R
AND SUPPORT ASSEMBLY TAIL ROTOR 7-85. ~ INSPECTION CYLINDER AND
CONTROL. SUPPORT ASSEMBLY TAIL ROTOR
CONTROL.
a. Provide a clean work area. Remove cotter pin
(3, figure 7-22), nut (4), two washers (2) and bolt (1) a. Inspect cylinder assembly (5, figure 7-22) for
from cylinder assembly (5) and walking beam (19). damage, evidence of leaks and freedom of operation
Remove spacer (18) from walking beam (19). of control valve.
b. Break torque on nut (6) and remove clevis (7) b. Inspect support assembly (13) and plate
from piston rod of cylinder assembly (5). Remove nut assemblies (10 and 11) for cracks, elongated bolt
(6) from clevis (7). holes, corrosion damage, and surface damage, such
as nicks or scratches. The following limits apply:
c. Remove two nuts (8), four washers (9), two
bolts (12) and plate assemblies (10 and 11) from (1) Cracks are not acceptable in any part.
cylinder assembly (5) and support assembly (13).
(2) Reaction plate teflon-lined bushing radial
d. Remove cotter pin (16), nut (17), two washers wear (or egging) limit at contact point with cylinder is
(15) and bolt (14) from support assembly (13) and 0.003 inch.
walking beam (19). Remove walking beam from
support assembly. (3) Bolt hole elongation not to exceed 0.010
inch.
7-84. ~ C L E A N I N G C Y L I N D E R A N D
SUPPORT ASSEMBLY TAIL ROTOR (4) Maximum depth of reparable damage is
CONTROL. 0.060 inch for mechanical damage (nicks or
7-68
TM 55-1520-236-23
scratches), and 0.030 inch for corrosion damage. a. Disassembly Procedures.
Maximum depth after cleanup for either type damage
is 0.060 inch. NOTE
(5) No single area of rework shall exceed 3.5
Use a clean working area for disassemb-
inches in length and 0.5 inch width. Two or more
ly. As parts are removed, place in a
rework areas within 2.0 inches of each other shall be
clean container for protection against
considered as a single area. Total of all rework areas
dirt and rough handling. if unit is to
on any one surface must not exceed one-quarter of
remain disassembled for a considerable
the surface area.
length of time, protect parts from mois-
ture by immersing in preservative
7-86. q R E P A I R O R R E P L A C E M E N T hydraulic fluid.
CYLINDER AND SUPPORT ASSEMBLY
TAIL ROTOR CONTROL.
(1) Remove cotter pin (3), nut (4), washer (5)
and bracket (6). Remove bolt (7) from body (2) (Ref
a. Replace defective elbows (20 or 27, figure
fig. 7-22.1). Slide body (2) off of shaft (23).
7-22) fittings and packings at cylinder PRESSURE or
RETURN ports.
CAUTION
b. Replace cylinder assembly (5) if damaged or
malfunctioning. Shaft and body assembly (23 and 2, fig.
7-22.1) are select-fit, matched, and
precision lapped parts. If either part is
damaged, the complete assembly must
Do not use high-speed grinding wheels be replaced as a singie unit. Use ex-
to repair surface damage. treme caution when handling to prevent
damage to grooves and adjacent sur-
c. Rework damaged surfaces of support assembly faces. Wrap parts after disassembly for
(13) and plate assemblies (10 and 11) by polishing out protection and retain in set.
and blending edges of damaged area into
surrounding surface with a smooth contour. Cleanup NOTE
depth of mechanical damage (nicks, scratches, or
dents) need not be greater than depth of damage, if fliter (10) is damaged, remove retain-
provided none of the damage. remains. Cleanup depth
ing ring (8), washer (9) and fliter.
of corrosion pitting should be at least twice as deep as
the deepest pit. Total depth and area of rework shall
not exceed limits specified above (paragraph 7-85). (2) Remove preformed packings (11) from body
(2).
d. Replace any parts that are cracked or where
damage is not within reparable limits. (3) Cut Iockwire and loosen jam nut (15) from
barrel (17) and separate barrel from head (28).
7-86.1 REPAIR, TAIL ROTOR CONTROL
CYLINDER (4) Remove packing (26) from head (28).
Premaintenance Requirements for T/R Control (5) Remove shaft (23) and tube assembly (13)
Cylinder P/N1660 from shaft. Remove preformed packings (12 and 14).
Condition Requirements (6) Remove cap seal (25) and preformed pack-
ing or ring seal (24).
Model AH-1E, F, & P
Special tools N/A (7) Remove retaining rings (22), washers (21),
Test equipment Hydraulic Test Stand (52) scraper rings (20), channel seals (19) and preformed
Consumable materials (C37) (C61) (C63) (C91) packings (18) from both barrel (17) and head (28).
(C112) (C136) (C83.1)
Change 16 7-68.1
TM 55-1520-236-23
WARNING scratches, scoring, feathered edges, and damage
from corrosion.
Drycleaning solvent, P-D-680, used to
clean parts is potentially dangerous to (3) Check identification plate (16) for security of
personnel and property. Avoid repeated attachment and legibility.
and prolonged skin contact. Do not use
near open flame or excessive heat. (4) Examine parts for wear to excess of allow-
Flash point of solvent is 100 degrees F able wear limits as specified in Table 7-4.1.
to 138 degrees F (38 degrees C to 59
degrees C). NOTE
CAUTION Wear on shaft (23) is acceptable if
chrome plating is not worn through or is
Do not drop body (2) or shaft (23) into chipped. Wear on body (2) is acceptable
container of cleaning solvent. Hand hold if cylinder assembly leakage is within
to prevent damage to precision- limits as specified in final test proce-
machined surfaces. dures.
NOTE (5) Make visual check, using 10-power glass, of
all radii and corners.
Do not remove bushings (1) from body
(2), bushings (27) from head (28), or d. Repair Procedure.
name pIate (16) unless replacement is
necessary. (1) Except for critical surfaces (lapped parts) on
body (2, fig. 7-22.1) and shaft (23), polish out minor
b. Cleaning Procedure. scoring on nonsealing and nonbearing ferrous parts
with crocus cloth, (C37). Use polishing cloth, to polish
(1) Immerse and wash all metallic parts in dry- out minor scoring on aluminum parts. Thoroughly
cleaning solvent, (C112). Pay particular attention to clean any polished parts.
passages and threaded areas. Remove stubborn dirt
with a stiff-bristled, nonmetallic brush moistened in (2) Redate any parts not repairable by minor
solvent. polishing and any part worn beyond the allowable
wear limits specified in table 7-4.1.
WARNING
NOTE
Do not direct compressed air against
skin. Body (2, fig. 7-22.1) and shaft (23) are
precision-matched parts. If either body
(2) Dry all parts with dry, compressed air not in or shaft requires replacement, replace
excess of 15 psig (1.06 kg/sq cm). them as an assembly.
(3) If components are not to be used immedi- (3) Replace all packings, cotter pin, scraper
ately after cleaning, flush all parts with preservative rings, and retaining rings whenever these parts are
hydraulic fluid (C63) and place in a plastic bag and removed during disassembly.
dust-free containers.
e. Assembly Procedure.
c. Inspection Procedure.
(1) Lubrication. Lubricate all internal parts at
(1) Inspect all surfaces and threaded areas for final assembly in hydraulic fluid (C61) and lubricate all
damage, signs of wear, burrs, cross-threading, scor- preformed packings with technical petrolatum (C83.1)
ing, nicks, and/or corrosion. (Refer to table 7-4.1). prior to installation.
NOTE WARNING
Excessive wear is defined as any ob- Drycleaning solvent, P-D-680, used to
vious deformation or deterioration of clean parts is potentially dangerous to
parts which may render the unit in- personnel and property. Avoid repeated
operative. If doubt exists concerning the and prolonged skin contact. Do not use
serviceability of a part, replace the part. near open flame or excessive heat.
Flash point of solvent is 100 degrees F
(2) Mating surfaces and grooves on shaft (23, to 138 degrees F (38 degrees C to 59
fig. 7-22.1) and body (2) must be smooth and free of degrees C).
7-68.2 Change 16
TM 55-1520-236-23
Table 7-4.1 Inspection Criteria
ITEM
NUMBER NOMENCLATURE INSPECT FOR
-1 Bushing ID wear 0.252 inch
maximum
-2 Body Thread damage
Superficial damage and
corrosion
Cracks and distortion
-7 Bolt Damaged threads and
corrosion
-13 Tube Cracks, distortion, and
superficial damage
-15 Jamnut Thread damage
Crack distortion and
superficial damage
-17 Barrel Major ID 0.9405 inch max
Minor ID 0.6275 inch max
Thread damage
Cracks, distortion and
superficial damage
-23 Shaft Thread damage
Cracks and distortion
-27 Bushing OD 0.498 minimum
-28 Head ID 0.6275 maximum
Thread damage
Cracks, distortion, and
superficial damage
Change 16 7-68.3
TM 55-1520-236-23
Figure 7-22.1 Hydraulic Servocylinder, Part No. 1660 Series (Typical), Exploded View
7-68.4 Change 16
TM 55-1520-236-23
NOTE (a) install cylinder assembly in a suitable
hydraulic test stand capable of delivering hydraulic
Coat all internal parts with clean fluid continuously filtered to 10 microns, at pressures
hydraulic fluid (C61), to facilitate reas- up to 2250 psig (158.3 kg/sq cm) at 26.7 degrees C
aembly. (80 degrees F to 100 degrees F), as test medium.
Hydraulic test stand (52).
(2) if removed, press new bushings (1, fig.
7-22.1) into body (2) and bushings (27) onto head (b) Bleed all air from cylinder before testing.
(28).
(c) Connect PRESS and RET ports to
(3) When installing packings: hydraulic pressure source, and apply 2 psig for three
minutes. There shall be no external leakage.
(a) Visually inspect new packings for cuts,
nicks or flaws and discard when any evidence of these (d) Slowly increase pressure to 2250 psig
defects are present. (158.3 kg/sq cm) and hold for three minutes. There
shall be no external leakage.
(b) Ensure that packings are of proper size.
Uniform pressure on packings when installed is (e) Place servo body in center position and
necessary for satisfactory operation of servocylinder barrel in approximately midposition of travel. Apply
and to prevent leakage. 1100 psig (77.4 kg/sq cm) at PRESS port and hold
pressure for two minutes. Leakage from RET port
NOTE must not exceed 60 cubic centimeters per minute.
Ensure retaining ring is installed with (f) Apply 1100 psi (77.4 kg/sq cm) at PRESS
flat side outboard. port and cycle cylinder several times. Position body to
actuate barrel to fully extended position. After two
(c) Install preformed packings (18), channel minutes in this position, leakage at RET port must not
seals (19), scraper rings (20) and washers (21) and exceed 100 cubic centimeters per minute.
secure with retaining ring (22); in both head (28) and
barrel (17). (g) Actuate barrel to fully retracted position,
and repeat step f. Same leakage requirements must
(d) install preformed packing (26) into head be met.
(28).
(h) With 1500 psi (105.6 kg/sq cm) applied at
(e) Assemble ring seal on preformed packing PRESS port, force necessary to move servo valve
(24) and cap seal (25) onto shaft (23). body from any position must not exceed 2-1/2 lb
(1.135 kg).
(f) Install preformed packings (12 and 14) on
tube assembly (13) and insert tube into shaft (23). (f) Apply 50 psi (9.5 kg/sq cm) to return port
for three minutes. If seepage is present, continue test.
CAUTION
NOTE
Use care when torquing jam nut to
preclude damage to barrel (17) and head Combined leakage out of servo valve
(28). ends shall not exceed 1 drop in 15
minutes.
(g) Install barrel (17) and head (28) on shaft
(23) and fasten together with jam nut (15). Torque jam (2) Trouble Analysis. If any malfunction or
nut to 200-250 in-lb. Lockwire after testing. leakage is observed during tests, refer to table 7-4.2
troubleshooting chart, for probable cause and remedy.
(h) install preformed packings (11) in body (2) Replace parts if required and repeat all test proce-
and, if removed, install filter (10), washer (9) and dures.
retaining ring (8).
g. Post-Test Procedures.
(i) Install body (2) on shaft (23). Insert
shoulder bolt (7) through body and shaft and install (1) After satisfactory completion of all tests,
bracket (6), washer (5), nut (4) and cotter pin (3). flush cylinder assembly with preservative hydraulic
fluid (C61).
f. Final Performance Check.
(2) Lockwire jamnut (15), using Iockwire (C136).
(1) Test Procedures.
Change 16 7-68.5
TM 55-1520-236-23
Table 7-4.2 Troubleshooting Chart
TROUBLE PROBABLE CAUSE REMEDY
Leakage during test Faulty shaft and/or body Replace shaft (23, fig. 7-22.1)
procedure step e. and body (2).
Leakage during test Faulty shaft and/or body Replace shaft (23) and
procedure, steps f., and g. body (2).
Tube packings (12) or Replace packings as required.
packing (24) nicked
Leakage from either Faulty packings Replace packings as required.
end of piston
Excessive force required Shaft in barrel binding Replace barrel (17) and/or
to move barrel shaft (23) and body (2) and/or
head (28).
Valve travel check out Faulty shaft and/or body Replace shaft (23, fig. 7-22.1)
of limits and body (2) and retest.
Figure 7-22.2 Hydraulic Servocylinder
7-68.6 Change 16
TM 55-1520-236-23
Table 7-4.3 Leading Particulars T/R Control Cylinder
Pressure Data:
Operating 1500 psig (105.6 kg/sq cm)
Proof 2250 psig (158.3 kg/sq cm)
Burst 3750 psig (263.9 kg/sq cm)
Cylinder Stroke 3.500 to 3.540 in. (8.89 to 8.992 cm)
Effective Area 0.38 in.2 (2.45 sq/cm)
Port Data:
PRESS per AND 10050-4 for 1/4 in. tube
RET per AND 10050-5 for 5/16 in. tube
Servo Valve Data:
Servo Valve Stroke from Neutral 0.035 in. (0.089 cm)
CYL 1 and CYL 2 to RET 0.004 to 0.006 in. (0.010 to 0.015 cm) overlap
PRESS to CYL 1 and CYL 2 0.001 to 0.002 in. (0.003 to 0.005 cm) underlap
Pilot Input Force (after static
for 5 minutes and 1500 psi)
(105.6 kg/sq cm)) 2.5 lb (1.14 kg) (max.)
Hot Load on Valve 1000 lb (454 kg) (max.)
Breakout Force (Ports Open) 5.0 lb (2.27 kg) (max.) (P/N1660-9, -11, -15)
10.0 lb (4.54 kg) (max.) (P/N1660-17, -23)
Overall Dimensions (approx):
Length 14 in. (35.6 cm)
Width 1.5 in. (3.8 cm)
Height 2.56 in. (6.50 cm)
Weight (Dry) 1.75 lb (max.) (0.79 kg)
Operating Medium Hydraulic fluid, MIL-H-83282A
Operating Temperature Range -53.9 C to +82.2 C
(-65 F to +180 F)
Change 16 7-68.7/(7-68.8 blank)
TM 55-1520-236-23
7-87. q ASSEMBLY CYLINDER AND f. Install nut (26), ring (25) and packing (24) on el-
SUPPORT ASSEMBLY TAIL ROTOR bow (27). Apply a light film of hydraulic fluid (C61 or
CONTROL. C62) to threads of elbow (27) and packing (24) and
thread elbow in RETURN port of cylinder assembly
a. Provide a clean work area and place nut (6, (5). Postion elbow (27) forward as shown in view B and
figure 7-22) on clevis (7). Thread clevis into end of tighen nut (26).
cylinder assembly (5) piston rod. Adjust clevis (7)
1.22 inches from end of rod to center of clevis bolt g. Install nut (21), ring (22) and packing (23) on
holes (view A), with clevis aligned same direction as elbow (20). Apply a light film of hydraulic fluid (C61 or
valve clevis as shown. Tighten nut (6). C62) to threads of elbow (20) and packing (23) and
thread elbow in PRESSURE port of cylinder assembly
b. Install tape (C120) to inboard surface of plate (5). Position elbow (20) forward as shown in view B
assembly (10 and 11) bolt holes. Tape must extend and tighten nut (21).
0.25 inch beyond edges of plate assembly.
h. If cylinder and support assembly IS n o t
c. Place plate assemblies (10 and 11) on immediately being installed, install protective dust
trunnions of cylinder assembly (5). Position cylinder caps to open ports of elbows (20 and 27) and wrap
assembly (5) to support assembly (13). Apply primer with barrier material (C23) and secure with tape
(C88 or C91) to two bolts (12) and install bolt with four (C127).
washers (9) and two nuts (8) through plate
assemblies (10 and 11) and support assembly (13). 7-88. ~ INSTALLATION CYLINDER
AND SUPPORT ASSEMBLY TAIL ROTOR
d. Insert spacer (18) in bearing of walking beam
CONTROL.
(19). Position cylinder assembly (5) with PRESSURE
port at right and align clevis of cylinder assembly on
ends of spacer (18). Install bolt (1) with two washers a. Apply tape (C120) to bottom of four mounting
(2) and nut (4). Secure nut (4) with cotter pin (3). pads of cylinder and support assembly (7, figure
7-21). (See NOTE 1 of figure 7-21).
e. Place one washer (15) on bolt (14). Apply
primer (C88 or C91) to bolt (14). Position walking b. Position cylinder and support assembly (7) to
beam (19) in clevis of support assembly (13) and floor panel. Place two washers (18) on two bolts (17)
install bolt (14), washer (15) and nut (17). Secure nut and two washers (15) on two bolts (14). Install bolts
(17) with cotter pin (16).
Change 16 7-69
TM 55-1520-236-23
(17) through the floor panel and stabilization stop. (En- 7-90. ~ S O L E N O I D VALVE P/N
sure the stop is installed with the flat side toward the 88604-1.
rear). Apply a light coat of unreduced primer (C88 or
C91) to bolts (14 and 17), and install bolts. Install two
washers (18) and two nuts (19) to bolts (17) (lower side 7-91. q D E S C R I P T I O N S O L E N O I D
of floor panel). VALVE P/N 88604-1.
c. Position clevis of control tube (1) to walking One solenoid valve P/N 88604-1 is located in each
beam and install bolts (20), two washers (4) and nut hydraulic modular unit (1 and 15, figure 7-1). The
(5). Secure nut (5) with cotter pin (3). solenoid valves are controlled by the HYD TEST
switch in the pilot engine control panel.
d. Position bearing end of control tube (12) to
clevis of cylinder and support assembly (7) and install 7-92. ~ CLEANING SOLENOID VALVE
bolt (13), two washers (9) and nut (10). Secure nut P/N 88604-1.
(10) with cotter pin (11).
a. Clean the solenoid valves while installed in
e. Remove protective dust covers from hydraulic
hydraulic modular units (1 and 15, figure 7-1).
fittings (located on floor panel, inboard and outboard
of cylinder and support assembly) and connectors of
tube assembly (16). Install tube assembly (16) and
torque tube connectors in accordance with torque
limits outlined in table 7-4.
f. Remove protective dust covers from elbows (6
and 8) and connectors of hose assemblies (2 and 21). Cleaning solvent is flammable and toxic.
Install hose assemblies (2 and 21) and connectors. Provide adequate ventilation. Avoid
Torque connectors in accordance with torque prolonged breathing of solvent vapors
requirements outlined in table 7-4. Check cylinder and contact with skin or eyes.
and support assembly (7) for freedom of movement.
Ensure hose assemblies (2 and 21) do not restrict b. Clean the solenoid valves with a clean cloth
cylinder movement. moistened with solvent (C112). Use a soft bristle
brush to remove stubborn deposits of dirt or oil.
g. Move anti-torque pedals through full throw ten
times while pressure is on system to eliminate air.
operate helicopter engine (refer to TM 7-93. q I N S P E C T I O N S O L E N O I D
55-1520-236-10), or use hydraulic test stand (S2) to VALVE P/N 88604-1.
pressurize hydraulic system (paragraph 7-3).
a. Inspect solenoid valves installed in hydraulic
NOTE modular units (1 and 15, figure 7-1) for bent or broken
pins in electrical connectors.
If air is not eliminated by procedure b. Inspect external surfaces of solenoid valves for
outlined in step (g), feedback may be nicks, dents, and cracks. No cracks are acceptable.
experienced during flight. If feedback is
experienced, accomplish step (h). c. Inspect area around solenoid valves for
hydraulic fluid leaks.
h. Attach hydraulic test stand (S2) (paragraph
7-3). Disconnect control tube (12) at aft end of power 7-94. ~ REPAIR OR REPLACEMENT
cylinder and control tube (1) at lower end of walking SOLENOID VALVE P/N 88604-1. (AVIM)
beam (22) (paragraph 7-82, step g). Ensure that
cylinder will not strike any structure when actuated. Replace solenoid valve and hydraulic modular units (1
Move walking beam to cause power cylinder to move and 15, figure 7-1) as an assembly if solenoid valves
through full throw ten times. Reinstall control tube (1 fail to meet inspection requirements of paragraph
and 12). Refer to above steps c and d. Disconnect 7-93. Refer to paragraphs 7-39 and 7-43 for removal
hydraulic test stand (S2). and installation instructions.
7-89. ~ S O L E N O I D V A L V E S .
7-70 Change 12
TM 55-1520-236-23
7-95. m S O L E N O I D VALVE, P/N Two, three-way, two-position solenoid valves (3 and
204-076-504-3 FSCM 9 4 6 4 1 P / N 5) are included in the hydraulic system to permit use
1-U-1025-63 or FSCM 1 6 7 8 0 P / N of the electric, emergency hydraulic pump in the
event of failure of system no. 1 and system no. 2
130027-5 (3 and 5, Figure 7-2).
pumps. The solenoid valves are also used to permit
use of the electric, emergency pump during
boresighting procedures. The solenoid valves are
controlled by the EMER HYDR PUMP/BORESIGHT
7-96. m D E S C R I P T I O N S O L E N O I D switch. See FO-1 (foldout 1) for view of hydraulic
VALVES P/N 204-076-504-3 FSCM 94641 system schematic. See table 7-5 for leading
P/N 1-U-1025-63 or FSCM 16780 P/N particulars for solenoid valve P/N 204-076-504-3
130027-5 (3 and 5, Figure 7-2). FSCM 94641 P/N 1-U-1025-63.
Table 7-5. Leading Particulars for Solenoid Valve
P/N 204-076-504-3 FSCM 94641 (1-U-1025-63)
Operating Medium . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Fluid, Military
Specification MIL-H-5606 (C61)
or
Military Specification
MIL-L-83282 (C62)
Pressures:
Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1500 psig
Proof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3000 psig
Burst . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4500 psig
Leakage:
External . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . none
Internal (at 1500 psig) . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 cc per minute maximum with
solenoid energized; 1 cc per minute
maximum with solenoid de-energized
PE Drop
(Port 2 to 1, or 2 to 3):
At +21 degrees C (+70 degrees F) . . . . . . . . . . . . . . . . 75 psig (maximum) at 3 gpm flow
At -54 degrees (-65 degrees F) . . . . . . . . . . . . . . . . . . . 200 psig (maximum) at 3 gpm flow
Solenoid Characteristics:
Voltage Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 to 30 volts dc
Current Drain at 28 volts dc
and +21 degrees C (+70 degrees F) . . . . . . . . . . . . . . . 1.2 amperes (maximum)
7-71
TM 55-1520-236-23
Table 7-5. Leading Particulars for Solenoid Valve
P/N 204-076-504-3 FSCM 94641 (1-U-1025-63)
Ambient Temperature
Range: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -54 degrees C (-65 degrees F) to
+71 degrees C (+160 degrees F)
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.25 pounds
Premaintenance Requirements for (1) Remove right fuselage access panel (17,
Hydraulic Solenoid Valves figure 2-3).
Condition Requirements (2) Disconnect electrical connector from
solenoid valve (6, figure 7-23).
Model AH-1S
(3) Provide a suitable container to catch fluid
Part No. or Serial No. 204-076-504-3 seepage when disconnecting tube assemblies from
solenoid valve (6).
Special Tools None
Test Equipment Hydraulic test stand (S2) (4) Remove tube assembly (12) from solenoid
valve (6).
Pressure drop test setup
(figure 7-27) (5) Disconnect tube assemblies (1 and 10) from
solenoid valve (6).
Functional test setup
(figure 7-27) (6) Remove two bolts (16) and two washers (15)
attaching solenoid valve (6) to bulkhead and remove
solenoid valve.
30 vdc power supply
Support Equipment None (7) Drain hydraulic fluid from solenoid valve (6)
and remove fitting (13). Remove packing (14) from
Minimum Personnel Two fitting (13).
Required
(8) Loosen nut (9) and remove elbow (11) from
Consumable Materials (C22) (C30) (C31) solenoid valve (6). Remove packing (7), ring (backup)
(C36) (C37) (C61) (8) and nut (9) from elbow (11).
(C62) (C63) (C88)
(C91) (C112) (C137) (9) Loosen nut (3) and remove elbow (2) from
solenoid valve (6). Remove packing (5), ring (backup)
Special Environmental None (4) and nut (3) from elbow (2).
Conditions
(10) Install protective dust covers to open ports
and electrical connector of solenoid valve (6) to
7-97. q R E M O V A L S O L E N O I D prevent entry of foreign particles.
VALVES P/N 204-076-504-3 FSCM
94641 P/N 1-U-1025-63 OR FSCM b. Remove solenoid valve (24, figure 7-23) as
16780 P/N 130027-5 (3 AND 5, FIGURE follows:
7-2) AND (6 AND 24, FIGURE 7-23).
(1) Remove right fuselage access panel (17,
a. Remove solenoid valve (6, figure 7-23). figure 2-3).
7-72
TM 55-1520-236-23
Figure 7-23. Solenoid Valve P/N 204-076-504-3 Installation
7-73
TM 55-1520-236-23
(2) Disconnect electrical connector from b. Inspect ports for damaged threads.
solenoid valve (24, figure 7-23).
c. Inspect external surfaces for nicks, dents, and
(3) Provide a suitable container to catch fluid cracks. No cracked parts are acceptable.
when disconnecting tube assembly (28) from
solenoid valve (24). NOTE
(4) Remove tube assembly (28) from solenoid Inspect disassembled solenoid valve
valve (24). FSCM 94641 P/N 1-U-1025-63 as
outlined in paragraph 7-103.
(5) Disconnect tube assemblies (23 and 29)
from solenoid valve (24). 7-100. q REPAIR OR REPLACEMENT
SOLENOID VALVES P/N 204-076-504-3
(6) Remove two bolts (17) and two washers (18) FSCM 94641 P/N 1-U-1025-63 AND FSCM
attaching solenoid valve (24) to bulkhead and remove 16780 P/N 130027-5 (AVIM) (3 AND 5,
solenoid valve. FIGURE 7-2).
(7) Drain hydraulic fluid from solenoid valve
a. Inspect data plate on solenoid valve and
(24) and remove fitting (21). Remove packing (22)
determine whether valve is FSCM 94641 P/N
from fitting (21).
1-U-1025-63 or FSCM 16780 P/N 130027-5.
(8) Remove check valve (30) from tee (27) and
b. Replace solenoid valves FSCM 16780 P/N
remove packing (31) from check valve.
130027-5 that fail to meet inspection requirements
of paragraph 7-99.
(9) Loosen nut (32) and remove tee (27) from
solenoid valve (24). Remove packing (25), (backup)
c. Repair solenoid valves FSCM 94641 P/N
ring (26) and nut (32) from tee (27).
1-U-1025-63 that fail to meet inspection
requirements (paragraph 7-104).
(10) Remove plug (20) from solenoid valve (24)
and remove packing (19) from plug.
7-101. q DISASSEMBLY SOLENOID
(11) Install protective dust covers to open ports VALVE P/N 204-076-504-3 FSCM 94641
and electrical connector of solenoid valve (24) to P/N 1-U-1025-63.
prevent entry of foreign particles.
a. Install solenoid valve body (9, figure 7-24) in a
7-98. q C L E A N I N G SOLENOID smooth-jawed bench vise.
VALVES P/N 204-076-504-3 FSCM 94641
P/N 1-U-1025-63 OR FSCM 16780 P/N b. Remove Iockwire from nut (1).
130027-5 (3 AND 5, FIGURE 7-2).
c. Using a spanner wrench, remove nut (1) from
a. Clean assembled solenoid valves (3 and 5) in body (9).
same manner outlined in paragraph 7-111.
d. Remove pin (2), plunger assembly (3), pin (4),
b. Clean disassembled solenoid valves (3 and 5) pole (5), and coil assembly (17) from body (9).
FSCM 94641 P/N 1-U-1025-63 as outlined in
paragraph 7-102. e. Remove pin (4), pole (5) and plunger assembly
(3) from coil assembly (17).
7-99. q I N S P E C T I O N A S S E M B L E D
SOLENOID VALVES P/N 204-076-504-3
FSCM 94641 P/N 1-U-1025-63 AND FSCM
16780 P/N 130027-5 (3 AND 5, FIGURE 7-
2). Keep piston (16) and sleeve (8) together
to prevent damage to lapped surfaces.
a. Inspect electrical connector for bent or broken Parts are matched and are not
pins and damaged threads. interchangeable.
7-74
TM 55-1520-236-23
Figure 7-24. Solenoid Valve P/N 204-076-504-3 FSCM 94641 P/N 1-U-1025-63 Assembly
f. Remove sleeve (8) and piston (16) from bore of 7-102. ~ CLEANING DISASSEMBLED
body (9) with packings (6, 12, 13 and 14) and backup SOLENOID VALVE P/N 204-076-504-3
rings (7, 10, and 11) attached. FSCM 94641 P/N 1-U-1025-63.
g. Remove packings (6, 12, 13 and 14) and
(backup) rings (7, 10, and 11) from sleeve (8).
h. Remove spring (15) from bore of body (9). Cleaning solvent is flammable and toxic.
Provide adequate ventilation. Avoid
prolonged breathing of solvent vapors
NOTE and contact with skin or eyes. Eye
protection is required when using
Do not remove nameplate and four drive compressed air.
screws from body (9) unless nameplate is
damaged.
Handle detail parts of the solenoid valve
i. Remove body (9) from bench vise. carefully to avoid damage.
Change 3 7-75
TM 55-1520-236-23
a. Clean solenoid valve parts with solvent (C112). c. Inspect all packing grooves for surface defects
Use a soft bristle brush to remove stubborn deposits. that might cut packings during installation or cause
sealing failure during operation.
b. Allow to air dry or blow dry with clean, filtered,
compressed air. d. Check security of press fit of pin (2) in plunger
assembly (3).
7-103. q I N S P E C T I O N
DISASSEMBLED SOLENOID VALVE P/N e. Inspect plunger assembly (3) for galling or
204-076-504-3 FSCM 94641 P/N 1-U- scoring.
1025-63.
f. Inspect electrical receptacle of coil assembly
NOTE (17) for broken or bent pins.
The inspection procedures in this g. Inspect sleeve (8) and piston (16) for nicks,
paragraph are applicable to scratches, or other visible damage to lapped surfaces.
disassembled solenoid valve P/N 204-
076-504-3 FSCM 94641 P/N 1-U- h. Inspect spring (15) for deformity.
1025-63.
i. Inspect nameplate on body (9) for legibility and
a. Inspect all parts for nicks, cracks, scratches, security of attachment. Illegible, loosely attached, or
and corrosion. Use a strong light and magnifying missing nameplates are not acceptable.
glass. No cracked parts are acceptable.
j. Inspect parts in accordance with table 7-6.
b. Inspect body (9, figure 7-24) and nut (1) for
damaged threads. k. Inspect parts in accordance with table 7-7.
Table 7-6. Non-Destructive Test Requirements for Solenoid Valve
P/N 204-076-504-3 FSCM 94641 P/N 1-U-1025-63 (AVIM)
FIGURE
7-24
INDEX
NOMENCLATURE NO. TYPE OF TEST PROCEDURE REMARKS
Nut 1 Magnetic Particle Inspect for cracks and If defective, replace
Inspect strains per MIL-I-6868 with new part.
and TM 43-0103
Piston 16 Magnetic Particle Inspect for cracks and If defective, replace
Inspect strains per MIL-I-6868 with new part.
and TM 43-0103
Sleeve 8 Magnetic Particle Inspect for cracks and If defective, replace
Inspect strains per MIL-I-6868 with new part.
and TM 43-0103
7-76
TM 55-1520-236-23
Table 7-6. Non-Destructive Test Requirements for Solenoid Valve
P/N 204-076-504-3 FSCM 94641 P/N 1-U-1025-63 (AVIM) (Cont)
FIGURE
7-24
INDEX
NOMENCLATURE NO. TYPE OF TEST PROCEDURE REMARKS
Body 9 Fluorescent Inspect for cracks and If defective replace
Penetrant strains per MIL-I-6866 valve.
Inspect and TM 43-0103
Spring 15 Dimension and Test Load: 5 to 7 Permanent set shall not
Load pounds at 0.320 result from test load.
inch Spring shall not wobble
when rolled across a
flat surface.
Coil 17 Dielectric and Apply 1000 volts ac Replace coil assembly if
Assembly Insulation rms between both any evidence of dielectric
Resistance receptacle pins and coil breakdown or leakage.
assembly case for 10 Resistance shall be at
seconds. least 5 megohms.
Table 7-7. Diametrical Clearance Requirements for Solenoid Valve
P/N 204-076-504-3 FSCM 94641 P/N 1-U-1025-63 (AVIM)
FIGURE
7-24
INDEX DIAMETRICAL CLEARANCE (IN.)
NOMENCLATURE NO. MAX. MIN. REMARKS
Pin 4 0.0100 0.0030 Pin (4) to fit pole (5)
center I.D.
Plunger 3 0.0050 0.0025 Plunger assembly O.D.
Assembly fit to coil assembly
(17) I.D.
7-77
TM 55-1520-236-23
7-104. m REPAIR DISASSEMBLED b. Place body (9, figure 7-24) in a smooth jawed
SOLENOID VALVE P/N 204-076-504-3 bench vise.
FSCM 94641 P/N 1-U-1025-63. (AVlM)
c. Install packing (12, 13 and 14) and (backup)
a. Polish out minor nicks and scratches on metal rings (11 and 10) on sleeve (8). Carefully slide
parts with crocus cloth (C37) (for steel parts) and assembled sleeve in body (9) making certain that
abrasive cloth (C36) (for aluminum parts), provided packings are not damaged.
that dimensions specified in table 7-7 are
maintained, and seating and sealing surfaces are not
d. Insert spring (15) through sleeve (8) into body
damaged.
(9). Carefully slide piston (16) into sleeve (8), making
certain that spring (15) is nested in end of piston (16).
e. Install packing (6) and (backup) ring (7) on
The chemical film material is extremely protruding end of sleeve (8).
dangerous. Contact with combustible
materials will cause explosion or fire. f. Carefully slide plunger assembly (3) (with pin
Avoid contact with skin or eyes. (2)) and pole (5) into coil assembly (17). Insert pin (4) in
center hole of pole (5).
b. Treat repaired area of anodized finish, after
polishing, with chemical film material (C31). g. Slide assembled parts (2 through 5) and (17)
over protruding end of sleeve (8).
c. If pin (4, figure 7-24) requires replacement,
trim end of new pin to provide a stroke of 0.0380 TO h. Slide nut (1) over end of coil assembly (17) and
0.0390 inch when pin is installed in pole (5). thread to body (9).
d. Replace plunger assembly (3) if pin (2) is i. Using a spanner wrench, tighten nut (1).
damaged or loose, or if plunger assembly shows other
visible evidence of damage. j. If solenoid valve is not immediately being
installed on helicopter and will require storage, fill
e. Straighten bent pins of electrical receptacle of solenoid valve with preservative hydraulic fluid (C63).
coil assembly (17). If pins are broken, or if coil
assembly is defective, replace coil assembly.
7-106. q TESTING SOLENOID VALVE
f. Replace packings (6, 12, 13 and 14) and rings P/N 204-076-504-3 FSCM 94641 P/N 1-U-
(backup) (7, 10 and 11) each time valve is 1025-63 (AVIM).
disassembled.
a. Inspect hydraulic test stand (S2) to ensure that
g. If sleeve (8) or piston (16) is defective, replace it meets the following requirements:
both parts as an assembly.
(1) Capable of providing pressures to 2300
h. Replace all worn or damaged parts which psig at flow rate of 3 gpm.
cannot be reworked to meet inspection requirements.
(2) Equipped for filtration of particles to 1 0
i. Replace nameplate on body (9) when damaged, microns in size;
loosely attached, or missing.
(3) Serviced with clean hydraulic fluid (C61 or
C62).
7-105. ~ A S S E M B L Y S O L E N O I D (4) Capable of maintaining hydraulic fluid
VALVE P/N 204-076-504-3 FSCM 94641 within a temperature range of +21 degrees C (+70
P/N 1-U-1025-63. degrees F) to +43 degrees C (+110 degrees F).
a. Apply a light coat of hydraulic fluid (C61 or C62) b. Refer to table 7-8 if trouble is encountered
to all internal parts prior to assembly. during procedures in steps c through g.
7-78
TM 55-1520-236-23
Table 7-8. Troubleshooting During Testing of Solenoid Valve
P/N 204-076-504-3 FSCM 94641 P/N 1-U-1025-63 (AVIM)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. Solenoid valve does not operate smoothly and without hesitation.
STEP 1. Defective coil assembly (17, figure 7-24).
Replace coil assembly (17). Refer to paragraphs 7-97 through 7-107.
STEP 2. Pin (4) worn.
Replace pin (4). Refer to paragraph 7-104.
STEP 3. Defective plunger assembly (3).
Replace plunger assembly (3). Refer to paragraph 7-105.
STEP 4. Defective sleeve (8) or piston (16).
Damage to either sleeve (8) or piston (16) requires that both parts be replaced as an assembly.
Refer to paragraph 7-105.
STEP 5. Defective spring (15).
2. External leakage.
STEP 1. Packing (6) damaged or incorrectly installed.
Replace or reinstall packing (6). Refer to paragraph 7-105.
3. Internal leakage not within limits specified.
STEP 1. Defective sleeve (8) or piston (16).
Damage to either sleeve (8) or piston (16) requires that both parts be replaced as an assembly.
Refer to paragraph 7-105.
STEP 2. Defective spring (15).
Replace spring (15). Refer to paragraph 7-105.
STEP 3. Packings (12, 13 or 14) damaged or incorrectly installed.
Replace or reinstall packings (12, 13 or 14). Refer to paragraph 7-105.
7-79
TM 55-1520-236-23
c. Break-in Run Test. Install solenoid valve in a (4) After completion of proof pressure test,
test setup similar to that shown in figure 7-25 and reconnect pressure to port 3.
perform the following tests:
e. Internal Leakage Test. With solenoid valve still
(1) Check solenoid valve to ensure flow is as
installed in a test setup similar to that shown in figure
shown on figure 7-26 with the solenoid valve
7-25, perform the following tests:
energized and de-energized.
(1) Adjust pressure regulator to apply 1500
(2) Energize solenoid valve with 28 volts dc.
psig fluid pressure at port 3. Internal leakage from
port 1, after a 2 minute waiting period, not to exeed 1
(3) Adjust regulator valve until a fluid pressure
cubic centimeters per minute.
of 1500 psig is indicated on gage A.
(2) With 1500 psig pressure still applied at port
(4) Cycle solenoid valve under test 100 times by
3, enerize solenoid with 18 volts dc. Internal leakage
alternately de-energizing and energizing solenoid. If
from port 1, after a 2 minute waiting period, not to
the solenoid valve does not operate smoothly on each
exceed 3 cubic centimeters per minute.
cycle, disassemble and determine cause.
d. Proof Pressure Test. With solenoid valve still f. Operating Voltage Test. With solenoid valve
installed in a test setup similar to that shown in figure still installed in a test setup similar to that shown in
7-25, perform the following tests: figure 7-25, perform the following tests:
(1) Adjust regulator valve to apply 2250 psig (1) Adjust pressure regulator to apply 1500
fluid pressure at port 3. Maintain pressure for 2 psig fluid pressure at port 3.
minutes; there must be no evidence of external
leakage or visible distortion of valve. (2) Energize solenoid valve with 18 volts dc;
then de-energize solenoid valve. Valve operation, as
(2) Repeat preceding step (1) with 5 p s i g indicated by gage B, shall be instantaneous with no
pressure applied at port 3. evidence of sluggishness.
(3) Connect pressure source to port 1 and (3) Reduce pressure applied at port 3 to 200
repeat procedures of steps (1) and (2). psig. Repeat tests described in preceding step (2).
Figure 7-25. Functional Test Setup for Solenoid Valve
P/N 204-076-504-3 FSCM 94641 P/N 1-U-1025-63
7-80
TM 55-1520-236-23
(4) Adjust pressure regulator to gradually apply
pressure at port 2 until a flow rate of three gpm is
obtained at port 1. Maximum acceptable pressure
required to establish three gpm flow rate is 75 psig
plus tare. Record pressure required to obtain three
gpm flow.
(5) Remove solenoid valve and install a piece of
four inch long tubing with 0.375 inch outside
diameter and 0.041 inch maximum wall thickness.
Use identical fittings to those used in steps (1)
through (4). Adjust pressure regulator to gradually
apply pressure until a flow rate of three gpm is
obtained. Pressure required to obtain a three gpm
flow rate is tare. Record this tare figure.
Figure 7-26. Flow Diagram for Solenoid Valve
P/N 204-076-504-3 FSCM 94641 (6) Subtract tare figure from pressure
P/N 1-U-1025-63 recorded in step (1). If result is in excess of 75 psig,
the solenoid valve is unsatisfactory.
(4) Increase pressure applied at port 3 to 2250
psig. Repeat procedure described in preceding step (7) Subtract tare figure from pressure
(b), except energize solenoid valve with 28 volts Vdc. recorded in step (4). If result is in excess of 75 psig,
the solenoid valve is unsatisfactory.
g. Pressure Drop Test. Install solenoid valve in a
test setup similar to that shown in figure 7-27 and
perform the following tests:
7-107. ~ INSTALLATION SOLENOID
(1) Adjust pressure regulator to gradually apply VALVES P/N 204-076-504-3 FSCM 94641
pressure at port 3 until a flow rate of three gpm is P/N 1-U-1025-63 or FSCM 16780 P/N
obtained at port 2. Maximum acceptable pressure 130027-5 (3 and 5, figure 7-2).
required to establish three gpm flow is 75 psig plus
tare. Record pressure required to obtain three gpm a. Install solenoid valve (6, figure 7-23) as
flow. follows:
(2) Connect flowmeter to port 1, cap port 3, and (1) Remove protective dust covers from
connect pressure source to port 2. solenoid valve (6) and drain preservative hydraulic
fluid from solenoid valve. Flush solenoid valve with
(3) Energize solenoid valve with 18 volt dc. clean hydraulic fluid (C61 or C62).
Figure 7-27. Pressure Drop Test Setup for Solenoid Valve P/N 204-076-504-3 FSCM 94641 P/N 1-U-1025-63
7-81
TM 55-1520-236-23
(2) Apply a light film of hydraulic fluid (C61 or (3) Install nut (32), backup ring (26), and
C62) to all packings, threads and tube connectors packing (25) on tee (27).
prior to assembly of part, with the exception of bolts
(16). (4) Install packing (31) on check valve (30) and
install check valve into tee (27).
(3) Install nut (3), backup ring (4) and packing
(5) on elbow (2). Thread elbow into PORT 1, of (5) Thread tee (27) into PORT 2, position tee as
solenoid valve (6), position as shown and tighten nut shown and tighten nut (32).
(3).
(6) Install packing (19) on plug (20) and install
(4) Install nut (9), backup ring (8) and packing plug into PORT 1 of solenoid valve (24).
(7) on elbow (11). Thread elbow into PORT 2 of
solenoid valve (6) and tighten nut (9). (7) Install packing (22) on fitting (21) and install
fitting into PORT 3 of solenoid valve.
(5) Install packing (14) on fitting (13) and install
fitting into PORT 3. (8) Remove protective dust covers from tube
assemblies (23, 28 and 29).
(6) Buff mounting pads of solenoid valve (6) to
ensure good electrical bond. Position solenoid valve (9) Buff mounting pads of solenoid valve to
on bulkhead as shown and install two bolts (16) and ensure good electrical bond. Position solenoid valve
two washers (15). to bulkhead as shown and install two bolts (17) and
two washers (18).
(7) Connect and torque tube assemblies (1 and (10) Connect torque tube assemblies (23 and
10) in accordance with table 7-4. 29) in accordance with table 7-4.
(8) Install tube assembly (12) and torque (11) Install tube assembly (28) and torque
connectors of tube assembly in accordance with table connectors of tube assembly in accordance with table
7-4. 7-4.
(9) Install electrical connector to solenoid valve (12) Install electrical connector to solenoid
and secure with Iockwire (C137). valve and secure with Iockwire (C137).
(10) Fill reservoir to proper level. (Refer to (13) Fill reservoir to proper level. (Refer to
paragraph 7-6.) paragraph 7-6.)
(11) Perform operational check of hydraulic (14) Perform operational check of hydraulic
system. (Refer to paragraph 7-3.) Refill reservoir. system. (Refer to paragraph 7-3). Refill reservoir.
(12) Install right access panel to fuselage, (15) Install right access panel to fuselage,
under wing. below wing.
7-108. q SOLENOID VALVES P/N
b. Install solenoid valve (24, figure 7-23) as 209-076-023-1 FSCM 16780 P/N
follows: 15353 (7, 9, and 19, figure 7-1).
(1) Remove protective dust covers from 7-109. ~ DESCRIPTION SOLENOID
solenoid valve (24) and drain preservative hydraulic VALVES P/N 209-076-023-1 FSCM 16780
fluid from solenoid valve. Flush solenoid valve with P/N 15353 (7, 9, and 19, figure 7-1).
clean hydraulic fluid (C61 or C62). 7-1).
(2) Apply a light film of hydraulic fluid (C61 or Three, three-way, two-position solenoid valves (7, 9
C62) to all packings, threads and tube connectors and 19) are included in the hydraulic system to permit
prior to assembly of part, with the exception of bolts shutting off fluid circulation to any one of the three
(17). (SCAS) servo actuators. The solenoid valves are
7-82
TM 55-1520-236-23
controlled by the pitch, roll, and yaw switches on the (7) Remove components from solenoid valve
pilot (SCAS) control panel, see FO-1 (foldout 1) for (16) as follows:
view of hydraulic system schematic.
(a) Remove fitting (13) from solenoid valve
(16).
Premaintenance Requirements For
Hydraulic Solenoid Valves (b) Remove fittings (9 and 13) from filter (11)
and discard two packings (12) and packing (10). If
filter (11) is not immediately being installed, install
Condition Requirements protective dust covers to open ports.
(c) Loosen nut (21) and remove elbow (20)
Model AH-1S from solenoid valve (16). Remove packing (23),
(backup) ring (22) and nut (21) from elbow (20) and
Part No. or Serial No. 209-076-023-1 discard packing (23) and (backup) ring (22).
Special Tools None (d) Remove fittings (3, 31, and 33) from tee
(5) and discard packings (4, 32 and 29).
Test Equipment None
(e) Loosen nut (27) and remove fitting (28),
Support Equipment None with tee (5), from solenoid valve (16).
Minimum Personnel Two (f) Remove packing (25), (backup) ring (26),
Required and nut (27) from fitting (28). Discard packing (25) and
(backup) ring (26).
Consumable Materials (C112) (C61) (C62)
(g) Remove fitting (28) from tee (5) and
Special Environmental None discard packing (29).
Conditions
b. Remove solenoid valve (42, figure 7-28) for
lateral (SCAS) system as follows:
7-110. ~ REMOVAL SOLENOID
VALVES P/N 209-076-023-1 FSCM 16780 (1) Remove right access panel (17, figure 2-3).
P/N 15353 (7, 9, and 19, figure 7-1).
(2) Disconnect electrical connector from
a. Remove solenoid valve (16, figure 7-28) for fore solenoid valve (42, figure 7-28).
and aft (SCAS) system as folows:
(3) Provide a suitable container to catch fluid
(1) Remove right access panel (17, figure 2-3). seepage when disconnecting tube assemblies from
solenoid valve (42).
(2) Disconnect electrical connector from
solenoid valve (16, figure 7-28). (4) Disconnect tube assemblies (34, 37, and
48) from solenoid valve (42).
(3) Provide a suitable container to catch fluid
seepage when disconnecting tube assemblies from (5) Remove two nuts (51), two washers (52),
solenoid valve (16). two washers (41), two bolts (40) and remove solenoid
valve (42) from bracket (53).
(4) Disconnect tube assemblies (1, 2, 8, 19 and
30) from solenoid valve (16). (6) Install protective dust covers to open
connectors of tube assemblies (34, 37, and 48).
(5) Remove two nuts (15), two washers (14),
two washers (7), two bolts (6), and remove solenoid (7) Remove components from solenoid valve
(16) from bracket (24). (42) as follows:
(6) Install protective dust covers to open (a) Remove fitting (36) from solenoid valve
connectors of tube assemblies (1, 2, 8, 19 and 30). (42) and discard two packings (35).
7-83
TM 55-1520-236-23
Figure 7-28. Solenoid Valves (SCAS System) Installation (Sheet 1 of 4)
7-84
TM 55-1520-236-23
Figure 7-28. Solenoid Valves (SCAS System) Installation (Sheet 2 of 4)
7-85
TM 55-1520-236-23
Figure 7-28. Solenoid Valves (SCAS System) Installation (Sheet 3 of 4)
7-86
TM 55-1520-236-23
1. Tube assembly 48. Tube assembly
2. Tube assembly 49. Screw
3. Fitting 50. Washer
4. Packing 51. Nut
5. Tee 52. Washer
6. Bolt 53. Bracket
7. Washer 54. Packing
8. Tube assembly 55. Ring (backup)
56. Hose assembly
9. Fitting
10. Packing 57. Elbow
11. Filter 58. Nut
59. Ring (backup)
12. Packing
13. Fitting 60. Packing
61. Tee
14. Washer
15. Nut 62. Packing
63. Ring (backup)
16. Valve P/N 209-076-023-1
FSCM 16780 P/N 15353 64. Nut
17. Screw 65. Fitting
18. Washer 66. Packing
19. Tube assembly 67. Bushing
20. Elbow 68. Packing
21. Nut 69. Packing
22. Ring (backup) 70. Ring (backup)
23. Packing 71. Nut
24. Bracket 72. Elbow
73. Hose assembly
25. Packing
26. Ring (backup) 74. Washer
75. Spacer
27. Nut
76. Clamps
28. Fitting
77. Screw
29. Packing
78. Tube assembly
30. Tube assembly
79. Solenoid valve P/N 209-076-023-1
31. Fitting
FSCM 16780 P/N 15353
32. Packing
80. Spacer
33. Fitting
34. Tube assembly 81. Washer
35. Packing 82. Elbow
36. Fitting 83. Nut
37. Tube assembly 84. Ring (backup)
38. Elbow 85. Packing
39. Nut 86. Screw
40. Bolt 87. Tube assembly
41. Washer 88. Elbow
42. Solenoid valve P/N 209-076-023-2 89. Nut
FSCM 16780 P/N 15353 90. Ring (backup)
43. Packing 91. Packing
44. Fitting 92. Packing
45. Filter 93. Fitting
46. Packing 94. Tube assembly
47. Fitting
209076-54-4A
Figure 7-28. Solenoid Valves (SCAS System) Installation (Sheet 4 of 4)
7-87
TM 55-1520-236-23
(b) Loosen nut (39) and remove elbow (38) (a) Loosen nut (71) and remove elbow (72)
from solenoid valve (42). Remove packing (54), from solenoid valve (79). Remove packing (69),
(backup) ring (55) and nut (39) from elbow (38) and (backup) ring (70) and nut (71) from elbow (72).
discard packing (54) and (backup) ring (55). Discard packing (69) and (backup) ring (70).
(c) Remove fitting (44), with filter (45), from (b) Loosen nut (83) and remove elbow (82)
solenoid valve (42). Remove fittings (44 and 47) from from solenoid valve (79). Remove preformed packing
filter (45) and discard two packings (43) and packing (85), (backup) ring (84) and nut (83) from elbow (82).
(46). Discard packing (85) and (backup) ring (84).
(d) If filter (45) is not immediately being (c) Remove bushing (67), with tee (61) from
installed, install protective dust covers in open ports. solenoid valve (79).
(d) Remove bushing (67) from fitting (65) and
c. Remove solenoid valve (79, figure 7-28) for discard packings (66 and 68).
anti-torque (SCAS) system as follows.
(e) Remove fitting (93) from tee (61) and
(1) Remove access panel (38, figure 2-3). discard packing (92).
(2) Disconnect electrical connector from (f) Loosen nut (64) and remove fitting (65)
solenoid valve (79, figure 7-28). from tee (61). Remove packing (62), (backup) ring (63)
and nut (64) from fitting (65). Discard packing (62) and
(3) Provide a suitable container for catching (backup) ring (63).
fluid seepage when disconnecting hose assemblies
(56 and 73) and tube assemblies (78, 87, and 94) from (g) Loosen nut (89) and remove elbow (88)
solenoid valve (79). from tee (61). Remove packing (91), (backup) ring (90)
and nut (89) from elbow (88). Discard packing (91) and
(4) Remove hose assembly (56) from elbow (57) (backup) ring (90).
and install protective dust cover to hose connector.
(h) Loosen nut (58) and remove elbow (57)
from tee (61). Remove packing (60), (backup) ring (59)
(5) Remove hose assembly (73) from elbow (72) and nut (58) from elbow (57). Discard packing (60) and
and install protective dust cover to hose connector. (backup) ring (59).
(6) Remove screw (77), spacer (75), washer
7-111. M~ CLEANiNG ASSEMBLED
(74) and clamp (76).
SOLENOID VALVES P/N 209-076-023-1
FSCM 16780 P/N 15353 (7, 9, and 19, figure
(7) Remove tube assembly (78) from elbow (82)
7-1).
and install protective dust covers to connectors of
tube assembly.
(8) Disconnect tube assembly (87) from elbow
(88). Cleaning solvent is flammable and toxic.
Provide adequate ventilation. Avoid
(9) Disconnect tube assembly (94) from fitting prolonged breathing of solvent vapors
(93). and contact with skin or eyes. Eye
protection is required when using
(10) Remove two screws (86), two spacers (80), compressed air.
two washers (81) and remove solenoid valve (79).
(11) Install protective dust covers to
connectors of tube assemblies (87 and 94). To prevent damaging internal
components, do not submerge solenoid
(12) Remove components from solenoid valve valve in solvent. Cap open ports prior to
(79) as follows: cleaning.
7-88
TM 55-1520-236-23
a. Clean assembled solenoid valves (7, 9 and 19) (5) Install packing (10) on fitting (9) and install
with clean cloths dampened with solvent (C112), use fitting to filter (11).
a soft bristle brush and a piece of soft copper wire may
be required to remove stubborn deposits of dirt/oil (6) Install nut (21), backup ring (22), and
from exernal surfaces. packing (23) on elbow (20). Position and install elbow
into CYL port of solenoid valve (16).
b. Allow to air dry or blow dry using cleaned
filtered compressed air. (7) Install packing (29), nut (27), backup ring
(26) and packing (25) on fitting (28). Install fitting to
7-112. q INSPECTION SOLENOID tee (5).
VALVES P/N 209-076-023-1 FSCM 16780 P/N
15353 (7, 9, and 19 figure 7-1). (8) Install packing (29) on fitting (33) and install
fitting to tee (5).
a. Inspect electrical connector for bent or broken
pins and damaged threads. (9) Install packing (32) to fitting (31) and install
fitting to tee (5).
b. Inspect ports for damaged threads.
(10) Thread fitting into RET port of solenoid
c. Inspect external surfaces for nicks, dents and valve (16), position tee (5) as shown and tighten nut
cracks. No cracked parts are acceptable. (27).
7-113. q REPAIR OR REPLACEMENT (11) Remove protective dust covers from tube
SOLENOID VALVES P/N 209-076-023-1 assemblies (1, 8, 19 and 30).
FSCM 16780 P/N 15353 (AVIM) (7, 9, and
19, figure 7-1). (12) Buff mounting pads of solenoid valve to
ensure good electrical bond. Position solenoid valve
a. Replace solenoid valves (7, 9 and 19) that fail to (16) on bracket (24) and install two bolts (6), two
meet inspection requirements of paragraph 7-112. washers (7), two washers (14), and two nuts (15).
b. Refer to paragraphs 7-110 and 7-114 for (13) Install tube assemblies (1, 8, 19, and 30)
removal and installation instructions. on solenoid valve (16), and torque tube connectors in
accordance. with torque requirements outlined in
7-114. ~ INSTALLATION SOLENOID table 7-4.
VALVES P/N 209-076-023-1 FSCM 16780
P/N 15353 (7, 9 and 19, figure 7-1). (14) Connect electrical connector to solenoid
valve (16).
a. Install solenoid valve (16, figure 7-28) for fore
and aft (SCAS) system as follows: (15) Fill reservoirs to proper level with clean
hydraulic fluid (C61 or C62) (paragraph 7-6).
(1) Remove protective dust covers from
solenoid valve (16) and drain preservative hydraulic (16) Perform operational check of fore and aft
fluid from solenoid valve, flush solenoid valve with cyclic (SCAS) actuator and bleed hydraulic system
clean hydraulic fluid (C61 or C62). (paragraph 7-3). Refill reservoirs.
(2) Apply a light film of hydraulic fluid (C61 or
C62) to all packings, threads, and tube connectors b. Install solenoid valve (42, figure 7-28) for
prior to assembly of parts with the exception of bolts lateral (SCAS) system.
(17).
(1) Remove protective dust covers from
(3) Install two packings (12) on fitting (13) and solenoid valve (42) and drain preservative hydraulic
install fitting into PRESS port of solenoid valve (16). fluid from bypass solenoid valve. Flush solenoid valve
with clean hydraulic fluid (C61 or C62).
(4) Position filter (11), with directional flow
arrow pointing toward PRESS port, and install filter to (2) Apply a light film of hydraulic fluid (C61 or
fitting (13). C62) to all packings, threads and tube connectors
Change 16 7-89
TM 55-1520-236-23
prior to assembly of parts with the exception of bolts prior to assembly of parts with the exception of
(49). screws (86).
(3) Install two packings (43) on fitting (44) and (3) Install nut (64), backup ring (63) and two
install fitting into PRESS Port of solenoid valve (42). packings (62 and 66) on fitting (65) and install fitting
on bushing (67).
(4) Position filter (45), with directional flow
arrow pointing toward PRESS port and install filter to (4) Install packing (68) on bushing (67) and
fitting (44). install bushing into RET port of solenoid valve (79).
(5) Install packing (46) to fitting (47) and install (5) Install packing (92) on fitting (93) and install
fitting to filter (45). fitting on tee (61).
(6) Install packing (35) on fitting (36) and install (6) Install nut (58), backup ring (59) and packing
fitting to CYL port of solenoid valve (42). (60) on elbow (57). Thread elbow into tee (61),
position elbow as shown, and tighten nut (58).
(7) Install nut (39), backup ring (55) and packing
(54) on elbow (38). Thread elbow into RETURN port of (7) Install nut (89) backup ring (90), and packing
solenoid, position elbow as shown and tighten nut (91) on elbow (88). Thread elbow into tee (61),
(39). position elbow as shown, and tighten nut (89).
(8) Remove protective dust covers from tube (8) Thread fitting (65) into tee (61), position tee
assemblies (34, 37, and 48). as shown and tighten nut (64).
(9) Buff mounting pads of solenoid valve to (9) Install nut (71), backup ring (70), and
ensure good electrical bond. Position solenoid valve packing (69) on elbow (72). Thread elbow into CYL
(42) on bracket (53) and install two bolts (40), two port of solenoid valve (79), position elbow as shown,
washers (41), two washers (52) and two nuts (51). and tighten nut (71).
(10) Install tube assemlbies (34, 37, and 48) on (10) Install nut (83) backup ring (84), and
solenoid valve (42) and torque tube connectors in packing (85) on elbow (82). Thread elbow into PRESS
accordance with torque requirements outlined in port of solenoid valve (79), position elbow as shown,
table 7-4. and tighten nut (83).
(11) Connect electrical connector to solenoid (11) Remove protective dust covers from tube
valve (16). assemblies (78, 87, and 94).
(12) Fill reservoirs to proper level with clean (12) Buff mounting pads to solenoid valve to
hydraulic fluid (C61 or C62) (paragraph 7-6). ensure good electrical bond. Position solenoid valve
(79) to bracket and install two screws (86), two
(13) Perform operational check of lateral cyclic spacers (80) and two washers (81), as shown.
(SCAS) actuator and bleed hydraulic system
(paragraph 7-3). Refill reservoirs.
(13) Install tube assemblies (78, 87, and 94) to
solenoid valve (79). Refer to table 7-4 for torque
c. Install solenoid valve (79, figure 7-28) for anti- requirements of tube connectors.
torque (SCAS) system.
(14) Remove protective dust covers from hose
(1) Remove protective dust covers from assemblies (56 and 73) and install hose assemblies to
solenoid valve (79) and drain preservative hydraulic elbows (57 and 72). Torque hose connectors in
fluid from solenoid valve. Flush solenoid valve with accordance with torque requirements outlined in
clean hydraulic fluid (C61 or C62). table 7-4.
(2) Apply a light film of hydraulic fluid (C61 or (15) Install clamp (76), screw (77), spacer (75),
C62) to all packings, threads and tube connectors and washer (74) as shown.
7-90
TM 55-1520-236-23
(16) Connect electrical connector to solenoid 7-117. q R E M O V A L SOLENOID
valve (79). VALVES P/N 7U7464 (23 and 24, figure 7-1).
(17) Using hydraulic fluid dispenser (S1), fill a. Remove solenoid valve (4, figure 7-29) as
reservoirs to proper level with clean hydraulic fluid follows:
(C61 or C62) (paragraph 7-6).
(1) Remove left fuselage panel (17, figure 2-3).
(18) Perform operational check of directional
(SCAS) actuator and bleed hydraulic system (2) Disconnect electrical connector from
(paragraph 7-3). Refill reservoirs. solenoid valve, (4, figure 7-29).
7-115. q SOLENOID VALVE P/N (3) Provide a suitable container to catch fluid
7U7464 (23 and 24, figure 7-1). seepage when disconnecting tube assemblies (13
and 18).
7-116. q DESCRIPTION SOLENOID
VALVE P/N 7U7464 (23 and 24, figure 7-1). (4) Disconnect tube assemblies (1, 13, and 18)
from solenoid valve (4).
Two, two-position solenoid valves (23 and 24) are
included in the hydraulic system to permit shutting off (5) Remove two bolts (12) and two washer (5)
fluid circulation to the turret and the wing pylon attaching solenoid valve (4) to bulkhead and remove
actuators. The solenoid valves are controlled by the solenoid valve.
pilot MASTER ARM Switch. See FO-1 (foldout 1) for
view of hydraulic system schematic. (6) Drain fluid from solenoid valve (4) and
remove union reducer (2). Remove preformed packing
Premaintenance Requirements For (3) from union reducer (2).
Hydraulic Solenoid Valves
(7) Remove union (14) from tee (16) and,
Conditions Requirements remove packing (15) from union.
Model AH-1S (8) Remove union (17) from tee (16) and
remove packing (11) from union.
Part No. or Serial No. 7U7464
(9) Loosen nut (8) and remove tee (16) with
Special Tools None union reducer (9) from solenoid valve (4).
Test Equipment Hydraulic test stand (S2) (10) Remove packing (6), (backup) ring (7) and
Functional Test Setup nut (8) from union reducer (9).
(figure 7-31)
Pressure Drop Test Setup (11) Remove union reducer (9) from tee (16)
(figure 7-33) and remove packing (10) from union reducer.
30 Vdc Power Supply
(12) Install protective dust covers to open ports
Support Equipment None and electrical connector of solenoid valve (4) to
prevent entry of foreign particles.
Minimum Personnel Two
Required b. Remove solenoid valve (23, figure 7-29) as
follows:
Consumable Materials (C22) (C30) (C31) (C36)
(C37) (C61) (C62) (C63) (1) Remove left fuselage (7, figure 2-3) panel.
(C88) (C91) (C112) (C137)
(C138) (2) Disconnect electrical connector from
solenoid (23, figure 7-29).
Special Environmental None
Conditions (3) Provide a suitable container to catch fluid
seepage when disconnecting tube assembly (29).
7-91
TM 55-1520-236-23
Figure 7-29. q Solenoid Valve P/N 7U7464 Installation
7-92
TM 55-1520-236-23
(4) Disconnect tube assemblies (26 and 29) c. Using a spanner wrench, remove nut (13) from
from solenoid valve (23). solenoid valve.
(5) Remove two bolts (28) and two washers (27) d. Remove coil assembly (11) from body (1).
from attaching solenoid valve (23) to bulkhead and
remove solenoid valve. e. Rembve lap assembly (5) and spring (4) from
body (1).
(6) Drain hydraulic fluid from solenoid valve
(23) and remove union (25). Remove packing (24) f. Remove two backup rings (2) and two packings
from union (25). (3) from lap assembly (5).
(7) Loosen nut (20) and remove elbow (19) from g. Remove backup ring (6), packing (7), pole (8),
solenoid valve (23). Remove packing (22), (backup) and plunger assembly (10) from coil assembly (11).
ring (21) and nut (20) from elbow (19).
7-121. m I N S P E C T I O N SOLENOID
(8) Remove union (25).
VALVE P/N 7U7464 (AVIM) (23 and 24,
(9) Install protective dust covers to open ports
figure 7-1).
and electrical connector of solenoid valve (23) to
a. Inspect all parts for nicks, scratches, cracks and
prevent entry of foreign particles.
corrosion. Use a strong light and magnifying glass. No
cracked parts are acceptable.
7-118. m PROTECTIVE SOLENOID
VALVE P/N 7U7464 (23 and 24, figure 7-1). (1) Inspect body (1, figure 7-30) and nut (13) for
damaged threads.
a. Clean assembled solenoid valves (23 and 24) in
same manner outlined in paragraph 7-111. (2) Inspect all packing grooves for surface
defects that might cut packings during installation or
b. Clean disassembled solenoid valves (23 and cause sealing failure during operation.
24) as outlined in paragraph 7-102.
(3) Inspect plunger assembly (10) for evidence
7-119. m I N S P E C T I O N SOLENOID of galling or scoring.
VALVE P/N 7U7464 (23 and 24, figure 7-1).
(4) I n s p e c t e l e c t r i c a l r e c e p t a c l e o f c o i l
a. Inspect assembled solenoid valves (23 and 24) assembly (11) for broken or bent pins.
as follows:
(5) Inspect sleeve (5) and piston (14) for nicks,
(1) Inspect electrical connector for bent or scratches, or other visible damage to lapped surfaces.
broken pins and damaged threads.
(6) Inspect spring (4) for deformation.
(2) Inspect ports for damaged threads. Deformed springs are not acceptable.
(3) Inspect external surfaces for nicks, dents, (7) Inspect nameplate on body (1) for legibility
and cracks. No cracked parts are acceptable. and security of attachment. Damaged, loosely
attached, or missing nameplates are not acceptable.
b. Inspect disassembled solenoid valves (23 and
24) as outlined in paragraph 7-12). (8) Inspect parts listed in table 7-9, 1 for
conformance to non-destructive test data specified in
7-120. ~ DISASSEMBLY SOLENOID TM 43-0103.
VALVE P/N 7U7464 (23 and 24, figure 7-1).
(9) Inspect parts listed in table 7-10 for
a. Install solenoid valve (23 or 24) in a suitable conformance to dimensions specified.
smooth-jawed bench vise.
(10) Inspect parts listed in Table 7-10 for
b. Remove Iockwire from nut (13, figure 7-30). conformance to dimensions specified.
7-93
TM 55-1520-236-23
Table 7-9. ~ Non-Destructive Test Requirements For Solenoid Valve
P/N 7U7464 (AVIM)
FIGURE
7-30
INDEX
NOMENCLATURE NO. 23 TYPE OF TEST PROCEDURE REMARKS
Nut 13 Magnetic Particle Inspect for cracks and If defective, replace
Inspect strains per MIL-I-6868 with new part.
and TM 43-0103
Piston 14 Magnetic Particle Inspect for cracks and If defective, replace
Inspect strains per MIL-I-6868 with new part.
and TM 43-0103
Sleeve 5 Magnetic Particle Inspect for cracks and If defective, replace
Inspect strains per MIL-I-6868 with new part.
and TM 43-0103
Body 1 Fluorescent Inspect for cracks If defective, replace
Penetrant per MIL-I-6868 valve.
Inspect and TM 43-0103
Spring 4 Dimension Test Load: 15 0.5 Permanent set shall not
and Load pounds at 0.550 inch result from test load.
Spring shall not wobble
when rolled across a
flat surface.
Coil Assembly 11 Dielectric and Apply 1000 volts ac Replace coil assembly if
lnsulation- rms between both any evidence of dielectric
Resistance receptacle pins and breakdown or leakage.
coil assembly case Resistance shall be at
for 10 seconds least 5 megohms. Apply
500 Volts DC between
both receptacle pins and
ease coil assembly
7-94
TM 55-1520-236-23
Table 7-10. n Diametrical Clearance Requirements for Solenoid Valve
P/N 7U7464 (AVIM)
FIGURE
7-26
INDEX DIAMETRICAL CLEARANCE (IN)
NOMENCLATURE NO. MAX. MIN. REMARKS
Pin 9 0.0100 0.0030 Pin (9) to fit pole
(8) center I.D.
Figure 7-30. q Solenoid Valve P/N 7U7464 Assembly
7-95
TM 55-1520-236-23
7-122. q REPAIR DISASSEMBLED c. Install two packings (3) and two (backup) rings
SOLENOID VALVE P/N 7U7464 (AVIM) (23 (2) on lap assembly (5).
and 24, figure 7-1).
d. Install spring (4) and lap assembly (5) into body
a. Polish out minor nicks and scratches on metal (1).
parts with crocus cloth (C37) (for steel parts) and
abrasive cloth (C36) (for aluminum parts), provided e. Install plunger assembly (10), pin (9), pole (8),
that dimensions specified in table 7-9 are and packing (7) into coil assembly (11). Secure poIe (8)
maintained, and seating and sealing surfaces are not with backup ring (6).
damaged.
f. Install coil assembly (11) and nut (13) to body
(1). Torque nut (13) 140 TO 160 inch-pounds and
secure with Iockwire (C138).
g. Ensure that all open ports and electrical
Chemical film material is extremely connector are either plugged or capped.
dangerous. Contact with combustible
materials will cause explosion or fire. h. If solenoid valve is not immediately being
Avoid contact with skin or eyes. installed in helicopter and will require storage, fill
solenoid valve with preservative hydraulic fluid (C63).
b. Treat repaired area of anodized finish, after
polishing, with chemical film material (C31). 7-124. q TESTING SOLENOID VALVE
P/N 7U7464 (23 and 24, figure 7-1),
c. If pin (9, figure 7-30) requires replacement,
trim end of new pin to provide a stroke of 0.025 TO a. Inspect hydraulic test stand (S2) to ensure that
0.027 inch when pin is installed in pole (5). it meets the following requirements:
d. Replace plunger assembly (10) if pin (9) is (1) Capable of providing pressures to 2300
damaged, or loose, or if plunger assembly shows psig at flow rate of 3 gpm.
other visible evidence of damage.
(2) Equipped for filtration of particles to 1 0
e. Straighten bent pins of electrical receptacle microns in size.
(12) of coil assembly (11). If pins are broken, or if coil
assembly is defective, replace coil assembly. (3) Services with clean hydraulic fluid (C61 or
C62).
f. Replace packing (3 and 7) and rings (backup) (2
and 6) each time valve is disassembled. (4) Capable of maintaining hydraulic fluid
within a temperature range of +21 degrees C (+70
g. If sleeve (5) or piston (14) is defective, replace degrees F) to +43 degrees C (+110 degrees).
both parts as an assembly.
b. Refer to table 7-11 if trouble is encountered
h. Replace all worn or damaged parts which during procedures in steps c through g.
cannot be reworked to meet inspection requirements.
c. Break-in Run Test. Install solenoid valve in a
i. Replace nameplate on body (1) when damaged, test setup similar to that shown in figure 7-31 and
loosely attached, or missing. perform the following tests:
7-123. q A S S E M B L Y S O L E N O I D (1) Check solenoid valve to ensure flow is as
VALVES P/N 7U7464 (23 and 24, figure 7-1), shown on figure 7-32 with the solenoid valve
energized and de-energized.
a. Apply a light coat of hydraulic fluid (C61 or C62)
to all internal parts prior to assembly. (2) Energize solenoid valve with 18 volts dc.
b. Place body (1, figure 7-30) in a smooth-jawed (3) Adjust regulator valve until a fluid pressure
bench vise. of 1500 psig is indicated on gage A.
7-96
TM 55-1520-236-23
Table 7-11. Troubleshooting During Test of Solenoid Valve P/N 7U7464 (AVIM)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. Solenoid valve inoperative or does not operate smoothly.
STEP 1. Defective coil assembly (11, figure 7-30).
Replace coil assembly (11). Refer to paragraph 7-117.
STEP 2. Defective plunger assembly (10).
Replace plunger (10). Refer to paragraph 7-117.
STEP 3. Pin (9) worn.
Replace pin (9). Refer to paragraph 7-117.
STEP 4. Defective pole (8).
Replace pole (8). Refer to paragraph 7-117.
STEP 5. Defective lap assembly (5).
Replace lap assembly (5). Refer to paragraph 7-117.
STEP 6. Defective spring (4).
Replace spring (4). Refer to paragraph 7-117.
2. External leakage.
STEP 1. Packing (7) damaged or incorrectly installed.
Replace or reinstall packing (7), Refer to paragraph 7-117.
3. Internal leakage not within limits specified.
STEP 1. Packing(s) (3) damaged or incorrectly installed.
Replace or reinstall packing(s) (3). Refer to paragraph 7-117.
STEP 2. Defective spring (4).
Replace spring (4). Refer to paragraph 7-117.
STEP 3. Defective lap assembly (5).
Replace lap assembly (5). Damage to either sleeve (5) or piston (14) of lap assembly (5) required
that both parts be replaced as an assembly. Refer to paragraph 7-117.
7-97
TM 55-1520-236-23
Figure 7-31. ~ Functional Test Setup For Solenoid Valve P/N 7U7464
(4) Cycle solenoid valve under test 25 times by pressure for 2 minutes; there must be no evidence of
alternately energizing or de-energizing solenoid. external leakage or visible distortion of valve.
Valve shall operate smoothly and without hesitation
at a flow rate of 6 gpm. (3) Increase pressure to 2250 psig. Energize
and de-energize to equalize pressure. Maintain
(5) R e m o v e p r e s s u r e a n d d i s c o n n e c t pressure for 2 minutes; there must be no evidence of
flowmeter. external leakage or visible distortion.
d. Proof pressure test. Install solenoid valve in a (4) Decrease pressure to zero.
test setup similar to that shown in figure 7-31 and
perform the following: e. Operating Voltage Test. With solenoid valve
installed in a test setup similar to that shown in figure
(1) Adjust regulator valve to apply 2250 psig. 7-31, perform the following tests:
Energize and de-energize solenoid to equalize
pressure. Maintain pressure for 2 minutes; there (1) Ensure that coil temperature is between
must be no evidence of external leakage or visible +21 degrees C (+70 degrees F) and +43 degrees C
distortion of valve. (+110 degrees F).
(2) Reduce pressure to 25 psig. Energize and (2) Adjust pressure regulator to supply 1500
de-energize solenoid to equalize pressure. Maintain psig.
Figure 7-32. ~ Flow Diagram For Solenoid Valve P/N 7U7464
7-98
TM 55-1520-236-23
(3) Energize solenoid valve with a maximum of pressure regulator gradually to apply pressure until a
15,3 volts dc; then de-energize solenoid valve. Valve flow rate of 6 gpm is obtained. Pressure required to
operation, as indicated by gage B, must be obtain 6 gpm is tare. Record this tare figure.
instantaneous with no evidence of sluggishness.
(3) Subtract tare figure recorded in step (2)
(4) Increase applied pressure to 2250 psig. from pressure recorded in step (1). If result is in
Repeat procedure described in step (c), except excess of 50 psig, the solenoid valve is
energize solenoid valve to 28 volts dc. unsatisfactory.
f. Internal Leakage Test. With solenoid valve still h. Dieletric Strength Test.
installed in a test setup similar to that shown in figure
7-31, perform the following tests: (1) Apply 1000 volts ac between one pin of the
valve receptacle and the solenoid case for 1 0
(1). D e - e n e r g i z e solenoid and remove seconds. No breakdown or flashover is acceptable.
connections from outlet port.
(2) Repeat step (a) with the other pin in the
(2) Adjust pressure regulator to apply 1500 valve receptacle.
psig. Maintain pressure for at least 2 minutes.
Maximum acceptable internal leakage from the outlet i. Insulation Resistance Test.
port is 10 cubic centimeters per minute.
(1) Apply 500 volts dc between one pin of the
g. Pressure Drop Test. Install solenoid valve in a valve receptacle and the solenoid case. Minimum
test setup similar to that shown in figure 7-33 and acceptable resistance is 5 megohms.
perform the following tests:
(2) Repeat step (1) with the other pin in the
(1) Adjust pressure regulator to gradually apply valve receptacle.
pressure to obtain a flow rate of 6 gpm. Maximum
acceptable pressure required is 50 psig plus tare. j. Preservation. After completion of testing,
Record pressure required to obtain 6 gpm flow. torque nut (figure 7-30) 140 TO 160 inch-pounds
and secure with lockwire (C138). Flush solenoid valve
(2) Remove solenoid valve and install a piece of with hydraulic fluid (C63); drain fluid after flushing.
4.0 inch long tubing with 0.375 inch outside Mark rubber parts cure date on identification tag. Plug
diameter and 0.041 inch maximum wall thickness. or cap all ports with dust protective covers. Wrap
Use identical fittings to these used in step (1). Adjust solenoid valve in barrier material (C22) or equivalent.
Figure 7-33. ~ Pressure Drop Test Setup For Solenoid Valve P/N 7U7464
7-99
TM 55-1520-236-23
7-125. m INSTALLATION SOLENOID (14) Ensure that all air has been bled from
VALVE P/N 7U7464 (23 and 24, figure 7-1). system prior to next flight by cycling cyclic stick a
minimum of 10 full cycles.
a. install solenoid valve (4, figure 7-29) as
follows: b. Install solenoid valve (23, figure 7-29) as
follows:
(1) Remove protective dust covers from
solenoid valve and drain preservative hydraulic fluid
from solenoid valve. Flush solenoid valve with clean (1) Remove protective dust covers from
hydraulic fluid (C61 or C62). solenoid valve and drain preservative hydraulic fluid
from solenoid valve. Flush solenoid valve with clean
(2) Apply a light film of hydraulic fluid (C61 or hydraulic fluid (C61 or C62).
C62) to all packings, threads and tube connectors
prior to assembly or part, with the exception of bolts (2) Apply a light film or hydraulic fluid (C61 or
(28). C62) to all preformed packings, threads and tube
connectors prior to assembly of part, with the
(3) Install nut (8), (backup) ring (7) and packing exception of bolts (28).
(6) on union reducer (9). Thread union reduce into
OUTLET port of solenoid valve (4), position tee (16) as (3) Install nut (20), backup ring (21) and
shown and tighten nut (8). preformed packing (22) on elbow (19). Thread elbow
into OUTLET port of solenoid valve (23), position
(4) Install packing (11) on union (17) and install elbow as shown and tighten nut (20).
union into tee (16).
(4) Install preformed packing (24) on union (25)
(5) Install packing (15) on union (14) and install
and install union into INLET port of solenoid valve.
union into tee (16).
(6) Install packing (3) on union reducer (2) and (5) Buff mounting pads of solenoid valve (23)
install reducer into INLET port of solenoid valve (4). to ensure good electrical bond. Position solenoid
valve on bulkhead as shown and install two bolts (28)
(7) Remove protective dust covers from tube and two washers (27).
assemblies (1, 13, and 18).
(8) Buff mounting pads of solenoid valve (4) to (6) Connect and torque tube assemblies (26
ensure good electrical bond. Position solenoid cables and 29) in accordance with table 7-4.
valve to bulkhead as shown and install two bolts (21)
and two washers (5).
(7) Install electrical connector on solenoid
valve (23) and secure with Iockwire (C137).
(9) Connect and torque tube assemblies (1, 13,
and 18) in accordance with table 7-4.
(8) Install left access panel to fuselage, below
(10) Install electrical connector to solenoid wing.
valve (4) and secure with Iockwire (C137).
(9) Using hydraulic fluid dispenser (S1), fill
(11) Install left access panel to fuselage, below reservoirs to proper level with clean hydraulic fluid
wing. (C61 or C62) (paragraph 7-6).
(12) Fill reservoir to proper level with clean
hydraulic fluid (C61 or C62). Refer to paragraph 7-67 (10) Perform operational check of hydraulic
for servicing of reservoir. system (paragraph 7-3). Refill reservoirs.
(13) Perform operational check of hydraulic (11) Ensure that all air has been bled from
system. Refer to paragraph 7-3. Refill reservoir. system prior to next flight (paragraph 7-3).
7-100
TM 55-1520-236-23
7-126. m SERVO ACTUATOR Conditions Requirements
(ELECTROHYDRAULIC) ARMAMENT
WING PYLON.
Special Environmental Test bench must maintain
7-127. q DESCRIPTION SERVO Conditions the fluid temperature at
ACTUATOR (ELECTROHYDRAULIC) 90 degrees F 20 degrees F
ARMAMENT WING PYLON. (32 12 degrees C)
and be located in an area
Hydraulic provisions for the articulated wing pylon where the temperature can
consists of a solenoid operated shutoff valve, closed be maintained at 80
when de-energized and open when energized, which degrees F 10 degrees F
is located in hydraulic System No. 2 press line, to (27 6 degrees C)
direct flow to the electrohydraulic servo actuators
located on outboard end of each wing pylon. The
return flow from these servo actuators is directed 7-128. U REMOVAL SERVO
through wing pylons paralleling the pressure line and ACTUATOR (ELECTROHYDRAULIC)
terminating in the existing return line. ARMAMENT WING PYLON.
The electrohydraulic servo actuators used to power a. Remove cowling from rack assembly.
the articulated wing pylons are designed to operate as
one position locked members until solenoid valve is b. Provide a suitable container to catch spilled
opened to System No. 2 pressure; at this time the hydraulic fluid.
locking mechanism will disengage at 50 p s i g
increasing pressure, the servo actuator will then c. Disconnect electrical connector from servo
function as a load moving cylinder. To return to the actuator.
locked mode, the electrical circuit will be placed in
stow position, the servo actuator will return to a d. Disconnect hose from fittings at pressure and
predetermined position, and will automatically Iock at return port on servo actuator. Cover openings.
100 psig decreasing pressure.
e. Disconnect servo actuator from fittings by
Premaintenance Requirements for Armament removing bolts, nuts and washers.
Wing Pylon Servo Actuator
(Electrohydraulic) (AVIM) 7-129. ~ D I S A S S E M B L Y S E R V O
ACTUATOR (ELECTROHYDRAULIC)
ARMAMENT WING PYLON. (AVIM)
Condition Requirements
a. Remove Iockwire (4, figure 7-34) cap screws (2)
and servo valve (5) from body assembly (14 or 15).
Model AH-1S Install protective cover on servo valve (5).
Part No, or Serial No. 209-076-035-1 and b. Remove Iockwire (4) from cap screws (7).
-2 (2-7323-1 and -2)
c. Remove cap screws (7).
Special Tools (T5) (T6)
d. Remove locking key (30), jamnut (29), and
Test Equipment None spring seat (28) from piston (20).
Support Equipment (S2) (S13) e. Remove retaining plate (26) and rod scraper
(27).
Minimum Personnel Two
Required
f. Insert work aid (figure 7-35) into piston (20,
Consumable Materials (C61) (C62) (C112) (C137) figure 7-34) and screw tool into piston lock (17).
(C88) (C91) (C31) (C63) Tighten nut on work aid until piston lock bottoms in
(C102) (C37) (C116) piston (20). Remove piston (20), seal retainer (12),
7-101
TM 55-1520-236-23
Figure 7-34, Servo Actuator (Electrohydraulic) Wing Pylon Armament (Sheet 1 of 2)
7-102
TM 55-1520-236-23
1. Permanent plug 11. Packing 21. Packing
2. Cap screw 12. Seal retainer 22. Backup ring
3. Aluminum seal 13. Spherical bearing 23. Spring
4. Lockwire 14. Body assembly, LH shown 24. Foot seal
5. Servo valve 15. Body assembly, RH not shown 25. Packing
6. Nameplate 16. Lock ring 26. Retaning plate
7. Cap screw 17. Piston lock 27. Rod scraper
8. Drive screw 18. Packing 28. Spring seat
9. Check valve 19. Channel seal 29. Jam nut
10. Rod bearing 20. Piston 30. Locking key
31. Bearing
209076-41-2B
Figure 7-34. Servo Actuator (Electrohydraulic) Wing Pylon Armament (Sheet 2 of 2)
foot seal (24), packing (25) and rod bearing (10) from a. Clean external surfaces, except polished
body assembly (14 or 15) as a group. surfaces of piston rod by wiping with a cloth
moistened with solvent (C112).
g. Remove seal retainer (12), foot seal (24) and
packing (25) from piston (20). b. Carefully clean exposed polished surfaces of
piston rod with a cloth moistened with hydraulic fluid
h. Remove rod bearing (10) from piston (20). (C61 or C62).
i. Loosen nut on work aid until free. Remove work 7-131. ~ INSPECTION SERVO
aid. ACTUATOR (ELECTROHYDRAULIC)
ARMAMENT WING PYLON.
j. Remove piston lock (17), spring (23), and spring
set (28) from piston (20). a. Inspect spherical bearings (13 and 31, figure
7-34) for roughness when rotated by hand and for
k. Do not remove lock ring (16) from piston (20) secure installation. Damage and/or loosely installed
unless damage is evident. bearings are not acceptable.
l. Remove packing (11) from rod bearing (10). b. Inspect valve body (14 and 15) for nicks,
scratches, dents, and gouges, minor damage is
m. Remove packing (21) and (backup) rings (22) acceptable if polished out and depth after clean up
from piston lock (17). does not exceed 0.020 inch.
n. Remove packing (18) and channel seal (19) c. Inspect valve body (14 and 15) for corrosion,
from piston (20). minor corrosion damage is acceptable if polished out
to twice the depth of the corrosion and depth after
7-130. q CLEANING SERVO clean up does not exceed 0.020 inch.
ACTUATOR (ELECTROHYDRAULIC)
ARMAMENT WING PYLON. d. Inspect boss of servo valve (5) for nicks,
scratches, dents and gouges, minor damage is
acceptable if polished out and depth after repair does
not exceed 0.032 inch.
e. Inspect boss of servo valve boss (5) for
corrosion. minor corrosion damage is acceptable if
polished out to twice the depths of the corrosion and
Cleaning solvent is flammable and toxic. depth after repair does not exceed 0.032 inch.
Provide adequate ventilation. Avoid
prolonged breathing of solvent vapors f. Inspect exposed surface of piston (20) for
and contact with skin or eyes. scratches, dents and nicks. Minor damage is
7-103
TM 55-1520-236-23
ALL DIMENSIONS ARE IN INCHES UNLESS OTHERWISE NOTED.
209076-34A
Figure 7-35. Work Aid for Wing Pylon Armament Servo Actuator Disassembly/Assembly
acceptable if polished out and minimum piston rod c. Polish out mechanical and/or corrosion
diameter after polishing out is not less than 0.621 damage on valve body and servo valve boss which is
inch. within limits noted in paragraph 7-128. Use 600 grit
sandpaper (C102) and polish to original finish. Clean
g. Inspect threaded areas for damage to threads. polished area with solvent (C112). Treat polished area
Maximum acceptable damage is: with chemical film (C31). Touch up repair area with
primer (C88 or C91).
(1) one-third of thread depth
d. Polish out mechanical damage on piston rod
(2) 0.125 inch in length which is within limits noted in paragraph 7-128. Use
crocus cloth (C37) or fine India stone (C116). Clean
(3) maximum number of damaged threads is repaired area with a clean cloth dampened with
two. hydraulic fluid (C61 or C62).
h. Inspect for residue around rod of piston (20). e. Clean up damage on threads which is within
Black residue in this area is acceptable. limits noted in paragraph 7-131.
7-132. q REPAIR AND REPLACEMENT f. Replace ail packings when fluid leakage or
SERVO ACTUATOR (ELECTROHYDRAULIC) damage necessitates disassembly of servo actuator.
ARMAMENT WING PYLON (AVIM).
7-133. ~ ASSEMBLY SERVO
a. Replace spherical bearings (13 and 31, figure ACTUATOR (ELECTROHYDRAULIC)
7-34) which fail to meet inspection requirements of ARMAMENT WING PYLON. (AVIM)
paragraph 7-131.
a. Lubricate all packing channel seal and foot seal
b. Replace servo actuator if mechanical and/or with hydraulic fluid (C61 or C62).
corrosion damage on valve body or servo valve boss
exceeds the limits noted in paragraph 7-131. b. Install packing (18, figure 7-34) into channel
seal (19).
NOTE
Cleaning solvent is flammable and toxic. Installation may be aided by heating
Provide adequate ventilation, Avoid channel seal and packing with a heat
prolonged breathing of solvent vapors lamp; however, h e a t i n g i s n o t
and contact with skin or eyes. mandatory.
7-104
TM 55-1520-236-23
c. Install packing (18) and channel seal (19) in h. Insert piston lock (17) into piston (20) until both
piston (20) with a conical sleeve type work aid. See ends are flush. While holding the piston lock in this
figure 7-36 for instructions to fabricate work aid. position, insert work aid (figure 7-35) into piston lock
and tighten nut until piston lock bottoms in piston.
d. Install packing (25, figure 7-36) onto rod When the piston lock bottoms in piston, the lock ring
bearing (10). should be fully contracted in the piston.
e. Install packing (21) and channel seal (19) onto i. Install piston (20, figure 7-34) into body
piston lock (17). assembly (14 and 15) approximately halfway down.
Remove work aid.
f. If lock ring (16) was removed at disassembly,
install lock ring (16) onto piston (20). j. Install packing (25) onto foot seal (24).
NOTE k. Install rod bearing (10) into body assembly (14
or 1 5).
Install lock ring with chamfer on inside l. Install foot seal and packing onto piston (20).
diameter toward channel seal in piston. Push foot seal and packing into cavity in rod bearing.
g. Install spring seat (28) and spring (23) onto m. Install seal retainer (12) onto piston (20) and
piston (20). push into foot seal cavity.
SECTION A-A
Make seal installation tool from aluminum alloy
ALL DIMENSIONS ARE IN INCHES UNLESS OTHERWISE NOTED. 209001-68A
Figure 7-36. Work Aid For Seal Installation on Wing Pylon Armament Servo Actuator
7-105
TM 55-1520-236-23
n. Install rod scraper (27) onto piston (20). d. If necessary, continue reducing pressure by 5
pound increments and repeating lock test. The servo
o. Install retaining plate (26) onto piston (20). actuator must lock at a pressure of 100 TO 250 psig.
Position area of plate without tapped hole toward
return fluid port. e. Record the pressure at which the servo
actuator locks.
p. Install cap screws (7) through retaining plate
(26) and into body assembly (14 or 15). Torque cap
screws 50 TO 60 inch-pounds. Secure with Iockwire 7-136. ~ UNLOCK PRESSURE TEST
(C138). SERVO ACTUATOR (ELECTROHYDRAULIC)
ARMAMENT WING PYLON. (AVIM)
q. Install jamnut (29) and locking key (30) onto
bearing (31). a. With servo actuator in the locked condition,
apply an extend signal and slowly increase pressure
r. Install bearing (31) into piston (20). at PRESSURE port until servo actuator unlocks.
NOTE b. Record the unlock pressure.
A test sheet (figure 7-37) is provided for c. Rotate piston rod 90 degrees and repeat test.
recording test data while performing test
functions of the armament pylon servo d. Make ten unlock tests.
actuator P/N 209-076-035 (Vendor No.
2-7323). e. Rotate piston rod 90 degrees each time. The
unlock pressure must be 100 TO 250 psig.
7-134. ~ FUNCTIONAL TEST SERVO
ACTUATOR (ELECTROHYDRAULIC)
ARMAMENT WING PYLON. (AVIM) 7-137. ~ BACKLASH TEST SERVO
ACTUATOR (ELECTROHYDRAULIC)
a. Install servo actuator that is to be tested as ARMAMENT WING PYLON. (AVIM)
shown in figure 7-38.
a. Install servo actuator in Part Number E.D.0889
b. Apply a pressure of 1500 psig to the (75) test fixture as shown in figure 7-39.
PRESSURE port and cycle the servo actuator until all
air is bled. b. Apply a 200 pound tension load and then a
200 pound compression load on servo actuator
c. Maintain 1500 psig pressure and proceed to piston rod.
step d.
c. Measure total free play and record. Maximum
d. Apply a differential current of 5 ma to extend permissible free play is 0.017 inch.
the servo actuator and then to retract. The servo
actuator must move to its full stroke position in the 7-138. q PROOF PRESSURE TEST
proper direction. SERVO ACTUATOR (ELECTROHYDRAULIC)
ARMAMENT WING PYLON. (AVIM)
7-135. ~ L O C K P R E S S U R E T E S T
SERVO ACTUATOR (ELECTROHYDRAULIC) a. Set servo actuator to its mid-stroke position
ARMAMENT WING PYLON. (AVIM) and block the RETURN port.
a. Apply 1500 psig to the PRESSURE port and b. Apply 2250 psig to PRESSURE port for 2
move servo actuator to its retracted position. minutes.
b. Reduce pressure to 250 psig and slowly extend c. Reduce pressure to 5 psig for 2 minutes.
servo actuator until the locked position is reached.
d. Check for evidence of external leakage,
c. If servo actuator does not lock, reduce pressure loosening, permanent deformation and rupture of
5 psig and repeat test. parts.
7-106
TM 55-1520-236-23
Figure 7-37.
7-107
TM 55-1520-236-23
Figure 7-38. Schematic Diagram Wing Pylon Armament Servo Actuator Connections For Bench Test
e. Record the results and if any of these b. Cycle servo actuator through 25 complete
discrepancies were noted, reject servo actuator. cycles.
c. Check leakage at rod seal and record.
f. Repeat proof pressure test with PRESSURE Maximum allowable leakage is one drop in 25 cycles.
port blocked and 1500 psig applied to the RETURN
port. 7-140. q lNTERNAL LEAKAGE TESTS
SERVO ACTUATOR (ELECTROHYDRAULIC)
ARMAMENT WING PYLON. (AVIM)
g. Inspect for leaks, distortion, etc., as listed
above. Record results. a. Disconnect electrical connector from the servo
actuator.
7-139. ~ LEAKAGE TESTS SERVO
ACTUATOR (ELECTROHYDRAULIC) b. Apply 1500 psig to the PRESSURE port.
ARMAMENT WING PYLON. (AVIM)
c. Attach a filled drip spout to RETURN port.
Measure and record amount of leakage at RETURN
a. Hookup servo actuator as shown in figure 7-38 port for 1 minute. Maximum allowable Ieakage is
and apply 1500 psig to the PRESSURE port. 37.8 cubic centimeters.
7-108
TM 55-1520-236-23
Figure 7-39. Tool ApplicationWing Pylon Armament Servo Actuator Test Fixture
7-141. q SERVO VALVE FREQUENCY NOTE
RESPONSESERVO ACTUATOR (ELECTRO-
HYDRAULIC)ARMAMENT WING PYLON. (AVIM) The servo actuator is factory adjusted
and calibrated for proper length.
a. Attach copies of the frequency response Adjustment of the actuator will be
characteristics, that are delivered with each servo accomplished during final alignment and
valve, to the test results recorded in the preceding boresighting of the system.
paragraphs.
b. The servo valve frequency response must not b. Install servo actuator on rack assembly and
have resonance below 160 Hz. secure with attaching bolts, nuts, and washers. Torque
(top) bolt EWSB-22-6-14 and (lower) bolt
c. The amplitude ratio must not be down less than EWSB22-6-16 to 5 inch-pounds maximum.
3 dB at 100 Hz and the phase lag must be less than 55
degrees at 100 Hz. c. Connect electrical connector to servo actuator.
d. After completion of the test, unlock the servo
actuator and move the piston rod to its retracted
position. Plug the PRESSURE and RETURN ports.
Wipe off all hydraulic fluid. Missile launcher must be unloaded prior
to functional check of servo actuators.
e. If the servo actuator is not to be installed
immediately, package in an individual container that will
provide adequate protection. d. Connect hydraulic lines to servo actuator, bleed
hydraulic system and functionally check elevation of
7-142. q INSTALLATION-SERVO ACTUATOR ejector rack. Refer to TM 55-1520-236-10 and
(ELECTROHYDRAULIC)ARMAMENT WING paragraph 7-3.
PYLON.
7-143. q HYDRAULIC LINE FABRICATION. (AVIM)
a. If servo actuator is being replaced, install
adapting parts from old actuator. Refer to Appendix D.
Change 18 7-109
TM 55-1520-236-23
7-144. HYDRAULIC SYSTEM and free of air. A small accumulator, 1.0 cubic inch, is
connected to the pressurized lockout valve to make up
NOTE normal leakage of the cyclic actuators and to help
maintain the 650 psig trapped in the actuators. The
Refer to paragraph 7-2 for description of pilot can then move the flight controls by engaging
hydraulic system for helicopters the mechanical stops on the servo-actuators and
coded moving the cylinders through direct mechanical
coupling and internal irreversible valves. When the
7-145. DESCRIPTION pilot moves the servo-actuator with no hydraulic
HYDRAULIC SYSTEM pressure available, the fluid is moved from one side of
the actuator to the other through flow passages in the
NOTE actuator head. When the feed-back forces exceed the
pressure setting of a differential relief valve, the valve
The hydraulic systems for helicopters will open, allowing a slight amount of fluid bypass
coded are identical to the hydraulic through the actuator pressure to the return actuator
systems for helicopters coded passages. This will warn the pilot of an overloading
except that helicopters coded condition.
have a one way check valve (45,
figure 7-40) installed. The check valve c. An emergency system is provided to furnish
serves to prevent the electric hydraulic hydraulic power to the collective hydraulic cylinder
pump from cycling on and off when pressure is lost in System No. 1 and System No.
excessively. 2. The emergency system consists basically of an
electric motor driven pump, reservoir, solenoid
a. Two similar but separate hydraulic systems are valves, filter, check valves, and pressure switch. The
used to operate flight controls power cylinders, system is also used to power the wing pylon
stability and control augmentation system (SCAS) armament systems for boresight capability without
servo-actuators, and the M65 TOW missile Iauncher the hydraulic test stand. The description of the
actuator. A schematic diagram of the hydraulic emergency system in paragraph b is applicable to the
system for helicopters coded ~ and helicopters cyclic control hydraulic cylinders and to the collective
coded ~ is shown on figure FO-2. (foldout page control hydraulic cylinder except that when the
FO-2). Systems No. 1 and No. 2 are exactly alike as to emergency electric hydraulic pump switch is
their reservoirs, transmission driven pumps, and positioned to emergency, hydraulic fluid under
module assemblies which contain system filters, pressure will be supplied to the collective cylinder,
solenoid valves, relief valves and pressure switches The remainder of System No. 2 will be closed off by
for the caution panel. Although both systems operate solenoid valves. The primary purpose of the
three dual servo hydraulic cylinders in main rotor emergency system is to ensure that hydraulic power
controls there is not connection between systems is furnished to the collective hydraulic cylinder. The
because they uae separate passages and piston pilot cannot maintain collective control without
chambers inside each dual cylinder and valve hydraulic pressure at the collective hydraulic
assembly. Both systems and an emergency system cylinder.
also have other hydraulic circuits and functions
different and separate from each other. d. In the event of a dual hydraulic system and
starter/generator failure, the emergency electrical
b. An emergency system is provided to enable the system with a fully charged battery, is capable of
pilot to execute a landing in the event that pressure is supplying the essential bus loads for at least 17.8
lost in both System No. 1 and System No. 2. The minutes, with the emergency hydraulic pump being
emergency system consists basically of a pressurized used during low speed flight prior to landing, and,
lockout valve, a pressure operated shutoff valve, during landing operations not to exceed 5 minutes.
solenoid operated shutoff valve, and check valves.
See schematic diagram figure FO-2 (foldout page FO- 7-146. OPERATIONAL CHECK
2). If the pressure in hydraulic System No. 1 should AND TESTING HYDRAULIC SYSTEM.
fall to 650 psig for any reason, the pressurized
lockout valve will close locking 650 psig on both The following principles of operation of System No. 1,
pressure and return sides of the servo-actuators. This System No. 2, and emergency system informs the
is done to ensure that the actuators remain full of oil mechanic how each system functions prior to
7-110
TM 55-1520-236-23
209076-60-1A
Figure 7-40. Hydraulic System (Sheet 1 of 5)
7-111
TM 55-1520-236-23
Figure 7-40.
7-112
TM 55-1520-236-23
Figure 7-40.
7-113
TM 55-1520-236-23
Figure 7-40.
7-114
TM 55-1520-236-23
1. Pressure switch 25. Test connectors
2. Solenoid valve (system 2) P/N 88604-1 26. Reservoir assembly
3. Hydraulic Modular unit 27. Relief valve
4. Relief valve 28. Solenoid Valve (system 1)
5. Check valve P/N 88604-1
6. Pump 29. Pressure switch
7. Solenoid valve P/N 204-076-504-3 FSCM 94641 29A. Modular unit
P/N 1-U-1025-63 or FSCM 16780 P/N 130027-5 30. Check valve
8. Solenoid valve P/N 204-076-504-3 FSCM 94641 31. Pump
P/N 1-U-1025-63 or FSCM 16780 P/N 130027-5 32. Check valve
9. Relief valve 33. Check valve
10. Check valve 34. Relief valve
11. Flow regulator 35. Flow regulator
12. Check valve 36. Check valve
13. Pressure relief valve 37. Solenoid valve (SCAS system)
14. Pressure switch P/N 209-076-023-1 FSCM 16879 P/N 15353
15. Filter 38. Filter
16. Check valve 39. Lockout valve
17. Solenoid valve (SCAS system) 40. Accumulator assembly
P/N 209-076-023-1 FSCM 16780 P/N 15353 41. Solenoid valve (armament)
18. Filter P/N 204-076-504-3 FSCM 94641
19. Check valve P/N 1-U-1025-63 or FSCM 16780
20. Check valve P/N 130027-5
21. Solenoid valve (SCAS system) 42. Check valve
P/N 209-076-023-1 FSCM 16780 P/N 15353 43. Servo actuator
22. Filter 44. Servo actuator
23. Check valve 45. Check valve only
24. Reservoir assembly 46. Cross
209076-60-4B
Figure 7-40. Hydraulic System (Sheet 5 of 5)
performing testing and operational checks of system. A pressure switch will cause the caution
hydraulic systems after maintenance requirements panel to light if hydraulic modular unit outlet pressure
have been accomplished. decreases (at 600 TO 400 psi).
a. Principles of Operation. (typical for both (1) Beyond the hydraulic modular unit, fluid
systems). In normal operation of each system, under pressure is delivered through tubes and hoses
hydraulic fluid is supplied from its nonpressurized to three dual hydraulic servo cylinders in main rotor
reservoir by gravity feed and suction to a cyclic and collective control systems. Fluid flows into
transmission-driven pump. The pump is a variable- and out of one functional half of each dual cylinder
displacement type with internal pressure when its servo control valve is moved mechanically by
compensation, preset to provide 1500 (plus or minus linkage from a control stick, causing the cylinder
25) psi output pressure and 6.5 gpm flow rate at piston rod to make corresponding movements of
4170 operating rpm according to system demands. linkages to the main rotor. The cylinder valves also
Fluid bypassed in pump, to regulate pressure and have internal functions which tend to prevent
flow, is released through a line to the return side of feedback of motion from the rotor to the control stick.
the hydraulic modular unit. Pump output is delivered Either system alone can operate the cylinders, butthe
into the hydraulic modular unit and passes through dual (or tandem) arrangement is used for added safety
the pressure filter. A relief valve in the module guards of operation.
the system against excessive pressure; relief va Ive is
set to open at 1626 TO 2140 psi. The system (2) Fluid is returned from power cylinder and
solenoid valve is normally de-energized and open to other units through external Iines to the SYS RET inlet
the SYS PRESS outlet of the module but can be of the hydraulic modular unit, to pass through the
electrically energized to bypass position by placing return filter. Normal return flow from hydraulic
the HYD TEST switch to position marked for opposite modular unit to reservoir is through a hose connected
7-115
TM 55-1520-236-23
on the quick-disconnect coupling which is at other switch controls the M65 TOW missile launcher rack
times used to connect ground test equipment. hydraulic servo actuator ON-OFF solenoid valve. The
However, if this hose has not been connected, a low three-way, two-position solenoid valve can be de-
pressure (45 psi) will open a relief valve and allow eneraized (turned off) by the gunners pilot override
flow through another line from the hydraulic modular switch.
unit RES RET outlet to the reservoir BYPASS inlet.
(3) Both hydraulic modular units are equipped
with quick-disconnect couplings to allow ground
operation with a portable hydraulic test stand (S2).
System operation with such a unit is the same as Ensure that fluid in hydraulic test stand is
described for normal operation, except that the the same type fluid as in the helicopter.
reservoir and transmission-driven pump are not
being used. External dc power will also be required for d. Ground Testing of Hydraulic Systems with
electrically operated valves, caution panels, and Hydraulic Test Stand (S2). The following ground
electric driven hydraulic pump when engine is not operational check of the three hydraulic systems is to
operating. aid in troubleshooting table 7-9 or test for proper
functioning of each system after maintenance.
b. Special Functions of System No. 1. In addition Whenever possible, hydraulic systems should be
to typicaI operation described in preceding pressurized simultaneously to avoid introducing air
paragraphs for both systems, hydraulic System No. 1 into the unpressurized system. When this is not
has the following special functions. possible, a v o i d r a p i d c o n t r o l m o v e m e n t w h e n
operating with a single pressurized system.
(1) Tail rotor controls hydraulic cylinder. This is
a single hydraulic cylinder and servo valve assembly, Premaintenance Requirements for Testing
mechanically connected into control linkage to the Hydraulic System
tail rotor.
Condition Requirements
(2) Yaw stability and control augmentation
system (SCAS) servo actuator. This circuit includes a Model AH-IS
pressure line filter, a three-way, two-position
solenoid valve, and an electro-hydraulic servo Part No. or Serial No. All
actuator connected in the tail rotor control linkage.
Special Tools None
c. Special Functions of System No. 2. In addition
to typical operation described for both systems in Test Equipment None
paragraph 7-145, hydraulic System No. 2 has the
following special functions: Support Equipment (S1), (S2), (S10),
(S12), (S13), (S26)
(1) Pitch and roll stability and control
augmentation system (SCAS) actuators. Circuits are Minimum Personnel Two
provided for pitch and roll functions of stability Required
augmentation system. Each of the two circuits
includes a pressure line filter, a three-way, two- Consumable Materials (C61), (C62)
position solenoid valve, and an electro-hydraulic
servo actuator connected into the fore-and-aft and Special Environmental None
lateral cyclic control linkage. Conditions
(2) A r m a m e n t s y s t e m h y d r a u l i c p o w e r
provisions (figures 7-40, 7-41 and F02 (fold-out 2)). (1) Use hydraulic test stand (S2) or provide a
Hydraulic provisions for left and right M65 TOW similar hydraulic test stand conforming to the
missile launchers ejector racks are installed. This following requirements:
circuit provides pressure and return hydraulic lines to
a hydraulic servo actuator mounted on each of the (a) T h o r o u g h l y c l e a n , a n d s e r v i c e w i t h
TOW missile launcher racks. The MASTER ARM prescribed hydraulic fluid (C61 or C62).
7-116
TM 55-1520-236-23
1. Filler cap
2. Reservoir assembly
3. Solenoid valve (system return)
P/N 204-076-504-3 FSCM 94691
P/N 1-U-1025-63 or FSCM 16780 P/N 130027-5
4. Solenoid valve (system pressure
P/N 204-076-504-3 FSCM 94641
P/N 1-U-1025-63 or FSCM 16780 P/N 130027-5
5. Filter
6. Pressure relief valve
7. Pressure switch
8. Sight gage
9. Emergency hydraulic pump package
209076-69A
Figure 7-41. Emergency (Electric Motor Driven) Hydraulic System
Change 5 7-117
TM 55-1520-236-23
(b) E q u i p p e d w i t h 1 0 micron filter in
pressure and return lines through which all fluid
passes before leaving and returning to unit.
Verify that universal turret is unloaded.
(c) Capable of 2300 psig pressure and at
least 6 gpm flow rate.
(d) Having a calibrated pressure gage of
2500 psi minimum capacity.
Ensure main rotor tiedown is removed to
minimize possible contact of main rotor
(e) Pressure and return lines equipped to
hub components with each other in
connect to both hydraulic systems for simultaneous
extreme positions during ground
operation.
operation with external power.
(2) Visually inspect entire hydraulic system of (5) Remove main rotor tie-down. Apply 28 volt
helicopter to make sure all lines and components are dc electrical auxiliary power unit (S12) to external
secure and appear capable of operation. Obtain power receptacle at left side of fuselage. On pilot
access as follows: console, set switches to activate both hydraulic
systems, a r m a m e n t system, and stability
(a) Open left and right doors (11, figure 2-3). augmentation system.
(b) Open left and right transmission cowls (6) Operate hydraulic test stand (S2) applying
(11). Place maintenance platforms (S10) in position pressure (1475 TO 1525 psig) to hydraulic systems
on right and left side of helicopter. for at least 15 minutes. During this time, perform the
following:
(c) Remove left and right doors (17) attached
with cowl fasteners directly below wings at both (a) Observe all parts of systems for evidence
sides. of leakage, taking corrective action as necessary. See
table 7-1 for maximum allowable leakage.
(d) Remove panel door, attached with cowl
fasteners on right side of fuselage below tailpipe (b) Slowly cycle all controls to limits of stroke,
fairing, for access to tail rotor control power cylinder. observing movement of hydraulic power cylinders.
Check that all moving parts have clearance so that
(e) R e m o v e s c r e w - m o u n t e d p a n e l s f r o m there is no fouling or binding. Give particular
sides of fuselage for access to lines leading to attention to flexible connections, to make sure hoses
armament hydraulic connections and stability are not pinched and that vibration does not tend to
augmentation system actuators. loosen fittings.
(f) Remove cowling from right and left TOW (c) Work out air from systems by actuating
pylons for access to hydraulic cylinders. cyclic stick, collective stick, and taiI rotor control
pedals through at least ten full strokes. Some chatter
in tail rotor controls is normal with hydraulic test
(3) P r e p a r e h y d r a u l i c t e s t s t a n d ( S 2 ) f o r stand (S2). If air is eliminated satisfactorily, proceed
operation. Pressure relief valve set for 2100 psig to step e. If air is not eliminated, accomplish step (d).
cracking pressure; pump set to provide at least 6 gpm
flow; pressure compensation set at 1475 TO 1525 (d) When air is not removed by
psig. accomplishing procedures in step (c), perform the
following:
(4) On each of two hydraulic modular units,
located above reservoirs, prepare ground test 1 . Disconnect collective cylinder (5, figure
couplings by removing cap from pressure coupling 7-3) from collective lever (4).
and disconnecting reservoir return hose from return
coupling. Connect hydraulic test stand (S2) hoses to 2 . Disconnect fore and aft cyclic cylinder
both hydraulic modular units. (17) from swashplate (3).
7-118
TM 55-1520-236-23
3 . Disconnect lateral cyclic cylinder (9) from (8) Check operation of caution panel circuits as
swashplate (3). follows:
4 . Disconnect control tube (22) from (a) Energize electrical system.
bellcrank at lower end.
(b) Close CAUTION LTS circuit breakers.
5 . Disconnect control tube (7) from
bellcrank at lower end. (c) With test unit pressure reduced to O psig,
cycle controls to lose residual pressure. Pilot #1 HYD
6 . Disconnect control tube (6) from PRESS, pilot #2 HYD PRESS, gunner #1 HYD PRESS,
bellcrank at lower end. and gunner #2 HYD PRESS caution panel worded
segments should be illuminated.
(d) With external hydraulic power applied,
slowly increase test unit pressure. Pilot #1 HYD
PRESS, pilot #2 HYD PRESS, gunner #1 HYD PRESS,
Ensure that upper ends of cylinders (5, and gunner #2 HYD PRESS caution panel worded
17 and 9) will not strike any object when segments should extinguish at 700 TO 900 psig.
m o v e d t h r o u g h f u l l t h r o w during
accomplishment of following steps. (e) Slowly reduce pressure. Pilot #1 HYD
PRESS, pilot #2 HYD PRESS, gunner #1 HYD PRESS,
and gunner #2 HYD PRESS caution panel worded
7 . Check hydraulic test stand (S2) to ensure segments should illuminate at 600 TO 400 P S I G .
it is operating as described in step (6).
8 . Push up on fore and aft cyclic control (9) C h e c k o p e r a t i o n o f s i n g l e s y s t e m s a s
tube (22) and hold until cylinder (17) moves through follows:
full throw. Pull down on tube (22) until cylinder (17)
moves through full throw. Repeat through ten full (a) Close HYD CONTR and CAUTION LTS
Strokes. circuit breakers.
9 . Move cylinder (5) and cylinder (9) (b) Apply external hydraulic test stand (S2)
through ten full strokes by same procedure outlined pressure to System No. 1 and System No. 2 test
in step 8 . connectors.
1 0 . Connect control tube (22) to bellcrank (c) Energize electrical system.
at lower end.
(d) While operating hydraulic test stand (S2)
at 1475 TO 1525 psig pressure, place HYD TEST
1 1 . Connect control tube (7) to bellcrank at switch (located on console) to SYS 1. Pilot #2 HYD
lower end. PRESS and gunner #2 HYD PRESS caution panel
worded segments should be illuminated. Pilot #1 HYD
1 2 . Connect control tube (6) to bellcrank at PRESS and gunner #1 HYD PRESS caution panel
lower end. worded segments should be extinguished.
1 3 . Connect collective cylinder (5) to (e) Operate cyclic, collective and tail rotor
collective lever (4). controls checking for smooth and positive response.
14. Connect fore and aft cyclic cylinder (17) (f) On console, place HYD TEST switch to
to swashplate (3). SYS 2. Pilot NO. 1 HYD PRESS, and gunner HYD #1
caution panel worded segments should illuminate.
1 5 . Connect lateral cyclic cylinder (9) to Pilot NO. 2 HYD PRESS and gunner HYD #2 PRESS
swashplate (3). caution panel worded segments should be
extinguished. Operate cyclic and collective controls,
e. Reduce pressure in both systems to O psig. and check for smooth and positive response.
Change 3 7-119
TM 55-1520-236-23
NOTE NOTE
System No. 2 does not provide boost Refer to table 7-12 for emergency
power for tail rotor controls. hydraulic system operational switching
sequence.
(g) Operate tail rotor controls. Tail rotor (g) position pilot or gunner EMER HYDR
controls will lack hydraulic power, and should require PUMP switch to EMER. Pilot and gunner green
more force than in normal operation. EMERG HYD PUMP ON caution panel worded
segments should illuminate. Check that collective
(h) Release HYD TEST switch. actuator is powered and wing pylons are not
powered.
NOTE
(h) Remove filter bowls, drain fluid and check
Continued operation of the cyclic filters for contamination. Replace filter if required.
actuator on System No. 1 (with System Torque filter bowls 100 TO 140 inch pounds and
No. 2 unpressurized), could result in the secure with lockwire (C137).
hydraulic fluid being evacuated from the
System No. 2 cylinders. This fluid will be (i) Apply 1 0 0 0 psig to both systems and
displaced to the System No. 2 reservoir bleed air from the systems by cycling all controls
which could overflow. On engine start through full travel a minimum of ten cycles.
and operation of flight controls, fluid will
return to system No. 2 cylinders. (j) Reduce pressure in both systems to 0 psig.
Shut down hydraulic test stand (S2).
(i) D e c r e a s e h y d r a u l i c t e s t s t a n d ( S 1 2 ) (11) Test hydraulic relief valves as follows:
pressure to O psig.
(a) Disconnect System No. 2 from test unit.
(j) S h u t d o w n a n d d i s c o n n e c t e l e c t r i c a l
auxiliary power unit (S12) from helicopter. (b) Slowly increase System No. 1 pressure
until relief valve (located on module unit) opens.
(1O) Check emergency hydraulic system as Check that relief valve opens between 1626 a n d
follows: 2140 psig.
(a) C h e c k e m e r g e n c y h y d r a u l i c s y s t e m (c) Reconnect System No. 2 and disconnect
reservoir, located in right side of fuselage, under System No. 1 from the hydraulic test stand (S2).
wing, for proper fluid level.
(d) R e p e a t t e s t p r o c e d u r e s o u t l i n e d i n
(b) Using electrical auxiliary power unit (S12) preceding sub-step (b) for System No. 2.
engage EMERG HYD PUMP circuit breaker.
(e) Reduce pressure in both Systems No. 1
(c) Position pilot or gunner EMER HYDR and No. 2 to 0 psig. Shut down (S2) hydraulic test
PUMP switch to BORESIGHT. Pilot and gunner green stand.
EMERG HYDR PUMP ON caution panel worded
segments should illuminate. (12) Using hydraulic fluid dispenser (S1), fill
reservoirs with clean hydraulic fluid (C61 or C62).
(d) Check that collective cylinder is powered.
(13) Perform operational checks of armament
(e) Engage WING PYLON switch and check hydraulics system in accordance with applicable
that the wing pylon actuators are powered. instructions outlined in the following step e and TM
55-1520-236-10.
(f) Turn all switches to the OFF position and
check that the collective actuator is not powered. Pilot (14) Check filter bypass indicators on each
and gunner green EMERG HYD PUMP ON caution hydraulic system module. Replace filters as required.
panel worded segments should extinguish. After replacing any filters, operate hydraulic test
7-120
TM 55-1520-236-23
stand (S2) to check for leaks (refer to table 7-1) and NOTE
replenish fluid in system.
Refer to Note 7 of Table 7-1.
NOTE
(3) Wing pylons. Functional check wing pylon
actuators in accordance with procedures outlines in
Before shut-down of operation on
TM 55-1520-236-10.
hydraulic test stand (S2), center cyclic
and place collective stick full down.
(4) Operational check of emergency
hydraulic system. Perform operational check of
(15) Disconnect electrical auxiliary power unit emergency hydraulic system as follows:
(S12) from helicopter. Shut down hydraulic test stand
(S2) and disconnect hoses from couplings on (a) Run up helicopter (TM 55-1520-236-10).
modules. Install caps on pressure test couplings.
Connect hoses from reservoirs to return test (b) With the engine running at flight idle,
couplings on modules. position HYD TEST switch to SYS 1. Pilot No. 2 HYDR
PRESS and gunner HYDR PRESS #2 caution panel
worded segments should illuminate. Position pilot or
(16) Install fuselage panels removed for gunner EMER HYDR PUMP switch to EMER. Pilot and
access. Close cowling and compartment doors. gunner green EMER HYDR PUMP caution panel
worded segments should illuminate.
e. Operation Check of Hydraulic Systems
(c) Position pilot and gunner EMER HYDR
Utilizing Helicopter Power. Perform ground runup
PUMP switches to OFF.
operational check of hydraulic Systems No. 1 and No.
2 and emergency hydraulic system as follows:
(d) Release HYD TEST switch.
(1) Pretest procedure.
(e) Shut down engine (TM 55-1520-236-10).
(a) Check hydraulic reservoir for proper fluid
NOTE
level. If required, using hydraulic fluid dispenser(Sl),
fill reservoir with hydraulic fluid (C62 or C63)
Refer to Note 7 of Table 7-1.
(paragraph 7-6).
(b) Check all ground test connections for
7-147. FLUSHING HYDRAULIC
replacement of dust caps.
SYSTEM.
(c) Connect a 0 TO 3000 p s i g c a l i b r a t e d
gage (S17) to each system at the pressure ground test Prior to flushing the hydraulic system, functionally
fittings. check the hydraulic test stand (S2) to ensure that it is
operating properly. Install new and unused hydraulic
(2) Test. Utilizing helicopter power (TM 55- filter elements in the test unit for maximum fluid
1520-236-10), perform the following: filtration. Using hydraulic fluid dispenser (S1), fill the
hydraulic reservoir to capacity with fresh, clean,
(a) With the cyclic, collective, and directional hydraulic fluid (C62 or C63) Inspect pressure and
controls stationary, run-up helicopter power until return hoses to hydraulic test stand (S2) for
main rotor is turning at 88 TO 98 percent. cleanliness. The requirements and procedures for
flushing the hydraulic system are as follows:
(b) Check pressure in both hydraulic Systems
No. 1 and No. 2 Pressure should be 1475 TO 1525 NOTE
psig.
Systems must be flushed individually at
(c) Shut down engine (TM 1520-236-10). 1000 psi. Flushing is required only if
system is rebuilt due to major damage or
(d) Remove hydraulic pressure gage (S17). if fluid has become contaminated.
7-121
TM 55-1520-236-23
Table 7-12. Emergency Hydraulic System Operational Switching Sequence
Pilot # 2 Wing Emergency Emergency Emergency Pilot and
HYDR Pylon System System System Gunner
PRESS Solenoid Solenoid Solenoid Hydraulic green EMERG
and VaIve Valve VaIve Pump HYDR PUMP
Gunner # 2 Press Return Press ON Caution
HYDR Panel
PRESS Worded
Caution Segments
Pilot and Gunner EMER Panel
HYDR PUMP Switch Worded
Positions Segments
Switch in OFF Position Off On* Off Off Off Off
with System No. 2 Operative
Switch in OFF Position On Off Off Off Off Off
with System No. 2 Non-Operative
Switch in EMER Position Off On* Off Off Off Off
with System No. 2 Operative
Switch in EMER Position On Off On On On On
with System No. 2 Non-Operative
Switch in BORESIGHT On On On On On On
Position with System No. 2
Non-Operative
LEGEND
On = Solenoid Valve Energized
*On = Solenoid Valve Energized if Selected
NOTE: Hydraulic System No. 1 has no interconnect with electric-hydraulic emergency system.
7-122
TM 55-1520-236-23
Premaintenance Requirements for (4) Include provisions in the pressure and
Flushing of Hydraulic System return lines for connecting both System No. 1 and
System No. 2 for simultaneous operation.
Condition Requirements b. Prepare and test hydraulic systems as follows:
NOTE
Model AH-1S
Immediately after disconnecting hoses,
Part No. or Serial No. All cap cylinder ports to prevent
contamination of system.
Special Tools None
(1) Disconnect hoses from cyclic and collective
Test Equipment MS21902D4 cylinders. Connect hose ends together with
Unions (3) MS21902D4 and MS21902D6 unions.
MS21916D5-4
Reducers (2) (2) Disconnect hoses from tail rotor control
MS21902D6 cylinder and SCAS servo actuators in the lateral, fore
Unions (5) and aft, and directional control systems. Connect
T15051-8D hose ends together with MS21916D5-4 reducers.
Coupling Half (2)
(3) Disconnect hoses from left and right wing
0 to 3000 PSI pylon servo actuators. Connect hose ends together
Gages (2) with MS21902D6 unions.
HAC No.
3234306 Test
Containers (2)
Support Equipment (S1) (S2) Use extreme caution in handling filter
(S10) (S12) element to prevent contamination
damage.
Minimum Personnel Two
Required (4) Remove filters and discard elements from
four filter element bowls of hydraulic modular
Consumable Materials (C61) (C62) units (paragraph 7-46). Do not remove packings.
(C112) (C137) Immediately after removing filter elements,
reinstall bowls. Torque bowls 100 TO 140 i n c h -
Special Environmental Dust Free pounds.
Conditions Well ventilated
area
.
a. T e s t E q u i p m e n t R e q u i r e m e n t s . T e s t
equipment shall consist of a thoroughly clean Both hydraulic Systems No. 1 and No. 2
hydraulic test stand (S2) serviced with hydraulic fluid cannot be flushed at the same time.
(C61 or C62) and as follows:
(5) Connect hydraulic test stand (S2) to System
(1) Be capable of producing pressures of 2300 No. 1 through ground test fittings (12, figure 7-1),
psig with minimum flow rate of 6 g p m . (located on service deck on right side of helicopter
inside access door).
(2) Include a calibrated pressure gage with a
minimum capacity of 2500 psig. (6) M a k e a t h o r o u g h v i s u a l i n s p e c t i o n o f
complete hydraulic system to ensure that all
(3) Include a 10-micron absolute metal filter in components and lines are securely attached and
the pressure line and a 10-micron absolute metal appear capable of satisfactory operation before
filter on the return line. continuing flushing.
Change 2 7-123
TM 55-1520-236-23
(7) When performing the following steps, (9) (b) Remove filler cap from the reservoir
through (14), observe all system lines and (figure 7-5) mounted on bulkhead at station 213.94 in
components for external leakage. Take appropriate the hydraulic compartment under right wing. Using
action to correct any leakage before proceeding. hydraulic fluid dispenser (S1), fill reservoir with clean
hydraulic fluid (C61 or C62) (paragraph 7-6).
(8) Connect external 28 Vdc electrical auxiliary
power unit (S12) to helicopter. (c) Connect electrical. auxiliary power unit
(S16) to helicopter and energize.
(9) Energize HYDR CONT circuit breaker.
(d) Energize the following circuit breakers:
(10) Turn hydraulic test stand (S2) ON. Adjust
hydraulic test stand (S2) to sufficient pressure to SECU PWR TMS BLWR
maintain six gallons per minute minimum flow rate. HYD CONTR REF XFMR
Energize the directional SCAS system solenoid valve. ARMT CONTR INV
Flush system for five minutes. Reduce pressure and WPN CONTR
turn hydraulic test stand (S2) OFF. De-energize the TMS PWR
directional SCAS system solenoid valve. Reconnect (e) Position the following switches:
all System 1 hoses except those on the two cyclic
actuators. Pilot BATT switch . . . . . . . RUN
PLT MASTER ARM. . . . . . STBY
NOTE
With all actuators bypassed, the lockout
valve isolates the cyclic actuators (650 to Gunner MODE SELECT
850 psi is required to open the lockout Switch . . . . . . . . . . . . . . . ARMED MAN
valve),
(11) Turn hydraulic test stand (S2) ON, adjust ARMED AUTO
outlet pressure to 800 TO 1000 psig and flush for a LAUNCHER ACTIVATE
minimum of three minutes. Reduce pressure and SWITCH
ahut hydraulic test stand (S2) off. Reconnect System Located in ammo bay. . . .LH or RH
1 hoses on the cyclic actuators. This will open the hydraulic solenoid valve
for the articulated pylons.
(12) Disconnect hydraulic test stand (S2) from
System No. 1 and connect to System No. 2 through
ground test fitting in module assembly.
(13) Turn hydraulic test stand (S2) ON. Adjust
hydraulic test stand (S2) pressure to maintain a flow
rate of six gallons per minute. Turn electrical auxiliary To prevent pump damage (running dry),
power unit ON. Energize the pitch and roll SCAS engage pilot or gunner EMER HYDR
system solenoid valves armament pylon actuator PUMP switch to BORESIGHT position
solenoid valve. This can be accomplished by with a momentary ON-OFF action until
positioning switches and circuit breakers as shown in the pump is filled.
steps (14), (d) and (14), (e). Flush system for 5
minutes. Reduce pressure and turn hydraulic test (f) Position pilot or gunner EMER HYDR
stand (S2) OFF. De-energize pitch and roll SCAS PUMP switch to BORESIGHT with a momentary ON-
system solenoid valve. Reconnect pitch, roll and OFF action until pump is filled, then oprate steadily for
cyclic actuators hoses. five minutes to flush the system.
(14) Fill and flush emergency hydraulic system (g) Continue filling reservoir during flushing
as follows: run until all air is purged and reservoir is full.
(a) Drain fluid from reservoir (2, figure 7-41), (h) Position pilot and gunner EMER HYDR
paragraph 7-152). pump switches to OFF.
7-124
TM 55-1520-236-23
(i) Turn electrical auxiliary power unit (S16) (16) Replace filter elements previously
OFF. removed. Torque filter bowls 100 TO 140 inch-
pounds and secure with Iockwire (C137).
(j) Switches listed in step (d) to OFF.
(k) De-energize the circuit breakers listed in (17) Using hydraulic fluid dispenser (S1), fill
step (d). System No. 1 and No. 2 reservoir with clean hydraulic
fluid (C61 or C62) until all air is purged and reservoirs
(15) Providea small container to catch oil when are full (paragraph 7-6).
disconnecting hoses after a flushing operation.
Remove dust caps from dual hydraulic cylinder ports.
Reconnect hoses to cyclic and collective dual (18) Bleed hydraulic system in accordance
hydraulic cylinders and to wing pylon servo actuators. with procedures outlined in paragraph 7-146.
(19) Disconnect hydraulic test stand (S2) and
NOTE electrical auxiliary power unit (S12) from helicopter.
Cyclic dual hydraulic cylinder lines may
have residual pressure caused by lockout 7-148. ~ m TROUBLESHOOTING
valve and accumulator assembly. HYDRAULIC SYSTEM.
NOTE
The following list of conditions, tests or
inspections and corrective actions is
intended to aid in hydraulic system
troubleshooting. This guide should be
used with other sources of information,
such as: (1) Hydraulic System Schematic
Illustration FO2. (2) Electrical diagrams;
and (3) Operational Ground Test and
other detailed procedures in this section.
Ensure that all normal operational checks
have been performed prior to using table
7-13. Any malfunctions not listed
require assistance of next higher level of
maintenance.
Table 7-13. Troubleshooting Hydraulic System
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. Pilot #1 HYD PRESS, pilot #2 HYD PRESS, gunner #1 HYD PRESS or gunner #2 HYD PRESS caution panel
worded segments reported being illuminated during normal operation.
STEP 1. Loss of fluid and pressure by leakage.
Locate and repair leaks; replace faulty lines, hoses, seals, or other parts. Service system as
required (paragraph 7-6).
7-125
TM 55-1520-236-23
Table 7-13. q Troubleshooting Hydraulic System (Cent)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
STEP 2. Total loss of fluid in system.
Replace pump (paragraphs 7-168 and 7-172).
STEP 3. Other malfunction in system.
Perform operational check with hydraulic test stand (S2) (paragraph 7-146).
STEP 4. If pilot #1 HYD PRESS, pilot #2 HYD PRESS, gunner #1 HYD PRESS or gunner #2 HYD PRESS
caution panel worded segments do not illuminate and system operates normally with hydraulic test stand
(S2), trouble maybe in pump circuitry or pump may be defective.
Replace pump (paragraphs 7-168 and 7-172).
STEP 5. Pump pressure line restricted or check valve reversed.
Replace or correct installation of parts (paragraph 7-159).
STEP 6. If system actuators operate normally on hydraulic test stand (S2), but caution panel worded
segment is illuminated, warning circuit or pressure switches may be faulty.
Replace pressure switch hydraulic modular unit (figure 7-4).
STEP 7. Electric circuit malfunction.
Check and repair electrical circuit (paragraphs 9-8 through 9-13 and paragraph 9-284).
STEP 8. If caution panel worded segment is illuminated, and system actuators do not operate normally with
hydraulic test stand (S2), trouble may be in hydraulic modular unit or in system beyond hydraulic modular
unit.
STEP 9. Hydraulic modular unit solenoid valve staying at OFF position or faulty HYD TEST switch.
Repair electrical circuit (paragraphs 9-8 through 9-13 and paragraph 9-317). Replace switches
(paragraphs 9-20 and 9-22). Replace hydraulic modular unit (paragraphs 7-182 and 7-1 86).
STEP 10. System relief valve staying open or relieving at too low pressure.
Replace relief valve in hydraulic modular unit (figure 7-4).
STEP 11. Internal leakage through a unit.
Isolate and replace defective unit.
7-126
TM 55-1520-236-23
Table 7-13. Troubleshooting Hydraulic System (Cent)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
2. (SCAS) actuator will not unlock from center position.
STEP 1. Faulty wiring, switches or connections.
Refer to chapter 11 and TM 11-1520-236-20 or TM 11-1520-236-34, Troubleshooting Stability
and Control Augmentation System (SCAS).
STEP 2. Filter clogged.
Replace in line hydraulic filter (paragraph 7-222).
STEP 3. Restricted flow in pump suction line.
Inspect reservoir and lines; replace faulty parts (paragraphs 7-155 and 7-163).
3. Pilot #1 HYD PRESS and/or gunner #l HYD PRESS caution panel worded segments do not illuminate when
HYD TEST switch is positioned to SYS 2 or Pilot #2 HYD PRESS and/or gunner #2 HYD PRESS caution panel
worded segments do not illuminate when HYD TEST switch is positioned to SYS 1.
STEP 1. Caution panel lamp or light indicating panel (caution panel) failed.
Replace panel lamp (paragraph 9-282) or light indicating panel (caution panel) (paragraphs 9-281
and 9-283).
STEP 2. Pressure switch in hydraulic modular unit or wiring faulty.
Replace pressure switch (figure 7-4) or repair electrical circuit (paragraphs 9-8 through 9-13 and
paragraph 9-284).
STEP 3. System solenoid or electrical circuit faulty.
Repair electrical circuit (paragraph 9-377) or replace hydraulic modular unit (paragraphs 7-182
and 7-186).
STEP 4. Faulty HYD TEST switch.
Replace switch.
4 . F i l t e r element differential pressure indicators tripped.
STEP 1. Fluid temperature below 20 degrees F (-7 degrees C).
Operate until fluid temperature is normal, then reset indicators by pushing buttons in. If not again
tripped, no further action needed (figure 7-4) (paragraph 7-45).
Change 3 7-127
TM 55-1520-236-23
Table 7-13. ~ Troubleshooting Hydraulic System (Cent)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
STEP 2. Indicators tripped by unusual vibration or hydraulic modular unit being struck.
Check hydraulic modular unit for damage, reset indicators. If not again tripped, no further action
needed (figure 7-4).
STEP 3. Clogged filter elements.
Inspect and replace filter eiements (paragraphs 7-189 and 7-193). Reset indicators (paragraph 7-
45).
STEP 4. Defective indicator assembly.
Replace hydraulic modular unit (paragraphs 7-182 and 7-186).
5. Servo cylinders chatter when controls are moved. (Some chatter in tail rotor control cylinder is normal when
using hydraulic test stand (S2).
STEP 1. Air in system.
Cycle controls at least ten full strokes at normal operating pressure to work out air (paragraph 7-
146).
STEP 2. Loose mounting bearing (9, figure 7-12) on dual hydraulic servo cylinder,
Replace dual hydraulic servo cylinder assembly (paragraphs 7-203 and 7-209).
STEP 3. Any internal looseness in dual hydraulic servo cylinder assembly.
Replace dual hydraulic servo cylinder assembly (paragraphs 7-203 and 7-209).
6. Controls do not operate smoothly.
STEP 1. Servo valve on dual hydraulic servo cylinder is binding (requires more than 12 oz. force to operate
valve.)
Check to ensure all bolts at servo head linkage are free to rotate by finger pressure. Replace dual
hydraulic servo cylinder assembly (paragraphs 7-203 and 7-209).
STEP 2. Incorrect bolts inserted.
Check the valve linkage bolts. Install correct bolts.
7. Excessive feedback in operation of controls.
STEP 1. Air in servo cylinders.
Cycle controls at least ten times to work out air (paragraph 7-146).
7-128
TM 55-1520-236-23
Table 7-13. Troubleshooting Hydraulic System (Cent)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
STEP 2. Loose or worn bearing housing mounting studs.
Tighten or replace mounting studs.
8. Hydraulic power inadequate or lacking at TMS launchers (other indications normal).
STEP 1. Faulty circuit to armament couplings or System No. 2 pressure is marginally low.
Check operation with hydraulic test stand (S2) (paragraph 7-146).
STEP 2. No improvement when using hydraulic test stand (S2) for normal system pressure, or TMS
solenoid valve inoperative.
Replace solenoid valve (paragraphs 7-240 and 7-244) or repair electrical circuit (paragraphs 9-8
through 9-13 and paragraph 9-374).
STEP 3. Restriction in test connectors (25, figure 7-4) or lines.
Replace defective parts (paragraphs 7-161 and 7-165).
STEP 4. Operation becomes normal on hydraulic test stand (S2). System No. 2 pump or lines defective.
Replace pump (paragraphs 7-168 and 7-172) or faulty lines (paragraphs 7-161 and 7-165).
9. System No. 2 reservoir overflows.
NOTE
Within one hour after helicopter shut down approximately 1 cubic inch of hydraulic fluid
from accumulator P/N 204-076-012-5 will be added to system 2. On start up
approximately 1 cubic inch of hydraulic fluid will be removed from system 1 reservoir to fill
accumulator P/N 204-076-012-5.
STEP 1. Repeat cyclic inputs with hydraulic system test switch in System No. 1 position.
Release hydraulic system test switch. Actuate cyclic stick, approximately ten full cycles, to
remove air from actuators (paragraph 7-146). Replenish fluid in reservoir (paragraph 7-149).
10. Either left or right TOW pylons inoperative or sluggish. (System No. 2 operation otherwise normal).
STEP 1. Electrical wiring faulty.
Repair electrical circuit (paragraphs 9-8 through 9-13 and paragraph 9-374).
STEP 2. Faulty electrical circuit to actuator.
Repair electrical circuit (paragraphs 9-8 through 9-13 and paragraph 9-374).
7-129
TM 55-1520-236-23
Table 7-13. Troubleshooting Hydraulic System (Cent)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
STEP 3. TOW solenoid valve stuck closed.
Replace solenoid valve (paragraphs 7-240 and 7-244).
STEP 4. Check SECU and TOW system.
11. Only one TOW pylon inoperative or sluggish. (Other TOW pylon operates normally.)
STEP 1. Restricted hydraulic flow in circuit of affected armament wing pylon servo actuator.
Inspect hoses and tubes; replace faulty parts (paragraph 7-159).
STEP 2. Faulty electrical circuit to affected armament wing pylon servo actuator.
Repair electrical circuit (paragraphs 9-8 through 9-13 and paragraph 9-374).
STEP 3. Defective armament wing pylon servo actuator.
Replace armament wing pylon servo actuator (paragraphs 7-254 and 7-268).
STEP 4. Check SECU and TOW system.
12. Pylons do not remain in stowed position with TOW system OFF and hydraulic system operations.
STEP 1. Fault in electrical wiring.
Repair electrical circuit (paragraphs 9-8 through 9-13 and paragraph 9-374).
STEP 2. Faulty electrical circuit to pylon servo actuators.
Repair electrical circuit (paragraphs 9-8 through 9-13 and paragraph 9-374).
STEP 3. TOW solenoid valve stuck open.
Replace solenoid valve (paragraphs 7-240 and 7-244).
STEP 4. Check valve installed backwards or stuck open.
Reverse or replace check valve (figure FO-1).
STEP 5. Check SECU.
7-130
TM 55-1520-236-23
Table 7-13. Troubleshooting Hydraulic System (Cent)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
13. With hydraulic test stand (S2) and electrical power unit (S12) connected to helicopter and operating, and
with pilot and/or gunner EMER HYDR PUMP switch in BORESIGHT position, pilot and/or gunner green
EMER HYDR PUMP caution panel worded segments do not illuminate.
STEP 1. If collective controls are powered, check for a faulty panel lamp or light indicating panel (caution
panel).
Replace panel lamp (paragraph 9-282) or light indicating panel (caution panel) (paragraphs 9-281
and 9-283).
STEP 2. If collective controls are powered, check for faulty electrical wiring.
Repair wiring (paragraphs 9-8 through 9-13 and paragraph 9-284).
STEP 3. If collective controls are powered, check for faulty pressure switch.
Replace pressure switch in hydraulic modular unit (figure 7-4).
STEP 4. If collective controls are unpowered and emergency electric motor driven pump package failed,
check for faulty wiring or switch.
Repair wiring (paragraph 9-8 through 9-13) or replace switch (paragraphs 9-20 through 9-22) or
replace emergency electric motor driven pump package (paragraphs 7-175 and 7-179).
14. With electrical power unit (S12) connected to helicopter and operating, and with pilot and/or gunner EMER
HYDR PUMP switch in BORESIGHT or EMER position, and pilot and gunner green EMER HYDR PUMP
caution panel worded segments illuminated, System No. 2 is non-operative and collective controls are
unpowered.
STEP 1. Faulty electrical wiring.
Repair wiring. Refer to paragraphs 9-8 through 9-13 and paragraphs 9-374.
STEP 2. Pressure or return solenoid valve failed.
Replace pressure or return solenoid valve (paragraphs 7-240 and 7-244).
15. With electrical auxiliary power unit (S12) connected to helicopter and turned ON, pilot and/or gunner EMER
HYDR PUMP switch in EMER position, System No. 2 non-operative armament wing pylons are powered
when switches are engaged.
STEP 1. Faulty electrical wiring to armament wing pylon solenoid valve.
Repair wiring. Refer to paragraphs 9-8 through 9-13 and paragraph 9-374.
7-131
TM 55-1520-236-23
Table 7-13. Troubleshooting Hydraulic System (Cont)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
16. With electrical auxiliary power unit (S12) connected to helicopter and turned ON, pilot and/or gunner EMER
HYDR PUMP switch in BORESIGHT position, System No. 2 non-operative, wing pylons are not powered
when switches are engaged.
STEP 1. Faulty electrical wiring to armament wing pylon solenoid valve.
Repair wiring (paragraphs 9-8 through 9-13 and paragraph 9-374), or replace pylon solenoid
valve (paragraphs 7-240 and 7-244), or replace armament wing pylon servo actuator (paragraphs
7-254 and 7-268).
17. q Emergency electric hydraulic pump cycles on and off at very short intervals.
STEP 1. One-way check valve (45, figure 7-40) inoperative due to internal leakage.
Replace one-way check valve (45, figure 7-40).
7-149. SERVICING 7-154. q ~ CLEANING HYDRAULIC
HYDRAULIC SYSTEM. RESERVOIR.
Service hydraulic system in same manner outlined Clean hydraulic reservoir by same procedure outlined
for coded helicopters (paragraph 7-6). for ~ coded helicopters (paragraph 7-11).
7-150. HYDRAULIC
RESERVOIR. 7-155. q ~ INSPECTION
HYDRAULIC RESERVOIR.
7-151. DESCRIPTION
HYDRAULIC RESERVOIR. Inspect hydraulic reservoir by same procedure
outlined for q coded helicopters (paragraph 7-12).
The hydraulic reservoirs on ~ and ~ c o d e d
helicopters are similar to the reservoirs on ~ coded
helicopters (paragraph 7-8). 7-156. H ~ REPAIR OR
REPLACEMENT HYDRAULIC
7-152. q ~ REMOVAL HYDRAULIC RESERVOIR.
RESERVOIR.
Repair hydraulic reservoir by same procedure
Remove hydraulic reservoir by same procedure outlined for ~ coded helicopters (paragraph 7-13).
outlined for q coded helicopters (paragraph 7-9).
7-153. ~ ~ DISASSEMBLY 7-157. ~ ~ ASSEMBLY HYDRAULIC
HYDRAULIC RESERVOIR. RESERVOIR.
Disassemble hydraulic reservoir by same procedure Assemble hydraulic reservoir by same procedure
outlined for ~ coded helicopters (paragraph 7-10). outlined for q coded helicopters (paragraph 7-14).
7-132
TM 55-1520-236-23
7-158. q R INSTALLATION nicks, scratches, and dents on fittings are acceptable
HYDRAULIC RESERVOIR. provided they are sanded smooth with 600 grit
sandpaper (C102), treated with chemical film
a. Install hydraulic reservoir by same procedure material (C31) and touched up with primer (C88 or
outlined for ~ coded helicopters (paragraph 7-15). C91).
b. Perform functional test of hydraulic system b. I n s p e c t t h r e a d e d p a r t s f o r c o r r o s i o n a n d
(paragraph 7-143). mechanical damage. Damaged threads are not
acceptable.
7-159. q ~ HOSES, TUBES, AND
c. I n s p e c t hoses for fraying, cuts, and
FITTINGS.
deterioration. Damage more severe than superficial
is not acceptable.
7-160. q ~ DESCRIPTION HOSES,
TUBING AND FlTTINGS. 7-164. q ~ REPAIR OR
REPLACEMENT HOSES, TUBING, AND
Throughout No. 1, No. 2 and emergency hydraulic FITTINGS.
systems are hoses, tubing, and fittings that
interconnect reservoirs, check valves, relief valves,
a. Replace parts that fail to meet inspection
solenoid valves, pumps, etc. and are attached to requirements of paragraph 7-163.
fuselage structure with clamps, spacers, screws and
nuts.
b. R e f e r to appendix D and to TM
55-1500-204-25/1 for instructions to fabricate
7-161. q R REMOVAL HOSES, tubing and hoses.
TUBING AND FlTTINGS.
Remove hoses, tubing and fittings as required to 7-165. q R INSTALLATION HOSES,
perform maintenance functions (figure 7-40). TUBING, AND FITTINGS (figures 7-40 and
7-41).
7-162. ~ ~ C L E A N I N G H O S E S ,
TUBING AND FITTINGS. a. Ensure that hoses and tubes are clear of
obstructions prior to installation.
b. Coat seals, packings and threads with clean
hydraulic fluid (C61 or C62).
Cleaning solvent is flammable and toxic. c. Position tubing or hose assembly in helicopter.
Provide adequate ventilation. Avoid See figures 7-40 and 7-41. Align the tubing or hose
prolonged breathing of solvent vapors assembly and install end connectors. Ensure that
and contact with skin or eyes. Eye hoses do not twist during tightening end connectors.
protection is required when using Torque end connectors to value shown in table 7-4.
compressed air.
d. Inspect hoses for free movement and for
a. Wash hoses, tubing, and fittings with solvent chafing on adjacent components when cylinders are
(C112) and dry with clean filtered compressed air. operating through full throw.
b. Clean hoses, tubing and fittings with clean e. Spiral wrap all areas on hoses where chafing
filtered compressed air prior to installation. may occur. Use teflon tape (C178).
7-163. ~ ~ I N S P E C T I O N H O S E S , f. Inspect for hydraulic fluid leaks while the
TUBING, AND FITTINGS. system is under pressure.
a. Inspect tubing for nicks, cuts, cracks, and Perform functional check of the hydraulic
deformed condition (TM 55-1500-204-25/1). Minor system (paragraph 7-146).
7-133
TM 55-1520-236-23
7-166. q m H Y D R A U L I C PUMPS a. Clean external surface of pump with solvent
(TRANSMISSION DRIVEN). (C112). A soft bristle brush maybe required to loosen
caked dirt/grease deposit. Do not submerge pump in
solvent.
7-167. ~ ~ DESCRIPTION
HYDRAULIC PUMPS (TRANSMISSION b. Dry pump using clean filtered compressed air.
DRIVEN)
Dual hydraulic pumps are mounted on a drive quill
located on the transmission lower case, and is 7-170. q ~ INSPECTION
accessible by opening right transmission cowling PUMPS (TRANSMISSION
HYDRAULIC
door (11, figure 2-3). System No. 1 pump is on aft pad
DRIVEN).
of drivequill, and System No. 2 pump is on forward
pad. See figure 7-40. a. Inspect pump for leaks (table 7-1).
7-168. q ~ REMOVAL HYDRAULIC b. Inspect pump for cracks. No cracks are
PUMPS (TRANSMISSION DRIVEN). acceptable.
Either pump can be removed in the same manner. c. Inspect pump for security.
a. Open right transmission cowling (11, figure d. Inspect drive pad on transmission for leaks.
2-3). Place a suitable container under pump to catch
spilled fluid. e. Inspect attaching hose connections for leaks.
b. Loosen hose nuts on SUCTION port fitting on f. I n s p e c t p u m p f o r c o r r o s i o n . S u p e r f i c i a l
outboard end of pump and pressure port fitting at corrosion is acceptable on external surfaces if
forward side. Allow fluid to drain into container. polished out and treated for corrosion protection.
Disconnect both hoses. Cap hoses and fittings. Corrosion on threads or internal parts is not
acceptable.
c. Disconnect hose from CASE DRAIN port fitting
at top inboard on pump. Cap hose and fitting. g. Check pressure in both hydraulic systems
No. 1 and No. 2. Pressure should be 1475 to 1525
d. Disconnect hose from SEAL DRAIN port fitting psi.
at bottom inboard on pump. Cap hose and fitting.
e. Remove washers and nuts from four mounting
studs at flange of pump. Pull pump and gasket from
drive pad. Cover drive pad to protect from dirt.
7-171. m m REPAIR OR
f. If pump is being replaced, remove fittings from REPLACEMENT HYDRAULIC PUMPS
ports for use on replacement pump. Cover open pump (TRANSMISSION DRIVEN).
ports. Protect driveshaft from dirt and damage.
a. Replace pumps that fail to meet inspection
requirements of paragraph 7-170.
7-169. pm CLEANING HYDRAULIC
PUMPS (TRANSMISSION DRIVEN).
b. Polish out superficial corrosion on external
surface. Polish to original surface finish with 600 grit
sandpaper (C102).
Cleaning solvent is flammable and toxic. c. Treat with chemical film (C31).
Provide adequate ventilation. Avoid
prolonged breathing of solvent vapors d. Touch up with primer (C88 or C91).
and contact with skin or eyes. Eye
protection is required when using
compressed air.
7-134 Change 5
TM 55-1520-236-23
7-172. q ~ lNSTALLATlON
HYDRAULIC PUMP (TRANSMISSION
DRIVEN). Install P/N 212-076-364-3 or vendor
P/N 2514-6 check valve in pump case
a. Install pump (6, figure 7-40) or pump (31) in the drain port.
same manner.
Change 5 7-134.1/(7-134.2 blank)
TM 55-1520-236-23
b. Before installing fitting on new pump, remove Rated voltage 28 volt dc nominal
case drain plug and drain preservative fluid from pump.
Fill pump with clean hydraulic fluid (C61 or C62) and Rated current 40 amperes maximum at full flow
install check valve.
18 amperes maximum zero flow
c. If the same pump is not being reinstalled, install
fittings from old pump at suction port on outboard end, Speed 5400 rpm maximum at zero flow
pressure port on forward side, case drain port at top
inboard end, and seal drain port at bottom inboard end.
Use new packings. 7-175. REMOVAL HYDRAULIC PUMP
(EMERGENCY ELECTRIC MOTOR DRIVEN).
d. Apply a thin film of antisieze compound (C21) to
pump splines and to mating splines in transmission. a. Gain access to emergency hydraulic pump by
removing right access panel (17, figure 2-3).
e. Position new gasket and pump (6 or 31) on
transmission drive pad. Engage splines. Install wash- b. Remove Iockwire and disconnect electrical plug
ers and nuts on studs. from pump assembly (4, figure 7-7).
f. Connect hoses to suction, pressure, case drain c. Remove four bolts (5) and four washers (6)
and seal drain port fittings. Seal area around hydraulic attaching pump assembly (4) to shelf.
pump and quill assembly mating flanges (Paragraph 6-
54.f.). d. Provide a suitable one gallon container. Place
container under pump assembly directly below SUC-
g. Refill reservoir (paragraph 7-149). Bleed system TION hose connection. Break torque on connector of
(paragraph 7-146). tube (10) and allow fluid to drain from system slowly. It
may be necessary to remove filler caps from all three
7-173. HYDRAULIC PUMP (EMER- reservoirs to allow better drainage. Remove tube (10)
GENCY ELECTRIC MOTOR DRIVEN). from fitting (11) and install protective dust cap to tube.
e. Remove tube (13) from fitting (14). Install pro-
7-174. DESCRIPTION HYDRAULIC tective dust cover to tube connector.
PUMP (EMERGENCY ELECTRIC MOTOR
DRIVEN). f. Remove tube (3) from fitting (2). Install protec-
tive dust cover to tube connector.
The emergency hydraulic system is powered by an
electric motor driven, pressure compensated, variable g. Remove hose assembly (9) from fitting (8) and
delivery, hydraulic pump (9, figure 7-41 ). The leading remove pump assembly (4) from helicopter. Install pro-
particulars for both the hydraulic pump and the electric tective dust cover to hose connector. Remove fitting (8)
motor are as follows: from pump assembly and card packing (7).
Pump: h. Drain remainder of fluid from pump assembly.
Rated discharge pressure i. Remove fitting (11) and discard packing (12)
from pump assembly (4).
Full Flow 1100 psig minimum
j. Remove fitting (2) from pump assembly (4).
Zero flow 1250 psig maximum Remove packing (1) from fitting (2). Discard packing.
Rated inlet pressure 10 psig k. Remove fitting (14) from pump assembly (4).
Remove packing (15) from fitting (14). Discard packing.
Rated full flow 1.0 gpm minimum
l. Clean pump assembly (paragraph 7-176).
Electric motor:
Change 19 7-135
TM 55-1520-236-23
m. Fill pump assembly (4) with hydraulic fluid Electric motor 0,030 inch (0,060 inch after
preservative (C61 or C62) and plug or cap all open port cleanup).
holes and electrical connector.
(2) Nicks and scratched maximum depth:
n. Wrap pump assembly in barrier material (C22)
and secure with tape (C127). Send pump to next Hydraulic pump 0,030 inch (0.030 inch after
higher level of maintenance. cleanup).
7-176. CLEANING HYDRAULIC Electric motor 0.060 inch (0.060 inch after
PUMP (EMERGENCY ELECTRIC MOTOR cleanup).
DRIVEN).
(3) Dent or deformation maximum depth:
Hydraulic pump 0.010 inch (0.030 inch after
Cleaning solvent is flammable and toxic. cleanup).
Provide adequate ventilation. Avoid
prolonged breathing of solvent vapors Electric motor 0.050 inch (0.060 inch after
and contact with skin or eyes. Eye cleanup).
protection is required when using
compressed air. (4) Cracks: No cracks are acceptable.
c. Inspect electrical connection to pump
assembly (4) for corrosion, damaged threads, and
Do not submerge pump assembly (4, bent or broken pins.
figure 7-4) in dry cleaning solvent as it
will damage internal components. d. Inspect threaded ports in pump for damage.
Maximum accpetable thread damage is one-third of
a. Wash pump assembly with a clean rag thread depth 0.250 inch in length, and one damage
saturated with solvent (C112). A soft bristle brush per port.
may be required to remove stubborn deposits of caked
dirt and oil. e. Pumps that seem excessively noisy in comparison
to other AH-IS emergency pumps, should be removed
b. Dry pump assembly with clean filtered and sent to the appropriate depot for analysis and re-
compressed air. sulting required maintenance.
7-177. INSPECTION 7-178. REPAIR OR
HYDRAULIC PUMP (EMERGENCY REPLACEMENT H Y D R A U L I C P U M P
ELECTRIC MOTOR DRIVEN). ( E M E R G E N C Y ELECTRIC MOTOR
DRIVEN).
NOTE
The following inspection procedures are a. Replace pumps which fail to meet inspection
applicable to external surfaces and requirement of paragraph 7-177.
threaded bosses only. No internal
inspections of the pump are authorized at b. Polish out mechanical and corrosion damage
this level of maintenance. that is within repairable limits noted in paragraph
7-177. Use 600 grit sandpaper (C102) and polish to
a. Inspect hydraulic pump assembly (4, figure. original finish.
7-7) for leaks (table 7-1).
c. Touch up with primer (C88 or C91).
b. Inspect pump/ motor package for corrosion and
mechanical damage. Damage within limits noted 7-179. INSTALLATION
below is acceptable if polished out. HYDRAULIC PUMP (EMERGENCY
ELECTRIC MOTOR DRIVEN).
(1) Corrosion damage maximum depth:
a. Remove case drain plug from top of Pump
Hydraulic pump 0.015 inch (0.030 inch after assembly and drain preservative fluid. Using
cleanup).
7-136 Change 7
TM 55-1520-236-23
hydraulic fluid dispenser (S1), fill pump with clean doors (8, figure 2-3) at each side give access to the
hydraulic fluid (C61 or C62) and install case drain compartment. Each hydraulic modular unit consists
plug. Secure case drain plug with lockwire (C137). of a housing equipped with the system solenoid valve,
relief valve, pressure switch for caution panel light,
b. Install packing (1, figure 7-7) on fitting (2) and pressure and return filters, filter indicators (popout
install fitting into CASE DRAIN port, located top button), marked ports for system connections. Two
center of pump. quick-disconnect couplings are located on right
modular unit for connection of hydraulic test stand
c. Install packing (7) on fitting (8) and install fitting (S2). One coupling is also used in normal operation
into SEAL DRAIN port, located on lower end of pump. for the return hose to the reservoir. System No. 1
hydraulic modular unit is at left, and System No. 2
d. Install packing (12) on fitting (11) and install hydraulic modular unit at right on bulkhead.
fitting into SUCTION port, located on forward face of
pump (outboard). 7-182. REMOVAL HYDRAULIC
MODULAR UNIT.
e. Install packing (15) on fitting (14) and install
fitting into PRESSURE port, located on forward face of a. Open left and right door (8, figure 2-3).
pump (inboard).
b. Place a container under module (3, figure 7-40)
f. Remove protective dust covers from connectors or the opposite model that is being removed.
of tubes (3, 10, and 13) and hose assembly (9). Check
tube and hose connectors for thread damage. c. Disconnect electrical connectors from solenoid
and pressure switch at top of module.
g. Position pump assembly (4) on shelf and under
bonding strap. Install four bolts (5), and four washers d. D i s c o n n e c t r e t u r n l i n e h o s e f r o m q u i c k -
(6). disconnect coupling on front of module, and four
tubes from fittings at side ports. Cap fittings and open
ends of tubes.
e. Remove three bolts, with washers and nuts, to
Ensure that tubes and the hose are free of detach module from bulkhead. Remove module from
obstructions prior to installation. compartment.
h. Install tubes (3, 10 and 13) on fittings (2, 11 and f. If module is not to be reinstalled, remove
14). Torque per table 7-4. fittings for installation on replacement module.
i. Install hose (9) on fitting (8). Ensure that hose 7-183. CLEANING HYDRAULIC
does not kink during installation procedure. Torque MODULAR UNIT.
per figure 7-4.
i. Connect electrical plug to pump assembly and
lockwire.
Cleaning solvent is flammable and toxic.
k. Perform functional check of hydraulic system Provide adequate ventilation. Avoid
(paragraph 7-146). prolonged breathing of solvent vapors
and contact with skin or eyes. Eye
7-180. HYDRAULIC protection is required when using
MODULAR UNIT. compressed air.
a. Clean electrical components with dry, filtered
7-181. DESCRIPTION compressed air.
HYDRAULIC MODULAR UNIT.
Two hydraulic modular units are located in a
compartment at top of the fuselage between pilot Do not submerge module unit in dry
canopy and the transmission pylon, on front of cleaning solvent.
bulkhead at Station 186.25. See figure 7-40. Hinged
Change 12 7-137
TM 55-1520-236-23
b. Clean external surfaces of module with solvent f. Perform operational check of hydraulic system
(C112). (paragraph 7-146).
7-187. FILTER ELEMENTS.
7-184. INSPECTION -
HYDRAULIC MODULAR UNIT.
7-188. DESCRIPTION - FILTER
a. I n s p e c t m o d u l a r u n i t s f o r n i c k s , d e n t s , ELEMENTS.
scratches and cracks. Superficial mechanical
damage is acceptable without repair. No cracks The filter elements on and coded helicopters
allowed. are similar to the filter elements on coded
helicopters (paragraph 7-45).
b. Inspect thread, in threaded bosses for damage.
Thread damage that could affect function is not 7-189. REMOVAL - FILTER
acceptable. ELEMENTS.
c. Inspect modular units for leaks and Remove filter elements using same procedures
malfunction during operational checks (paragraph outlined for coded helicopters (paragraph 7-46).
7-146).
7-190. CLEANING - FILTER
7-185. REPAIR OR ELEMENTS.
REPLACEMENT - HYDRAULIC MODULAR
UNIT. (AVIM) Do not clean paper-type filter elements.
a. Replace modular units that fail to meet 7-191. INSPECTION - FILTER
inspection requirements of paragraph 7-184. ELEMENTS.
b. Touch up external finish with primer (C88 or Inspect filter elements using same procedures
C91). outlined for coded helicopters (paragraph 7-46,
step e).
7-186 INSTALLATION -
HYDRAULIC MODULAR UNIT. 7-192. REPAIR OR
Install pressure switch (1, figure 7-40),
REPLACEMENT - FILTER ELEMENTS.
a.
bypass solenoid valve (2), filters and fittings in
Install new paper-type filter elements P/N
module housing if not previously accomplished.
205-076-034-3.
Use new packings and gaskets. Torque pressure
switch jam nut 40 to 50 inch-pounds. Safety to
module housing using lockwire (C137).
7-193.
~ INSTALLATION - FILTER
ELEMENTS.
b. Position hydraulic modular unit (3) on bulkhead
with pressure ports at outboard side. Align mounting Install filter elements using same procedures
holes. Insert three bolts through module housing and outlined for q coded helicopters (paragraph 7-50).
bulkhead, and install washers and nuts at back of
bulkhead. 7-194. ~ m A C C U M U L A T O R AND
LOCKOUT VALVE.
c. Connect hydraulic system tubes to fittings at
marked ports. Connect hose from reservoir RETURN
port to quick-disconnect coupling. 7-195. q u DESCRIPTION -
ACCUMULATOR AND LOCKOUT VALVE.
d. Connect electrical connectors to bypass
solenoid valve (2) and to pressure switch (1). The accumulator and lockout valves on q and ~
coded helicopters are similar to the accumulator and
e. Install opposite hydraulic modular unit in same lockout valves used on q c o d e d h e l i c o p t e r s
manner outlined in steps a through d. (paragraph 7-52).
7-138 Change 5
TM 55-1520-236-23
7-196. q m REMOVAL - 7-204. ~ ~ D I S A S S E M B L Y - D U A L
ACCUMULATOR AND LOCKOUT VALVE. HYDRAULIC CYLINDERS (AVIM).
Remove the accumulator and lockout valve using the Disassemble dual hydraulic cylinders using same
same procedures outlined for ~ coded helicopters procedures outlined for q c o d e d h e l i c o p t e r s
(paragraph 7-53). (paragraph 7-58).
7-197. ~ ~ CLEANING -
ACCUMULATOR AND LOCKOUT VALVE. 7-205. m ~ CLEANING - DUAL
HYDRAULIC CYLINDERS.
Clean the accumulator and lockout valve using the
same procedures outlined for q coded helicopters Clean dual hydraulic cylinders using same
(paragraph 7-54). procedures outlined for ~ c o d e d h e l i c o p t e r s
(paragraph 7-62).
7-198. q ~ INSPECTION -
ACCUMULATOR AND LOCKOUT VALVE.
7-206. q m I N S P E C T I O N - D U A L
HYDRAULIC CYLINDERS.
Inspect the accumulator and lockout valve using the
same procedures outlined for ~ coded helicopters
Inspect dual hydraulic cylinders using procedures
(paragraph 7-55).
outlined for q coded helicopters (paragraph 7-63).
7-199. q ~ REPAIR OR
REPLACEMENT - ACCUMULATOR AND 7-207. q ~ REPAIR OR
LOCKOUT VALVE. REPLACEMENT - DUAL HYDRAULIC
CYLINDERS.
Repair or replace the accumulator and lockout valve
using same procedures outlined for q c o d e d Repair or replace dual hydraulic cylinders using same
helicopters (paragraph 7-56). procedures outlined for ~ c o d e d h e l i c o p t e r s
(paragraph 7-64).
7-200. q ~ INSTALLATION -
ACCUMULATOR AND LOCKOUT VALVE.
7-208. ~ ~ ASSEMBLY - DUAL
Install the accumulator and lockout valve using the HYDRAULIC CYLINDERS (AVIM).
same procedures outlined for ~ coded helicopters
(paragraph 7-57). Assemble dual hydraulic cylinders using same
procedures outlined for ~ c o d e d h e l i c o p t e r s
7-201. q ~ D U A L HYDRAULIC (paragraph 7-65).
CYLINDERS.
7-202. q ~ DESCRIPTION - DUAL 7-209. ~ ~ INSTALLATION - DUAL
HYDRAULIC CYLINDERS. HYDRAULIC CYLINDERS.
The dual hydraulic cylinders on q and ~ coded Install dual hydraulic cylinders using same
helicopters are similar to the dual hydraulic cylinders procedures outlined for q coded helicopters
used on q coded helicopters (paragraph 7-59). (paragraph 7-66).
7-203. ~ ~ REMOVAL - DUAL 7-210. ~ ~ INTERSYSTEM LEAKAGE
HYDRAULIC CYLINDERS. - DUAL HYDRAULIC CYLINDERS.
Remove dual hydraulic cylinders using same Dual hydraulic cylinders on q and ~ c o d e d
procedures outlined for ~ c o d e d h e l i c o p t e r s helicopters are similar to dual hydraulic cylinders on
(paragraph 7-60). ~ coded helicopters (paragraph 7-67).
Change 5 7-139
TM 55-1520-236-23
7 - 2 1 1 . ~ S E R V O VALVE 7-219. REPAIR OR REPLACEMENT
R E P L A C E M E N T - DUAL HYDRAULIC - (SCAS) SERVO ACTUATORS.
CYLINDERS (AVIM).
Repair or replace (SCAS) servo actuators using same
Replace dual hydraulic cylinder servo valves using procedures outlined for q c o d e d h e l i c o p t e r s
same procedures outlined for ~ coded helicopters (paragraph 7-76).
(paragraph 9-68).
7-220. q ~ INSTALLATION - (SCAS)
SERVO ACTUATORS.
7 - 2 1 2 . ~~ R E M O V A L - S E R V O
VALVE - DUAL HYDRAULIC CYLINDERS. Install (SCAS) servo actuators using same procedures
outlined for ~ coded helicopters (paragraph 7-77).
Remove dual hydraulic cylinder servo valves using
same procedures outlined for ~ coded helicopters
7-221. q m ( S C A S ) FILTER
(paragraph 7-69).
REPLACEMENT.
7-222. q ~ DESCRIPTION - (SCAS)
7-213. ~ INSTALLATION - SERVO FILTER REPLACEMENT.
VALVE - DUAL HYDRAULIC CYLINDERS.
Install dual hydraulic cylinder servo valves using
The (SCAS) filters on H and ~ coded
helicopters aresimilar to (SCAS) filters on q coded
same procedures outlined for q coded helicopters
helicopters (SCAS) filter replacement is similar
(paragraph 7-70).
(paragraph 7-79).
7 - 2 1 4 . ~ ( S C A S ) SERVO 7-223. ~ CYLINDER AND SUPPORT
ACTUATORS. ASSEMBLY - TAIL ROTOR CONTROL.
7-215. ~~ DESCRIPTION - (SCAS) 7 - 2 2 4 . ~ D E S C R I P T I O N
SERVO ACTUATORS. CYLINDER AND SUPPORT ASSEMBLY -
TAIL ROTOR CONTROL.
The (SCAS) servo actuators on q and ~ coded
helicopters are similar to the (SCAS) servo actuators Tail rotor control cylinder and support assemblies
on q coded helicopters (paragraph 7-72). on q and m coded helicopters are similar to
tail rotor cylinder and support assemblies on ~
7 - 2 1 6 . mm R E M O V A L - (SCAS) coded helicopters (paragraph 7-81).
SERVO ACTUATORS,
Remove (SCAS) servo actuators using same 7-225. q m REMOVAL - CYLINDER
procedures outlined for ~ c o d e d h e l i c o p t e r s AND SUPPORT ASSEMBLY - TAIL ROTOR
(paragraph 7-73). CONTROL.
Remove tail rotor control cylinder and support
7 - 2 1 7 . ~ C L E A N I N G - (SCAS) same procedures outlined
assembly by
SERVO ACTUATORS. for q coded helicopters (paragraph 7-82).
Clean (SCAS) servo actuators using same procedures
outlined for ~ coded helicopters (paragraph 7-74).
7 - 2 2 6 . ~ D I S A S S E M B L Y -
7-218. m ~ INSPECTION - (SCAS) CYLINDER AND SUPPORT ASSEMBLY -
SERVO ACTUATORS. TAIL ROTOR CONTROL.
Inspect (SCAS) servo actuators using same Disassemble tail rotor control cylinder and support
procedures outlined for ~ c o d e d h e l i c o p t e r s assembly using same procedures outlined
(paragraph 7-75). for ~ coded helicopters (paragraph 7-83).
7-140
TM 55-1520-236-23
7-227. ~ ~ CLEANING - CYLINDER 7 - 2 3 4 . ~ D E S C R I P T I O N
AND SUPPORT ASSEMBLY - TAIL ROTOR SOLENOID VALVE P/N 88604-1 (2 AND 28,
CONTROL. FIGURE 7-40).
Solenoid valves (2 and 28) are located in the filter
Clean tail rotor control cylinder and support assembly modules. The solenoid valves are controlled by the
using same procedures outlined for ~ c o d e d HYD TEST switch in the pilot engine control panel.
helicopters (paragraph 7-84).
7-235. ~ ~ CLEANING - SOLENOID
7-228. q ~ INSPECTION - CYLINDER VALVE P/N 88604-1.
AND SUPPORT ASSEMBLY - TAIL ROTOR
a. Clean solenoid valves (2 and 28, figure 7-40)
CONTROL.
while the valves are installed in the filter modules
(paragraph 7-183).
Inspect tail rotor control cylinder and support
assembly using same procedures outlined forb
coded helicopters (paragraph 7-85).
Cleaning solvent is flammable and toxic.
7-229. ~ REPAIR OR REPLACEMENT
Provide adequate ventilation. Avoid
- CYLINDER AND SUPPORT ASSEMBLY -
prolonged breathing of solvent vapors
TAIL ROTOR CONTROL.
and contact with skin or eyes.
Repair or replace tail rotor control cylinder and b. Clean the solenoid valves with a clean cloth
support assembly using same procedures outlined moistened with solvent (C112). Use a soft bristle
for ~ coded helicopters (paragraph 7-86). brush to remove stubborn deposits of dirt or oil.
7-230. q ~ ASSEMBLY - CYLINDER 7-236. ~ INSPECTlON - SOLENOID
AND SUPPORT ASSEMBLY - TAIL ROTOR VALVE P/N 88604-1.
CONTROL.
a. Inspect solenoid valves (2 and 28, figure 7-40)
electrical connectors for bent or broken pins and
Assemble tail rotor control cylinder and support damaged threads.
assembly using same procedures outlined
for ~ coded helicopters (paragraph 7-87). b. Inspect external surfaces of solenoid valves for
nicks, dents and cracks. No cracks are acceptable.
7-231. q m INSTALLATION - c. I n s p e c t a r e a a r o u n d s o l e n o i d v a l v e s f o r
CYLINDER AND SUPPORT ASSEMBLY - hydraulic fluid leaks.
TAIL ROTOR CONTROL.
7-237. ~~ REPAIR OR REPLACEMENT
Install tail rotor control cylinder and support assembly - SOLENOID VALVES P/N 88604-1 (AVIM).
using same procedures outlined for q coded
helicopters (paragraph 7-88). a. Replace solenoid valve (2, figure 7-40) and
hydraulic modular unit (3) as an assembly if solenoid
valve (2) fails to meet inspection requirements of
paragraph 7-250. Refer to paragraphs 7-39 and 7-43
7-232. ~ ~ SOLENOID VALVES.
for removal and installation instructions.
7-233. ~ g S O L E N O I D V A L V E P / N b. Replace solenoid valve (28) in the same
88604-1 (2 AND 28, FIGURE 7-40). manner outlined in the preceding step.
7-141
TM 55-1520-236-23
7-238.
~ SOLENOID VALVES Three, three-way, two position solenoid valves (7, 8
and 41) are included in the hydraulic system to permit
P/N 204-076-504-3, FSCM 94641 P/N
1-U-1025-63 OR FSCM 16780P/N use of the electric, emergency hydraulic pump in the
130027-5 (7, 8 AND 41, FIGURE 7-40). event of failure of system No. 1 and system No. 2
pumps. The solenoid valves are also used to permit
use of the electric, emergency pump during
boresighting procedures. The solenoid valves are
controlled by the pilot and/or gunner EMER HYDR
7-239.
~ DESCRIPTION - PUMP/BORESIGHT switch and the pilot MASTER
SOLENOID VALVES P/N 204-076-504-3, ARM switch. See FO-2 (foldout 2) for view of
FSCM 94641 P/N 1-U-1025-63 OR FSCM hydraulic system schematic. See table 7-14 for
16780 P/N 130027-5 (7, 8 AND 41, FIGURE leading particulars for solenoid valve (P/N 204-076-
7-40). 504-3 FSCM 94641 P/N 1-U-1025-63.
Table 7-14. Leading Particulars for Solenoid Valve P/N 204-076-504-3 FSCM 94641 1-U-1025-63
Operating Medium . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic fluid: Military
Specification MIL-H-5605 (C62)
or
Military Specification
MIL-L-83282 (C61)
Pressures:
Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1500 psig
Proof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3000 psig
Burst . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4500 psig
Leakage:
External . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . none
Internal (at 3000 psig) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 cc per minute maximum with
solenoid energized; 1 cc per
minute maximum with solenoid
de-energized
PE Drop
(Port 2 to 1, or 2 to 3):
At +21 degrees C (+70 degrees F) . . . . . . . . . . . . . . . . . . . . 75 psig (maximum) at 3 gpm flow
At -54 degrees (-65 degrees F) . . . . . . . . . . . . . . . . . . . . . . . 200 psig (maximum at gpm flow
Solenoid Characteristics:
Voltage Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 to 30 volts dc
Current Drain at 28 volts dc
and +21 degrees C (+70 degrees F) . . . . . . . . . . . . . . . . . . . 1.2 amperes (maximum)
7-142
TM 55-1520-236-23
Table 7-14. Leading Particulars for Solenoid Valve P/N 204-076-504-3
FSCM 94641 1-U-1025-63 (Cont)
Ambient Temperature
Range: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -54 degrees C (-65 degrees F) to
+71 degrees C (+160 degrees F)
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.25 pounds
Premaintenance Requirements for Solenoid Valves (2) D i s c o n n e c t electrical connector from
P/N 204-076-504-3, FSCM 94641 P/N solenoid valve (6, figure 7-42).
1-U-1025-63 or FSCM 16780 P/N 130027-5
(3) Provide a suitable container to catch fluid
when disconnecting tubes (1, 10 and 14) from
Conditions Requirements solenoid valve (6).
Model AH-1S (4) Remove tube (14) from solenoid valve (6).
Part No. or Serial No. 204-076-504-3 (5) Disconnect tubes (1 and 10) from solenoid
valve (6).
Special Tools None
(6) Remove two bolts (31) and two washers (32)
Test Equipment Hydraulic test stand (S2) attaching solenoid valve (6) to bulkhead and remove
Pressure drop test setup solenoid valve.
(figure 7-25)
functionaI test setup (7) Drain hydraulic fluid from solenoid valve (6)
(figure 7-26) and remove fitting (13). Remove packing (12) from
30 Vdc power supply fitting (13).
Support Equipment (8) Loosen nut (9) and remove elbow (11) from
solenoid valve (6). Remove packing (7), ring (backup)
Minimum Personnel Two (8), and nut (9) from elbow (11).
Required
(9) Loosen nut (3) and remove elbow (2) from
Consumable Materials (C22) (C30) (C31) (C36) (C37) bypass solenoid valve (6). Remove packing (5), ring
(C61) (C62) (C63) (C88) (C91) (backup) (4), and nut (3) from elbow (2).
(C112) (C137)
(10) Install protective dust covers to open ports
Special Environmental None and electrical connector of solenoid valve (6) to
Conditions prevent entry of foreign particles.
b. Remove solenoid valve (23, figure 7-42) as
follows:
7-240. ~ REMOVAL - SOLENOID
VALVES P/N 204-076-504-3 FSCM 94641 (1) Remove right fuselage access panel (17,
P/N 1-U-1025-63 OR FSCM 16780 P/N figure 2-3).
130027-5 (7, 8, AND 41, FIGURE 7-40).
(2) D i s c o n n e c t e l e c t r i c a l connector from
a. Remove solenoid valve (6, figure 7-42) as solenoid valve (23, figure 7-42).
follows:
(3) Provide a suitable container to catch fluid
(1) Remove right fuselage access panel (17, when disconnecting tube (22) from solenoid valve
figure 2-3). (23).
7-143
TM 55-1520-236-23
1. Tube 12. Packing 24. Bolts (2)
2. Elbow 13. Fitting (union) 25. Washer (2)
3. Nut 14. Tube 26. Packing
4. Ring (backup) 15. Elbow 27. Ring (backup)
5. Packing 16. Tube 28. Nut
6. Solenoid valve P/N 204-076 -504-3 17. Nuts (2) 29. Elbow
FSCM 94641 P/N 1 -U-1025-63 18. Rings (backup) (2) 30. Tube
or FSCM 16780 P/N 130027-6 19. Packing 31. Bolts (2)
7. Packing 20. Packing 32. Washers (2)
Ring (backup) 21. Fitting (union)
:: Nut 22. Tube
10. Tube 23. Solenoid valve P/N 204-076 -504-3
11. Elbow FSCM 94641 P/N 1 -U-1 025-63
or FSCM 16780 P/N 130027-5
209076-65B
Figure 7-42. ~ Solenoid Valves P/N 204-076-504-3 - Installation (Sheet 1 of2)
7-144 Change 3
TM 55-1520-236-23
33. Tube
34. Fitting (union)
35. Packing
36. Packing
37. Fitting (union)
38. Tube
39. Solenoid valve P/N 204-076 -504-3
FSCM 94641 P/N 1-U-1025-63
or FSCM 16780 P/N 130027-5
40. Bolts
41. Washers
42. Packing
43. Fitting (union)
44. Tube
209076-66A
Figure 7-42. - Solenoid Valves P/N 204-076-504-3 - Installation (Sheet 2 of 2)
7-145
TM 55-1520-236-23
(4) Remove tube (22) from solenoid valve (23). 7 - 2 4 1 . ~ C L E A N I N G - S O L E N O I D
VALVES P/N 204-076-504-3 FSC 9461 P/N
(5) Disconnect tubes (16 and 30) from solenoid 1-U-1025-63 OR FSCM 16780 P/N
valve (23). 130027-5 (7, 8 AND 41, FIGURE 7-40).
(6) Remove two bolts (24) and two washers (25)
a. Clean assembled solenoid valves (7, 8 and 41)
attaching solenoid valve (23) to bulkhead and remove
in same manner outlined in paragraphs 7-111).
solenoid valve.
b. Clean disassembled solenoid valves (7, 8, and
(7) Drain hydraulic fluid from solenoid valve
41) FSCM 94641 P/N 1-U-1025-63 in same manner
(23) and remove fitting (21). Remove packing (20)
outlined in paragraph 7-102.
from fitting (21).
(8) Loosen nut (17) and remove elbow (29) from
7-242. ~ INSPECTION - SOLENOID
solenoid valve (23). Remove packing (19), ring
(backup) (18), and nut (17), from elbow (15).
VALVES P/N 204-076-504-3 FSCM 94641
P/N 1-U-1025-63 OR FSCM 16780 P/N
(9) Loosen nut (28) and remove elbow (29) from
130027-5 (AVIM) (7, 8 AND 41, FIGURE 7-
solenoid valve (23). Remove packing (26), ring
40).
(backup) (27), and nut (28) from elbow (29).
a. Inspect assembled solenoid valves (7, 8 and 41
as follows:
(10) Install protective dust covers to open ports
and electrical connector of solenoid valve (23) to
(1) Inspect electrical connector for bent or
prevent entry of foreign particles.
broken pins and damaged threads.
c. Remove solenoid valve (39, figure 7-42). (2) Inspect ports for damaged threads.
(1) Remove left fuselage panel (17, figure 2-3). (3) Inspect external surfaces for nicks, dents,
and cracks. No cracked parts are acceptable.
(2) 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
solenoid valve (39, figure 7-42). b. Inspect disassembled solenoid valve FSCM
94641 P/N 1-U-1025-63 in same manner outlined in
paragraph 7-103.
(3) Provide a suitable container to catch fluid
when disconnecting tube assemblies (33, 38, and
44).
7-243. ~ ~ REPAIR OR REPLACEMENT
(4) Disconnect tube assemblies (33, 38, and - SOLENOID VALVES P/N 204-076-504-3
44) from solenoid valve (39). FSCM 94641 P/N 1-U-1025-63 OR FSCM
16780 P/N 130027-5 (AVIM) (7, 8 AND 41,
(5) Remove two bolts (40) and two washers (41) FIGURE 7-40).
attaching solenoid valve (39) to bulkhead and remove
solenoid valve. Cap all open lines. a. Inspect data plate on solenoid valve and
determine whether valve is FSCM 94641 P/N 1-U-
1025-63 or FSCM 16780 P/N 130027-5.
(6) Drain fluid from solenoid valve (39) and
remove fitting (34). Remove packing (35) from fitting. b. Replace solenoid valves FSCM 16780 P/N
Discard packing. 130027-5 that fail to meet inspection requirements
of paragraph 7-242.
(7) Remove fitting (37) from solenoid valve (39).
Remove packing (36) from fitting. Discard packing. c. Repair solenoid valves FSCM 94641 P/N 1-U-
1025-63 that fail to meet inspection requirements.
(8) Remove fitting (43) from solenoid valve (39). Use same procedure outlined in paragraphs 7-101
Remove packing (42) from fitting. Discard packing. through 7-106.
7-146
TM 55-1520-236-23
7-244. ~ ~ INSTALLATION - SOLENOID fluid from solenoid valve. Flush solenoid valve with
VALVES P/N 204-076-504-3 FSCM 94641 P/N clean hydraulic fluid (C61 or C62).
1-U-1025-63 OR FSCM 16780 P/N 130027-5
(7, 8, AND 41, FIGURE 7-40). (2) Apply a light film of hydraulic fluid (C61 or
C62) to all packings, threads and tube connectors
a. Install solenoid valve (6, figure 7-42). prior to assembly of part, with the exception of bolts
(24).
(1) R e m o v e p r o t e c t i v e d u s t c o v e r s f r o m
solenoid valve. Flush solenoid valve with clean (3) Install nut (17), backup ring (18), and
hydraulic fluid (C61 or C62). packing (19) on elbow (15). Thread elbow (15) into
PORT 3; position elbow as shown and tighten nut
(2) Apply a light film of hydraulic fluid (C61 or (17).
C62) to all packings, threads, and tube connectors
prior to assembly of part, with the exception of bolts (4) Install nut (28), backup ring (27), and
(31). packing (26) on elbow (29). Thread elbow (29) into
PORT 1; position as shown and tighten nut (28).
(3) Install nut (3), backup ring (4), and packing
(5) on elbow (2). Thread elbow into PORT 1 of solenoid (5) Install packing (20) on fitting (21) and install
valve (6); position as shown and tighten nut (3). fitting into PORT 2.
(4) Install nut (9), backup ring (8), and packing (6) Remove protective dust covers from tubes
(7) on elbow (11). Thread elbow into PORT 2 of (16, 22, and 30).
solenoid valve (6); position as shown and tighten nut
(9). (7) Buff mounting pads of bypass solenoid
valve (23) to ensure good electrical bond. Position
(5) Install packing (12) on fitting (13) and install solenoid valve on bulkhead as shown and install two
fitting into PORT 3. bolts (24) and two washers (25).
(6) Remove protective dust covers from tubes (8) Install and torque tubes (16, 22 and 30) in
(1, 10 and 14). accordance with table 7-4.
(7) Buff mounting pads of bypass solenoid (9) Remove protective dust cover from solenoid
valve (6) to ensure good electrical bond. Position valve (23). Install electrical connector on solenoid
solenoid valve on bulkhead, as shown, and install two valve (23) and secure with lockwire (137).
bolts (31) and two washers (32).
(10) Fill reservoir to proper level. (Paragraph
(8) Connect and torque tubes (1, 10 and 14) in 7-6).
accordance with table 7-4.
(11) Perform operational check of hydraulic
(9) Install electrical connector to solenoid valve system (Paragraph 7-146).
(6) and secure with Iockwire (C137).
(12) Install right access panel (17, figure 2-3).
(10) Fill reservoir to proper level. (Paragraph
7-6).
c. Install solenoid valve (39, figure 7-42).
(11) Perform operational check of hydraulic
(1) R e m o v e p r o t e c t i v e d u s t c o v e r s f r o m
system. (Paragraph 7-143). Refill reservoir.
solenoid (39) and drain preservative hydraulic fluid
from solenoid valve. Flush solenoid valve with clean
(12) Install right access panel (17, figure 2-3).
hydraulic fluid (C61 or C62).
b. Install solenoid valve (23, figure 7-42). (2) Apply a light film of hydraulic fluid (C61 or
C62) to all packings, threads, and tube connectors
(1) R e m o v e p r o t e c t i v e d u s t c o v e r s f r o m prior to assembly of part, with the exception of bolts
solenoid valve (23), and drain preservative hydraulic (40).
7-147
TM 55-1520-236-23
(3) Install packing (35) on fitting (34) and install Premaintenance Requirements For
fitting into PORT 3 of solenoid valve (39). Hydraulic Solenoid Valves P/N 209-076-023-1
FSCM 16780 P/N 15353
(4) Install packing (42) on fitting (43) and install
fitting into PORT 1 of solenoid valve (39). Conditions Requirements
Model AH-1S
(5) Install packing (36) on fitting (37) and install
fitting into PORT 2 of solenoid valve (39). Part No. or Serial No. 209-076-023-1
FSCM 16780 P/N 15353
(6) Remove protective dust covers from tubes
Special Tools None
(33, 38, and 44).
Test Equipment None
(7) Buff mounting pads of bypass solenoid
valve (7) to ensure good electrical bond. Position Support Equipment (S1)(S2)
solenoid valve on bulkhead as shown and install two
bolts (40) and two washers (41). Minimum Personnel One
Required
(8) Connect and torque tubes (33, 38, and 44) in
accordance with table 7-4. Consumable Materials (C61 or C62) (C112)
(9) Install electrical connector on solenoid Special Environmental None
valve (39) and secure with lockwire (C137). Conditions
(10) Fill reservoir to proper level with clean 7-247. ~ ~ REMOVAL - SOLENOID
hydraulic fluid (C61 or C62). (Paragraph 7-6). VALVES P/N 209-076-023-1, FSCM 16780
P/N 15353 (17, 21, AND 37, FIGURE 7-40).
(11) Perform operational check of hydraulic
system (paragraph 7-146). Refill reservoir. a. Remove solenoid valve(16, figure 7-43) for fore
and aft (SCAS) system as follows:
(12) Install left access panel (17, figure 2-3).
(1) Remove right access panel (17, figure 2-3).
(13) Ensure that all air has been bled from
system prior to next flight by cycling cyclic stick a (2) 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
minimum of 10 full cycles. solenoid valve (16, figure 7-43).
(3) Provide a suitable container to catch fluid
seepage when disconnecting tube assemblies from
7-245. q ~ SOLENOID VALVES P/N
solenoid valve (16).
209-076-023-1, FSCM 16780 P/N 15353
(17, 21, AND 37, FIGURE 7-40). (4) Disconnect tube assemblies (1, 2, 8, 19 and
30) from solenoid valve (16).
7-246. ~ DESCRIPTION - SOLENOID
(5) Remove two nuts (15), two washers (14),
VALVES P/N 209-076-023-1, FSCM 16780 P/N
two washers (7), two bolts (6), and remove solenoid
15353 (17, 21, AND 37, FIGURE 7-40).
(16) from bracket (24).
(6) I n s t a l l p r o t e c t i v e d u s t c o v e r s t o o p e n
Three, three-way, two-position solenoid valves (17,
connectors of tube assemblies (1, 2, 8, 19 and 30).
21, and 37) are included in the hydraulic system to
permit shutting off fluid circulation to any one of the
(7) Remove components from solenoid valve
three (SCAS) servo actuators. The solenoid valves are
(16) as follows:
controlled by the pitch, roll, and yaw switches on the
pilot (SCAS) control panel. See FO-2 (foldout 2) for (a) Remove fitting (13) from solenoid valve
view of hydraulic system schematic. (16).
7-148
TM 55-1520-236-23
Figure 7-43. Solenoid Valves (SCAS System) - lnstaIlation (Sheet 1 of 4)
7-149
TM 55-1520-236-23
Figure 7-43. Solenoid Valves (SCAS System) - Installation (Sheet 2 of 4)
7-150
TM 55-1520-236-23
Figure 7-43. ~~Solenoid Valves (SCAS System) - Installation (Sheet 3 of 4)
7-151
TM 55-1520-236-23
48. Tube assembly
1. Tube assembly
49. Screw
2. Tube assembly
50. Washer
3. Fitting
51. Nut
4. Packing
52. Washer
5, Tee
53. Bracket
6. Bolt
54. Packing
7. Washer
55. Ring (backup)
8. Tube assembly
56. Hose assembly
9. Fitting
57. Elbow
10. Packing
58. Nut
11. Filter
59. Ring (backup)
12, Packing
60. Packing
13. Fitting
61. Tee
14. Washer
62. Packing
15. Nut
63. Ring (backup)
16. Valve P/N 209-076 -023-1
64. Nut
FSCM 16780 P/N 15353
65. Fitting
17. Screw
66. Packing
18. Washer
67. Bushing
19. Tube assembly
68. Packing
20. Elbow
69. Packing
21. Nut
70. Ring (backup)
22. Ring (backup)
71. Nut
23. Packing
72. Elbow
24. Bracket
73. Hose assembly
25. Packing
74. Washer
26. Ring (backup)
75. Spacer
27. Nut
76. Clamps
28. Fitting
77. Screw
29. Packing
78. Tube assembly
30. Tube assembly
79. Solenoid velve P/N 209-076 -023-1
31. Fitting
FSCM 16780 P/N 15353
32. Packing
80. Spacer
33. Fitting
81. Washer
34. Tube assembly
82. Elbow
35. Packing
83. Nut
36. Fitting
84. Ring (backup)
37. Tube assembly
85. Packing
38. Elbow
86. Screw
39. Nut
87. Tube assembly
40. Bolt
88. Elbow
41. Washer
89. Nut
42. Solenoid valve P/N 209-076 -023-2
90. Ring (backup)
FSCM 16780 P/N 15353
91. Packing
43. Packing
92. Packing
44. Fitting
93. Fitting
45. Filter
94. Tube assembly
46. Packing
47. Fitting
209076-54-4A
Figure 7-43.~ gSolenoid Valves (SCAS System) - Installation (Sheet 4 of 4)
7-152
TM 55-1520-236-23
(b) Remove fittings (9 and 13) from filter (11) (c) Remove fitting (44), with filter (45), from
and discard two packings (12) and packing (10). If solenoid valve (42). Remove fittings (44 and 47) from
filter (11) is not immediately being installed, install filter (45) and discard two packings (43) and packing
protective dust covers to open ports. (46).
(c) Loosen nut (21) and remove elbow (20) (d) If filter (45) is not being installed
from solenoid valve (16). Remove packing (23), immediately, install protective dust covers in open
(backup) ring (22) and nut (21) from elbow (20) and ports.
discard packing (23) and (backup) ring (22).
c. Remove solenoid valve (79, figure 7-43) for
(d) Remove fittings (3, 31, and 33) from tee anti-torque (SCAS) system.
(5) and discard packings (4, 32 and 29).
(1) Remove access panel (38, figure 2-3) from
(e) Loosen nut (27) and remove fitting (28), lower side of fuselage and provide a clean, dust free
with tee (5), from solenoid valve (16). work area.
(f) Remove packing (25), (backup) ring (26), (2) 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
and nut (27) from fitting (28). Discard packing (25) and solenoid valve (79, figure 7-43).
(backup) ring (26).
(3) Provide a suitable container for catching
(g) Remove fitting (28) from tee (5) and fluid seepage when disconnecting hose assemblies
discard packing (29). (56 and 73) and tube assemblies (78, 87, and 94) from
solenoid valve (79).
b. Remove solenoid valve (42, figure 7-43) for
lateral (SCAS) system. (4) Remove hose assembly (56) from elbow (57)
and install protective dust cover to hose connector.
(1) Remove right access panel (17, figure 2-3).
(5) Remove hose assembly (73) from elbow (72)
(2) 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
and install protective dust cover to hose connector.
solenoid valve (42, figure 7-43).
(6) Remove screw (77), spacer (75), washer
(3) Provide a suitable container to catch fluid
(74) and clamp (76).
seepage when disconnecting tube assemblies from
solenoid valve (42).
(7) Remove tube assembly (78) from elbow (82)
and install protective dust covers to connectors of
(4) Disconnect tube assemblies (34, 37, and
tube assembly.
48) from solenoid valve (42).
(8) Disconnect tube assembly (87) from elbow
(5) Remove two nuts (51), two washers (52),
(88).
two washers (41), two bolts (40) and remove solenoid
valve (42) from bracket (53).
(9) Disconnect tube assembly (94) from fitting
(93).
(6) I n s t a l l p r o t e c t i v e d u s t c o v e r s o n o p e n
connectors of tube assemblies (34, 37, and 48).
(10) Remove two screws (86), two spacers (80),
two washers (81) and remove solenoid valve (79).
(7) Remove components from solenoid valve
(42) as follows:
(11) Install protective dust covers to
connectors of tube assemblies (87 and 94).
(a) Remove fittings (36) from solenoid valve
(42) and discard two packings (35).
(12) Remove components from solenoid valve
(b) Loosen nut (39) and remove elbow (38) (79) as follows:
from solenoid valve (42). Remove packing (54),
(backup) ring (55) and nut (39) from elbow (38) and (a) Loosen nut (71) and remove elbow (72)
discard packing (54) and (backup) ring (55). from solenoid valve (79). Remove packing (69),
7-153
TM 55-1520-236-23
(backup) ring (70) and nut (71) from elbow (72). a. Clean solenoid valves (17, 21 and 37) with
Discard packing (69) and (backup) ring (70). clean cloths dampened with solvent (C112). Use a
soft bristle brush and a piece of soft copper wire may
(b) Loosen nut (83) and remove elbow (82) be required to remove stubborn deposits of dirt/oil
from solenoid valve (79). Remove packing (85), from external surfaces.
(backup) ring (84) and nut (83) from elbow (82).
Discard packing (85) and (backup) ring (84). b. Allow to air dry or blow dry using clean filtered
compressed air.
(c) Remove bushing (67), with tee (61) from
solenoid valve (79).
7-249. ~ INSPECTION - SOLENOID
(d) Remove bushing (67) from fitting (65) and VALVES P/N 209-076-023-1 FSCM 16780
discard packings (66 and 68). P/N 15353 (17, 21 AND 37, FIGURE 7-40).
(e) Remove fitting (93) from tee (61) and a. Inspect electrical connector for bent or broken
discard packing (92). pins and damaged threads.
(f) Loosen nut (64) and remove fitting (65) b. Inspect ports for damaged threads.
from tee (61 ). Remove packing (62), (backup) ring (63)
and nut (64) from fitting (65). Discard packing (62) and c. Inspect external surfaces for nicks, dents and
(backup) ring (63). cracks. No cracks are acceptable.
(g) Loosen nut (89) and remove elbow (88)
from tee (61). Remove packing (91), (backup) ring (90) 7-250. ~ m REPAIR OR REPLACEMENT
and nut (89) from elbow (88). Discard packing (91) and - SOLENOID VALVES P/N 209-076-023-1,
(backup) ring (90). FSCM 16780 P/N 15353 (17, 21 AND 37,
FIGURE 7-40).
(h) Loosen nut (58) and remove elbow (57)
from tee (61). Remove packing (60), (backup) ring (59) a. Replace solenoid valves (17, 21 and 37) that fail
and nut (58) from elbow (57). Discard packing (60) and to meet inspection requirements of paragraph 7-249.
(backup) ring (59),
b. Refer to paragraphs 7-247 and 7-251 for
7-248. q mm CLEANING - SOLENOID removal and installation instructions.
VALVES P/N 209-076-023-1, FSCM 16780
P/N 15353 (17, 21, AND 37, FIGURE 7-40).
7 - 2 5 1 . qm I N S T A L L A T I O N -
SOLENOID VALVES P/N 209-076-023-1,
FSCM 16780 P/N 15353 (17, 21, AND 37,
FIGURE 7-40).
a. Install solenoid valve (16, figure 7-43) for fore
Cleaning solvent is flammable and toxic.
and aft (SCAS) system as follows:
Provide adequate ventilation. Avoid
Prolonged breathing of solvent vapors
(1) R e m o v e p r o t e c t i v e d u s t c o v e r s f r o m
and contact with skin or eyes. Eye
solenoid valve (16) and drain preservative hydraulic
protection is required when using
fluid from solenoid valve. Flush solenoid valve with
compressed air.
clean hydraulic fluid (C61 or C62).
(2) Apply a light film of hydraulic fluid (C61 or
C62) to all packings, threads and tube connectors
prior to assembly of part with the exception of bolts
To prevent damaging internal (17).
components, do not submerge solenoid
valve in solvent. Cap open ports prior to (3) Install two packings (12) on fitting (13) and
cleaning. install fitting into PRESS port of solenoid valve (16).
7-154
TM 55-1520-236-23
(4) Position filter (11), with directional flow (2) Apply a light film of hydraulic fluid (C61 or
arrow pointing toward PRESS port, and install filter to C62) to all packings, threads and tube connectors
fitting (13). prior to assembly of parts with the exception of bolts
(49).
(5) Install packing (10) on fitting (9) and install
fitting on filter (11). (3) Install two packings (43) on fitting (44) and
install fitting into PRESS port of solenoid valve (42).
(6) Install nut (21), backup ring (22), and
packing (23) on elbow (20). Position and install elbow (4) Position filter (45), with directional flow
into CYL port of solenoid valve (16). arrow pointing toward PRESS port and install filter to
fitting (44).
(7) Install packing (29), nut (27), backup ring
(26) and packing (25) on fitting (28). Install fitting to (5) Install packing (46) to fitting (47) and install
tee (5). fitting to filter (45).
(8) Install packing (29) on fitting (33) and install (6) Install packing (35) to fitting (36) and install
fitting to tee (5). fitting to CYL port of solenoid valve (42).
(9) Install packing (32) to fitting (31) and install (7) Install nut (39) backup ring (55), and packing
fitting to tee (5). (54) on elbow (38). Thread elbow into RETURN port of
solenoid, position elbow as shown and tighten nut
(10) Thread fitting (28) into RET port of solenoid (39).
valve (16), position tee (5) as shown and tighten nut
(27).
(8) Remove protective dust covers from tube
(11) Remove protective dust covers from tube assemblies (34, 37, and 48).
assemblies (1, 8, 19, and 30).
(9) Buff mounting pads of solenoid valve to
(12) Buff mounting pads of solenoid valve to ensure good electrical bond. Position solenoid valve
ensure good electrical bond. Position solenoid valve (42) to bracket (53) and install two bolts (40), two
(16) to bracket (24) and install two bolts (6), two washers (41), two washers (52) and two nuts (51).
washers (7), two washers (14), and two nuts (15).
(10) Install tube assemblies (34, 37, and 48) to
(13) Install tube assemblies (1, 8, 19, and 30) solenoid valve (42) and torque tube connectors in
on solenoid valve (16) and torque tube connectors in accordance with torque requirements outlined in
accordance with torque requirements outlined in table 7-4.
table 7-4.
(11) Connect electrical connector to solenoid
(14) Connect electrical connector to solenoid valve (16).
valve (16).
(12) Fill reservoirs to proper level with clean
(15) Fill reservoirs to proper level with clean hydraulic fluid (C61 or C62) (paragraph 7-6).
hydraulic fluid (C61 or C62) (paragraph 7-6).
(13) Perform operational check of lateral cyclic
(16) Perform operational check of fore and aft
(SCAS) actuator and bleed hydraulic system
cyclic (SCAS) actuator and bleed hydraulic system
(paragraph 7-146). Refill reservoirs.
(paragraph 7-146). Refill reservoirs.
b. Install solenoid valve (42, figure 7-43) for c. Install solenoid valve (79, figure 7-43), for anti-
IateraI (SCAS) system. torque (SCAS) system.
(1) R e m o v e p r o t e c t i v e d u s t c o v e r s f r o m (1) R e m o v e p r o t e c t i v e d u s t c o v e r s f r o m
solenoid valve (42) and drain preservative hydraulic solenoid valve (79) and drain preservative hydraulic
fluid from solenoid valve. Flush solenoid valve with fluid from bypass solenoid valve. Flush solenoid valve
clean hydraulic fluid (C61 or C62). with clean hydraulic fluid (C61 or C62).
7-155
TM 55-1520-236-23
(2) Apply a light film of hydraulic fluid (C61 or (15) Install clamp (76), screw (77), spacer (75),
C62) to all packings, threads and tube connectors and washer (74) as shown.
prior to assembly of parts with the exception of bolts
(86). (16) Connect electrical connector to solenoid
valve (79).
(3) Install nut (64), backup ring (63) and two
packings (62 and 66) on fitting (65) and install fitting (17) Using hydraulic fluid dispenser (S1), fill
to bushing (67). reservoirs to proper level with clean hydraulic fluid
(C61 or C62) (paragraph 7-6).
(4) Install packing (68) on bushing (67) and (18) Perform operational check of directional
install bushing into RET port of solenoid valve (79). (SCAS) actuator and bleed hydraulic system
(paragraph 7-146). Refill reservoir.
(5) Install packing (92) on fitting (93) and install
fitting to tee (61).
7-252. q m S E R V O A C T U A T O R
(6) Install nut (58) backup ring (59) and packing
(ELECTROHYDRAULIC) - ARMAMENT
(60) on elbow (57). Thread elbow into tee (61),
WING PYLON.
position elbow as shown, and tighten nut (58).
7-253. ~ DESCRIPTION - SERVO
(7) Install nut (89) backup ring (90), and packing
ACTUATOR (ELECTROHYDRAULIC) -
(91) on elbow (88). Thread elbow into tee (61),
ARMAMENT WING PYLON.
position elbow as shown, and tighten nut (89).
The armament wing pylon (electro-hydraulic) servo
(8) Thread fitting (65) into tee (61), position tee
actuator on ~ and g coded helicopters are
as shown, and tighten nut (64).
similar to armament wing pylon (Electrohydraulic)
servo actuators used on ~ coded helicopters
(9) Install nut (71), backup ring (70), and
(paragraph 7-127).
packing (69) on elbow (72). Thread elbow into CYL
port of solenoid valve (79), position elbow as shown,
and tighten nut (71).
7-254. ~ ~ REMOVAL - SERVO
ACTUATOR (ELECTROHYDRAULIC) -
ARMAMENT WING PYLON.
(10) Install nut (83) backup ring (84), and
packing (85) on elbow (82). Thread elbow into PRESS Remove the armament wing pylon (electrohydraulic)
port of solenoid valve (79), position elbow as shown, servo actuator using same procedures outlined for
and tighten nut (83). q coded helicopters (paragraph 7-128).
(11) Remove protective dust covers from tube
assemblies (78, 87, and 94). 7-255. q ~ DISASSEMBLY - SERVO
ACTUATOR (ELECTROHYDRAULIC) -
(12) Buff mounting pads to solenoid valve to ARMAMENT WING PYLON. (AVIM)
ensure good electrical bond. Position solenoid valve
(79) on bracket and install two screws (86), two Disassemble the armament wing pylon
spacers (80) and two washers (81), as shown. (electrohydraulic) servo actuator using the same
procedures outlined for ~ c o d e d h e l i c o p t e r s
(13) Install tube assemblies (78, 87, and 94) on (paragraph 7-129).
solenoid valve (79). Refer to table 7-4 for torque
requirements of tube connectors. 7 - 2 5 6 . ~ C L E A N I N G - S E R V O
ACTUATOR (ELECTROHYDRAULIC) -
(14) Remove protective dust covers from hose ARMAMENT WING PYLON.
assemblies (56 and 73) and install hose assemblies
on elbows (57 and 72). Torque hose connectors in Clean the armament wing pylon (Electrohydraulic)
accordance with torque requirements outlined in servo actuator using the same procedures outlined
table 7-4. for q coded helicopters (paragraph 7-130).
7-156
TM 55-1520-236-23
7 - 2 5 7 . ~ I N S P E C T I O N - S E R V O The armament wing pylon (Electrohydraulic) servo
ACTUATOR (ELECTROHYDRAULIC) - actuator backlash test is similar to that performed
ARMAMENT WING PYLON. on ~ coded helicopters (paragraph 7-137).
Inspect the armament wing pylon (Electrohydraulic)
7-264. q ~ PROOF PRESSURE TEST -
servo actuator using the same procedures outlined
SERVO ACTUATOR (ELECTRO-
for ~ coded helicopters (paragraph 7-131).
HYDRAULIC) - ARMAMENT WING PYLON.
(AVIM)
7-258. q m REPAIR OR REPLACEMENT
- SERVO ACTUATOR The armament wing pylon (Electrohydraulic) servo
(ELECTROHYDRAULIC) - ARMAMENT actuator proof pressure test is similar to that
WING PYLON. (AVIM) performed on ~ coded helicopters (paragraph 7-
Repair or replace the armament wing pylon (Electro- 138).
hydraulic) servo actuator using the same procedures
outlined for ~ coded helicopters (paragraph 7- 7-265. ~ LEAKAGE TESTS - SERVO
132). ACTUATOR (ELECTROHYDRAULIC) -
ARMAMENT WING PYLON. (AVIM)
7 - 2 5 9 . g~ A S S E M B L Y - S E R V O
ACTUATOR (ELECTROHYDRAULIC) - The armament wing pylon (Electrohydraulic) servo
ARMAMENT WING PYLON. (AVIM) actuator leakage tests are similar to those used
on ~ coded helicopters (paragraph 7-139).
Assemble the armament wing pylon (Electro-
hydraulic) servo actuator using the same procedures 7-266. q ~ I N T E R N A L LEAKAGE
outlined for ~ coded helicopters (paragraph 7- T E S T S - SERVO ACTUATOR
133). (ELECTROHYDRAULIC) - ARMAMENT
WING PYLON. (AVIM)
7 - 2 6 0 . ~ F U N C T I O N A L T E S T -
SERVO ACTUATOR (ELECTROHYDRAULIC) The armament wing pylon (Electrohydraulic) servo
- ARMAMENT WING PYLON, actuator internal leakage tests are similar to those
performed on ~ coded helicopters (paragraph 7-
The armament wing pylon (Electrohydraulic) servo
140).
actuator functional test is similar to that performed
on ~ coded helicopters (paragraph 7-134).
7 - 2 6 7 . q mm S E R V O VALVE
7-261. ~ ~ LOCK PRESSURE TEST - FREQUENCY RESPONSE - SERVO
SERVO ACTUATOR (ELECTROHYDRAULIC) ACTUATOR (ELECTROHYDRAULIC) -
- ARMAMENT WING PYLON. ARMAMENT WING PYLON. (AVIM)
The armament wing pylon (Electro-hydraulic) servo
The armament wing pylon (Electrohydraulic) servo
actuator lock pressure test is similar to that
performed on ~ coded helicopters (paragraph 7- valve frequency response test is similar to that
performed on ~ coded helicopters (paragraph 7-
135).
141).
7-262. q ~ UNLOCK PRESSURE TEST
- SERVO ACTUATOR 7-268. q ~ INSTALLATION - SERVO
( E L E C T R O H Y D R A L I C ) - ARMAMENT ACTUATOR (ELECTROHYDRAULIC) -
WING PYLON. ARMAMENT WING PYLON.
The armament wing pylon (Electrohydraulic) servo Install the armament wing pylon (Electrohydraulic)
actuator unlock pressure test is similar to that servo actuator using the same procedures outlined
performed on ~ coded helicopters (paragraph 7- for q coded helicopters (paragraph 7-142).
136).
7-269. q ~ H Y D R A U L I C LINE
7-263. BACKLASH TEST - SERVO FABRICATION. (AVIM)
ACTUATOR (ELECTROHYDRAULIC) -
ARMAMENT WING PYLON. (AVIM) Refer to Appendix D.
7-157/(7-158 blank)
TM 55-1520-236-23
CHAPTER 8
INSTRUMENT SYSTEMS
SECTION I. INSTRUMENT MAINTENANCE
8-1. INSTRUMENT MAINTENANCE. instrument panel by the following general
procedures.
8-2. DESCRIPTION - INSTRUMENT
MAINTENANCE.
NOTE
~The f o l l o w i n g g e n e r a l i n s t r u m e n t
maintenance procedures are applicable to all
Removal of turbine gas temperature
instruments mounted in either the pilot or gunner
(TGT) and tachometer in the gunner
instrument panel (figure 8-1 ).~ Refer to Appendix
cockpit will require removal of gunner
F for equipment location chart.
sight hand control.
8-3. C L E A N I N G - INSTRUMENT a. Ensure all electrical power is OFF.
MAINTENANCE.
a. Clean panel and instrument cover glasses with b. Disconnect electrical leads and/or instrument
a suitable soft, lint-free cloth. piping from back of panel. Necessary access may be
made through side panels to pilot instrument panel,
and at back of gunner instrument panel.
b. ~ Clean head-up display (HUD) combiner
glasses with a soft, lint-free cloth.
c. Protect ends of electrical leads with electrical
tape (C121). Cap open piping and openings on
8-4. INSPECTION - INSTRUMENT instrument.
MAINTENANCE.
d. Remove mounting screws, or loosen mounting
a. Inspect for loose, cracked, or broken cover clamp screw. Remove instrument.
glasses.
8-6. REPAIR OR REPLACEMENT -
b. ~ Inspect HUD combiner glasses in INTRUMENT MAINTENANCE.
accordance with TM 9-1270-220-13.
a. Replace any required panel decals which are
c. Inspect for proper and secure mounting.
not clearly legible.
d. I n s p e c t r a n g e m a r k i n g s a n d d e c a l s f o r
completeness and legibility in accordance with TM b. Replace any instrument if cover glass is loose,
55-1520-236-10. c r a c k e d o r b r o k e n , or when found to be
unserviceable.
e. Inspect for proper operation.
8-7. INSTALLATION - INSTRUMENT
MAINTENANCE.
8-5. R E M O V A L - INSTRUMENT
MAINTENANCE.
Install any instrument in pilot or gunner instrument
Remove any instrument from pilot or gunner panel by the following general procedures.
8-1
TM 55-1520-236-23
Figure 8-1. Instrument Systems Equipment Location (Sheet 1 of 5)
8-2
TM 55-1520-236-23
Figure 8-1. ~~lnstrument Systems Equipment Location (Sheet 2 of 5)
8-3
TM 55-1520-236-23
Figure 8-1. ~~lnstrument Systems Equipment Location (Sheet 3 of 5)
8-4
TM 55-1520-236-23
Figure 8-1. ~ ~lnstrurnent Systems Equipment Location (Sheet 4 of 5)
Change 16 8-5
TM 55-1520-236-23
Figure 8-1. ~ Instrument Systems Equipment Location (Sheet 5 of 5)
8-6
TM 55-1520-236-23
piping. Use silicone compound (C110) on threads of
nylon fittings.
Do not tighten damps more than neces- c. Torque coupling nuts fingertight.
sary to hold Instrument as excessive
tension may deform Instrument case,
d. Check operation of instrument.
causing erroneous reading.
NOTE 8-8. INSTRUMENT PREMAINTENANCE
REQUIREMENTS.
An adapter cable Is required to match
aircraft connector when replacing the
lD-2.501/A RMI with the ID-250/A. Refer 8-9. DESCRIPTION INSTRUMENT
to Appendix D, Figure D-373. PREMAINTENANCE REQUIREMENTS.
a. Position instrument in panel. Install mounting Throughout this chapter, unless otherwise specified,
screws, or tighten screw of mounting damp. instrument maintenance, testing and troubleshooting
procedures will utilize only tools and equipment con-
tained in electrical equipment toolkit (T20); multimeter
(T2); turbine temperature indicating system test set,
(T68); field calibration unit (T79); and resistance
When connecting electrical plugs to bridge (T62 or T63), or equivalent.
dual tachometer Indicator, ensure that
plugs are connected to correct recap
NOTE
tacle.
b. Remove protective cape or covers, as neces- Multimeter (T3) is an acceptable substi-
sary. Connect electrical leads and/or instrument tute for resistance bridge (T62 or T63).
SECTION Il. ENGINE INSTRUMENTS
8-10. ENGINE INSTRUMENTS. one system; and pilot gas producer tachometer,
gunner gas producer tachometer, and gas producer
8-11. DESCRIPTION ENGINE INSTRU- tachometer generator as the other system.
MENTS.
8-14. TROUBLESHOOTING TACHO-
Engine instruments include the pilot and gunner METER INDICATING SYSTEMS.
torquemeter, pilot and gunner dual tachometer, pilot
and gunner turbine gas temperature indicator, pilot a. Use table 8-1 and perform neces-
engine oil temperature and pressure indoor, and sary checks to isolate trouble. Refer to figure 8-1 for
pilot and gunner gas producer tachometer. equipment location and paragraph F-9 in Appendix F
for wiring diagram. Broken or shorted wiring is always
8-12. TACHOMETER INDICATING a probable cause of malfunction or failure and has not
SYSTEMS. been included.
8-13. DESCRIPTION TACHOMETER b. Use table 8-1 and perform necessary
INDICATING SYSTEMS. checks to isolate trouble. Refer to paragraph F-9 in
Appendix F for wiring diagram and equipment location
The tachometer indicating systems are pilot dual chart. Broken or shorted wiring is always a probable
tachometer, gunner dual tachometer, rotor tachometer cause of malfunction or failure and has not been
generator, and power turbine tachometer generator as included.
Change 22 8-7
TM 55-1620-236-23
NOTE
Before you use this table, be sure you
have performed all normal operational
checks. If you have a malfunction which
is not listed in this table, notify the next
higher level of maintenance.
Table 8-1 Troubleshooting Tachometer Indicating Systems
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
Dual Tachometer
1. Tachometer has excessive scale error.
STEP 1. Determine if indicator is defective by substituting a known good indicator.
Replace indicator if defective (paragraph 8-1).
2. One of the pointers on pilot or gunner dual tachometer fails to respond.
STEP 1. Check for defective tach generator by substitution of known good tach generator.
Replace tach generator if defective (paragraph 8-23 or 8-31).
STEP 2. Check for defective tachometer by substitution of known good tachometer.
Replace tachometer if defective (paragraph 8-1).
STEP 3. Check for poor connection at indicator or generator.
Clean or tighten connections.
3. High or low reading on indicator, either constant or intermittent.
STEP 1. Determine if indicator is out of adjustment using procedure contained in paragraph 8-19,
Functional Test.
Replace indicator if defective (paragraph 8-1).
4. Any pointer on either the pilot or gunner tachometer indicates backwards.
STEP 1. Check if wires are reversed at pins of tach generator plugs.
Remove plug and reverse wires.
8-8
TM 55-1520-236-23
Table 8-1. Troubleshooting Tachometer Indicating Systems (Cont)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
Gas Producer Tachometer
1. Gas producer tachometer fails to respond.
STEP 1. Determine if tach generator is defective by substitution of known good tach generator.
Replace tach generator if defective (paragraph 8-47).
STEP 2. Determine if tachometer is defective by substitution of known good tachometer.
Replace tachometer if defective (paragraph 8-39).
2. Gas producer tachometer indicates incorrectly.
STEP 1. Determine if tach generator is defective by substitution of known good tach generator.
Replace tach generator if defective (paragraph 8-47).
STEP 2. Determine if tachometer is defective by substitution of known good tachometer.
Replace tachometer if defective (paragraph 8-39).
3. Gas producer tachometer indicates backwards.
STEP 1. Check if wires are reversed at pins of tach generator plug.
Remove plug and reverse wires.
8-15. DUAL TACHOMETERS. and rotor speeds are synchronized in normal
operation.
8-16. DESCRIPTION - DUAL
TACHOMETERS. 8-17. C L E A N I N G - DUAL
TACHOMETERS.
The pilot and gunner dual tachometers, each located
on respective instrument panel, indicate percentage Clean dual tachometers in accordance with
of rpm of both main rotor and engine output shaft. paragraph 8-3.
Each tachometer has a synchronous motor
connected electrically to a separate tachometer
generator. The system is energized from the 28 Vdc 8-18. INSPECTION - DUAL
essential bus when DUAL TACH circuit breaker TACHOMETERS.
(1CB20) is closed. The rotor pointer indicates on inner
scale of instrument and engine pointer indicates on Inspect dual tachometers in accordance with
outer scale. The pointers will be aligned when engine paragraph 8-4.
8-9
TM 55-1520-236-23
8-19. FUNCTIONAL TEST - DUAL stand and set controls according to instructions on cover
TACHOMETERS. of tester.
a. Disconnect plug (1G1P1) from rotor tachometer b. Check that rotor tachometer portion of indicator
generator. Connect plug to the MASTER GENERATOR indicates within tolerance of various check points in
output plug on tachometer test set (T21). Energize test following chart:
INDICATOR ROTOR POWER TURBINE TACHOMETER RPM**
PERCENT OF RPM RPM* MINIMUM MAXIMUM
20 65 796 860.112-925
30 97 1226 1355
40 130 1656 1785
50 162 2086 2215
60 194 2559 2602
70 227 2989 3032
80 259 3419 3462
90 292 3849 3892
100 324 4279 4300.56-322
110 356 4709 4752
*FOR REFERENCE ONLY
**USE RX1 RANGE
c. Disconnect plug (1G1P1) from test set (T21) and set controls according to test set instructions on rover
reconnect it to the rotor tachometer generator. Check of the test set.
that connector is properly mated and secure.
e. Check that the engine portion of indicator
d. Disconnect plug from power turbine tachometer indicates within tolerance of various check points in
generator. Connect plug to MASTER GENERATOR following chart:
output plug on test set (T21). Energize test stand and
INDICATOR ENGINE (N2) POWER TURBINE TACHOMETER RPM**
PERCENT OF RPM RPM* MINIMUM MAXIMUM
20 1321 780 906
30 1981 1202 1328
40 2642 1623 1749
50 3302 2044 2107.38-2171
60 3962 2508 2550
70 4623 2929 2971
80 5283 3351 3393
90 5944 3772 3814
100 6604 4194 4214.76-4236
110 7264 4615 4857
*FOR REFERENCE ONLY
* *USE RX1 RANGE
8-10 Change 18
TM 55-1520-236-23
f. Disconnect plug from test stand and reconnect 8-26. INSPECTION - POWER TURBINE
it to the power turbine tachometer generator. Check TACHOMETER GENERATOR.
that connector is properly mated and secure.
a. Inspect tachometer generator case for cracks,
8-20. R E M O V A L - DUAL excessive wear, or any visible damage.
TACHOMETERS.
b. Check connector for damaged or bent pins and
Remove dual tachometers in accordance with cracked inserts.
paragraph 8-5.
c. After removal, check that rotor turns freely and
8-21. REPAIR - DUAL TACHOMETERS. there is no visible indication of excessive wear to
bearings.
Repair dual tachometers in accordance with
paragraph 8-6. 8-27. REMOVAL - POWER TURBINE
TACHOMETER GENERATOR.
8-22. INSTALLATION - DUAL
TACHOMETERS. a. Open cowling on left side of engine.
Install dual tachometers in accordance with b. D i s c o n n e c t e l e c t r i c a l r e c e p t a c l e , r e m o v e
paragraph 8-7. mounting nuts and washers and lift tachometer
generator from engine.
8-23. POWER TURBINE
TACHOMETER GENERATOR. 8-28. REPAIR - POWER TURBINE
TACHOMETER GENERATOR.
8-24. DESCRIPTION - POWER TURBINE
TACHOMETER GENERATOR. a. Replace tachometer generator if case is
cracked or damaged.
The power turbine tachometer generator is mounted
on the governor and tachometer drive gearbox on left b. Replace tachometer generator if rotor does not
upper side of engine, and is connected to the dual turn freely or for visible indication of excessive wear
tachometer indicators on the instrument panels. to bearings.
l HRefer to figure 8-1 for equipment location.
Refer to paragraph F-9 in Appendix F for NOTE
8
equipment location chart.
Replacement of power turbine
8-25. CLEANING - P O W E R T U R B I N E tachometer generator will require testing
TACHOMETER GENERATOR. the rpm limit warning system (paragraph
9-287).
a. Remove moisture and loose dirt with a clean,
soft cloth. c. Repair damaged connectors.
8-29. FUNCTIONAL TEST - POWER
TURBINE TACHOMETER GENERATOR -
BENCH (AVIM).
Cleaning solvent is flammable and toxic.
Provide adequate ventilation. Avoid a. R e m o v e t a c h o m e t e r g e n e r a t o r f r o m
prolonged breathing of solvent vapors helicopter and mount on tachometer test set
and contact with skin or eyes. (T67.1). Connect generator t o t h e T E S T
GENERATOR INPUT. Operate testor according
b. Remove grease, fungus, and ground-in dirt to instructions on cover and check voltage out-
with a clean, lint-free cloth dampened with dry puts of the tachometer generator. With a 40 ohm
cleaning solvent (C112). Y connected resistance and a shaft speed of
4200 rpm, check voltage output across each
c. Remove dirt from electrical connectors with a phase of the generator (A-B, A-C and B-C). The
bristle brush. three voltage outputs should be 21.+ 0.5 Vac.
Change 10 8.11
TM 55-1520-236-23
b. Decrease generator speed to 1000 rpm with a 8-34. NSPECTION - ROTOR TACHOMETER
20 ohm Y connected resistance. GENERATOR.
c. Check volage output of the three phases. Inspect rotor tachometer generator in accordance with
Voltage should not go below 3.5 Vac. paragraph 8-26.
d. Disconnect tachometer generator and remove
from test set (T21). 8-35. REMOVAL - ROTOR TACHOMETER GEN-
ERATOR.
e. Measure resistance of each phase (A-B, A-C,
and B-C). At 25 degrees C (77 degrees F), the resis- a. Open cowling on left side of transmission.
tance should be between 15 AND 20 ohms. Each
phase should be within one ohm of each other. b. Disconnect electrical receptacle, remove
mounting nuts and washers, and lift rotor tachometer
f. At completion of testing, install tachometer gen- generator from helicopter.
erator and connect electrical plug and check for prop-
er mating and security.
8-36. REPAIR - ROTOR TACHOMETER GEN-
8-30. INSTALLATION - POWER TURBINE ERATOR.
TACHOMETER GENERATOR.
a. Replace tachometer generator if case is
a. Position tachometer generator and gasket on cracked or damaged.
studs and install mounting hardware.
b. Replace tachometer generator if rotor does not
b. Connect electrical receptacle and install cowl- turn freely or for visible indication of wear to bearings.
ing.
NOTE
NOTE
Replacement of rotor tachometer gener-
Coat tachometer generator shaft and ator will require testing the rpm limits
pack mating splines of shaft in accesso- warning system (paragraph 9-287).
ry drive gearbox 2/3 full with lubricant
(C85).
8-37. FUNCTIONAL TEST - ROTOR TACHOME-
8-31. ROTOR TACHOMETER GENERATOR. TER GENERATOR - BENCH (AVIM).
8-32. DESCRIPTION - ROTOR TACHOME- Bench test rotor tachometer generator in accordance
TER GENERATOR. with paragraph 8-29.
The rotor tachometer generator is located on lower left
side of the transmission. The generator is mounted on 8-38. INSTALLATION - ROTOR TACHOME-
hydraulic pump and tachometer drive quill assembly TER GENERATOR.
and is connected to the dual tachometer indicators on
the instrument panels. ~ H Refer to figure 8-1 for a. Apply a thin film of antiseize compound (C21) to
equipment location. ~ Refer to paragraph F-9 in tachometer generator splines and to mating splines in
Appendix F for equipment location chart. transmission.
8-33. CLEANING - ROTOR TACHOMETER b. Install rotor tachometer generator with electrical
GENERATOR. connector 180 degrees down. Secure with nuts and
washers on four studs. Connect and lockwire (C137)
Clean rotor tachometer generator in accordance with electrical cable connector.
paragraph 8-25.
8-12 Change 19
TM 55-1520-236-23
8-39. GAS PRODUCER TACHOMETERS. TEST POINTS INDICATOR TOLERANCE
8-40. D E S C R I P T I O N G A S P R O D U C E R
10% 5% 1.5%
TACHOMETERS.
20% 20% 1 .5%
70% 70% 0.5%
The pilot and gunner gas producer tachometers are
100% 100% 0.5%
located on their respective instrument panels. They
provide indication in percent rpm of the engine gas
producer (compressor) by connection to a common
synchronous generator, mounted on engine accessory 8-46. INSTALLATION GAS PRODUCER
drive section. The indicator and generator circuit TACHOMETER.
requires 28 Vdc power from the essential bus.
Install gas producer tachometer in accordance with
8-41. C L E A N I N G GAS PRODUCER paragraph 8-7.
TACHOMETERS.
8-47. GAS PRODUCER TACHOMETER
Clean gas producer tachometers in accordance with GENERATOR.
paragraph 8-3.
8-48. DESCRIPTION GAS P R O D U C E R
8-42. INSPECTION GAS PRODUCER TACHOMETER GENERATOR.
TACHOMETERS.
The gas producer tachometer generator, located on
Inspect gas producer tachometers in accordance with right side of engine on the accessory gearbox, monitors
paragraph 8-4. rpm of the gas producer turbine and transmits voltage
signals to drive the gas producer tachometer indicators.
8-43. R E M O V A L GAS PRODUCER
Refer to figure 8-1 for equipment location.
TACHOMETERS. Refer to paragraph F-9 in Appendix F for equipment
location chart.
Remove gas producer tachometers in accordance with
8-49. CLEANING GAS PRODUCER
paragraph 8-5.
TACHOMETER GENERATOR.
8-44. REPAIR GAS PRODUCER
Clean gas producer tachometer generator in
TACHOMETERS.
accordance with paragraph 8-25.
Repair gas producer tachometers in accordance with
8-50. I N S P E C T I O N G A S PRODUCER
paragraph 8-6.
TACHOMETER GENERATOR.
8-45. FUNCTIONAL TEST GAS PRODUCER
Inspect gas producer tachometer generator in
TACHOMETERS BENCH (AVIM).
accordance with paragraph 8-26.
a. Disconnect plug from gas producer tachometer
8-51. R E M O V A L GAS PRODUCER
generator. Connect plug to MASTER GENERATOR
output plug on test set (T67.1). Energize test stand and TACHOMETER GENERATOR.
set controls according to instructions on the cover of test
Remove gas producer tachometer generator in
set.
accordance with paragraph 8-27.
b. Check that the gas producer tachometer
indicator indicates within tolerance of various check 8-52. REPAIR GAS PRODUCER TACHOMETER
points in following chart: GENERATOR.
c. Disconnect plug from test set (T21) and Repair gas producer tachometer generator in
reconnect it to gas producer tachometer generator. accordance with paragraph 8-28.
Check that connector is properly mated and secure.
Change 18 8-13
TM 55-1520-236-23
8-53. FUNCTIONAL TEST - GAS PRODUC- The engine oil temperature and pressure indicating
ER TACHOMETER GENERATOR - BENCH system includes the pilot engine oil temperature and
(AVIM). pressure indicator, engine oil pressure transducer,
and engine oil temperature bulb. The system is pow-
Bench test gas producer tachometer generator in ered from the 28 Vdc bus, and is protected by a 5
accordance with paragraph 8-29. ampere TEMP IND ENG XMSN circuit breaker.
8-54. INSTALLATION - GAS PRODUCER 8-57. TROUBLESHOOTING - ENGINE AND
TACHOMETER GENERATOR. TRANSMISSION OIL TEMPERATURE AND
PRESSURE INDICATING SYSTEM.
a. Install gas producer tachometer generator in
accordance with paragraph 8-30. a. ~ ~ Use table 8-2 and perform necessary
checks to isolate trouble. Refer to figure 8-1 for equip-
b. Perform N1 system accuracy check in accor- ment location and paragraph F-9 in Appendix F for
dance with TM 55-4920-401-13& P. wiring diagram. Broken or shorted wiring is always a
probable cause of malfunction or failure and has not
8-55. ENGINE OIL TEMPERATURE AND been included.
PRESSURE INDICATING SYSTEM.
b. D Use table 8-2 and perform necessary
8-56. DESCRIPTION - ENGINE OIL TEM- checks to isolate trouble. Refer to paragraph F-9 in
PERATURE AND PRESSURE INDICATING Appendix F for wiring diagram and equipment loca-
SYSTEM. tion chart. Broken or shorted wiring is always a prob-
able cause of malfunction or failure and has not been
included.
NOTE
Before you use this table, be sure you have
performed all operational checks. If you have
a malfunction which is not listed in this table,
notify the next higher level of maintenance.
Table 8-2. Troubleshooting Engine and Transmission Oil Temperature
And Pressure Indicating System
CONDITION
TEST OR INSPECTION
CORRECTION ACTION
1. Low pressure indication on indicator.
STEP 1. Check for kinked or obstructed pressure line.
Replace or clean pressure line.
2. Indicator has inaccurate or sticking pressure indication.
STEP 1. Check for defective indicator by substitution of a known good indicator.
Replace indicator if defective (paragraph 8-1).
8-14 Change 19
TM 55-1520-236-23
Table 8-2. Troubleshooting Engine and Transmission Oil Temperature
And Pressure Indicating System (Cont)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
3. Indicator has sluggish pressure indication.
STEP 1. Check for sludge in pressure line using procedures contained in paragraph 8-62, functional test.
Bleed pressure line.
4. Indicator has fluctuating pressure indication.
STEP 1. Check for loose electrical connection, or instrument clamped too tight.
Check connections and/or readjust clamp.
STEP 2. Incorrect restrictor installed in system.
Install correct restrictor (0.018 to 0.020 inch opening).
STEP 3. Check for blocked or clogged restrictor.
Clean restrictor opening.
5. Indicator has no pressure indication.
STEP 1. Check for defective transducer by substitution of known good transducer or perform functional test
in accordance with paragraph 8-62.
Replace transducer if defective (paragraph 8-67).
STEP 2. Check for defective indicator by substitution of known good indicator or refer to paragraph 8-62 for
functional test.
Replace indicator if defective (paragraph 8-1).
6. Oil temperature indication off scale at low end, or low reading - either constant or intermittent.
STEP 1. Check for defective indicator by substitution of known good indicator or refer to paragraph 8-62 for
functional test.
Replace indicator if defective (paragraph 8-1).
STEP 2. Short circuit in leads from thermobulb to indicator.
Make continuity check and repair or replace leads.
8-15
TM 55-1520-236-23
Table 8-2. Troubleshooting Engine and Transmission Oil Temperature
And Pressure Indicating System (Cont)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
7. Oil temperature indication off scale at high end, or high reading - either constant or intermittent.
STEP 1. Check for open circuit in thermobulb.
Check continuity and repair wiring, or replace defective bulb.
STEP 2. Check for defective indicator by substitution of known good indicator or perform functional test in
accordance with paragraph 8-62.
Check continuity and repair wiring, or replace defective bulb (paragraph 8-75).
8. No indication of pressure or temperature on indicator.
STEP 1. Check for defective circuit breaker by use of multimeter or substitution of known good circuit
breaker.
Replace circuit breaker if defective (paragraph 9-23).
STEP 2. Check for defective indicator by substitution of known good indicator or perform functional test in
accordance with paragraph 8-62.
Replace indicator if defective (paragraph 8-1).
8-58. ENGINE OIL TEMPERATURE 8 - 6 1 . INSPECTION - E N G I N E O I L
AND PRESSURE INDICATOR. TEMPERATURE AND PRESSURE
INDICATOR.
8-59. DESCRIPTION - E N G I N E O I L
TEMPERATURE AND PRESSURE Inspect engine oil temperature and pressure indicator
INDICATOR. in accordance with paragraph 8-4.
The engine oil temperature and pressure indicator is 8-62. FUNCTIONAL TEST - ENGINE OIL
located in the pilot instrument panel and indicates TEMPERATURE AND PRESSURE
engine oil pressure in psi by means of the engine oil INDICATOR. (ON HELICOPTER).
pressure transducer. It also indicates engine oil
temperature in degrees celsius by means of an a. Perform functional test for oil pressure portion
electrical resistance type thermobulb. of indicator as follows:
8-60. CLEANING - ENGINE OIL (1) Disconnect pressure line from the engine
TEMPERATURE AND PRESSURE oil pressure transducer.
INDICATOR.
(2) Connect variable pressure (0-150 psi) tester
Clean engine oil temperature and pressure indicator (T12) or equivalent to input line on engine oil pressure
in accordance with paragraph 8-3. transducer.
8-16
TM 55-1520-236-23
(3) Close TEMP IND ENG XMSN circuit breaker. d. Set temperature selector switch (2) to
Place BAT switch to ON. Place BATTERY temperature points on the left inner scale (90.38
switch to START. ohms at zero degrees celsius temperature).
(4) Apply pressure to transducer input port e. Rotate switch (2) to required test points. Tap
while monitoring engine oil pressure indicator. indicator before taking a reading. The test points and
tolerances are listed in following chart:
(5) Various pressure and tolerances are listed
in the following chart:
INDICATOR INDICATOR
APPLIED INDICATOR TEST POINTS READING TOLERANCE
PRESSURE INDICATOR TOLERANCE
b. Perform functional test for oil temperature
portion of indicator as follows:
f. Turn switch (7) to the OFF" position and
disconnect indicator from tester. Install indicator in
(1) Close TEMP IND ENG XMSN circuit breaker.
instrument panel and check for security.
Place BAT switch to ON. Place Battery
switch to START.
8-64. REMOVAL ENGINE OIL
(2) Check that temperature indicators indicate TEMPERATURE AND PRESSURE
approximately ambient temperature. INDICATOR.
Remove engine oil temperature and pressure
8-63. FUNCTIONAL TEST ENGINE OIL indicator in accordance with paragraph 8-5.
TEMPERATURE AND PRESSURE
INDICATOR BENCH (AVIM).
8-65. REPAIR E N G I N E O I L
TEMPERATURE AND PRESSURE
Bench test for the temperature portion is as follows:
INDICATOR.
a. Disconnect electrical plug in back of oil
Repair engine oil temperature and pressure indicator
temperature indicator. Remove indicator from
in accordance with paragraph 8-6.
instrument panel. Connect indicator to electric
thermometer tester (T78), or equivalent, using the
appropriate adapter cable provided with the tester. 8-66. INSTALLATION ENGINE OIL
TEMPERATURE AND PRESSURE
INDICATOR.
Install engine oil temperature and pressure indicator
in accordance with paragraph 8-7.
Always ensure that the indicator is
connected before turning switch (7) to 8-67. ENGINE OIL PRESSURE
the 24 volt position. TRANSDUCER.
b. Check zero setting of voltmeter (1) and adjust if 8-68. DESCRIPTION ENGINE OIL
necessary. Turn switch (7) to the 24 volt position. PRESSURE TRANSDUCER.
c. Adjust pointer of voltmeter (1) to coincide with The engine oil pressure transducer located on top of
red line of 28.50 volts by operating rheostat (5). engine inlet section, monitors engine oil pressure and
Position switch (8) to the left and single position. transmits voltage signals to engine oil pressure
8-17
TM 55-1520-236-23
indicator. Refer to figure 8-1 for equipment Pin A to Pin B 875 to 2400 ohms
location. Refer to paragraph F-9 in Appendix F for Pin A to Pin C 875 to 2400 ohms
equipment location chart. Pin A to Pin D 1250 to 3050 ohms
Pin B to Pin C 300 to 1000 ohms
Pin B to Pin D 525 to 1400 ohms
8 - 6 9 . C L E A N I N G ENGINE OIL PRESSURE
Pin C to Pin D 525 to 1500 ohms
TRANSDUCER.
8 - 7 2 . R E M O V A L ENGINE OIL PRESSURE
Remove moisture and loose dirt with a dean, soft TRANSDUCER.
cloth.
a. Open engine cowling.
b. Disconnect electrical connector. Disconnect oil
line.
Cleaning advent is flammable and toxic c. Cap openings of oil line and protect electrical
Provide adequate ventialtion. Avoid pro connector with cap or tape.
longed breathing of advent vapors and
contact with skin or eyes. d Remove Iockwire mounting nut and packing. Re-
move transducer from helicopter.
b. Remove oil, grease, fungus, and ground-in dirt 8 - 7 3 . R E P A I R ENGINE OIL PRESSURE
with a dean, Iint-free cloth dampened with dry cleaning TRANSDUCER.
solvent (C112).
a. Repair damaged electrical connectors.
Remove dirt from electrical connectors with a
bristle brush. b. Tighten loose oil line or fitting connection.
c. Replace defective or damaged oil tine or fitting.
8-70. INSPECTION ENGINE OIL
PRESSURE TRANSDUCER. d. Replace pressure transducer if cracked or dam-
aged.
a. Inspect pressure transducer for crack, secure Reinstall improperly mounted pressure trans-
and proper mounting, and proper operation. ducer.
b. Inspect oil tine and fitting connection for leaks 8-74. INSTALLATION ENGINE OIL
and proper installation. PRESSURE TRANSDUCER.
Inspect electrical connector for damaged or bent Position transducer on bracket. Install damp and
pin and cracked inserts. grommet.
b. Remove protective covers and connect the oil
8 - 7 1 . FUNCTIONAL TEST ENGINE OIL line to transducer. Install electrical connectors.
PRESSURE TRANSDUCER.
c. Install cowling.
The pressure transducer is functionally tested during 8-75. ENGINE OIL TEMPERATURE BULB.
testing of the indicator using variable pressure tester
(paragraph 8-62). The following electrical resistance 8-76. DESCRIPTION ENGINE OIL
check may be conducted on pressure transducer TEMPERATURE BULB.
independently from indicator.
The engine oil temperature bulb, installed in the engine oil
a. Using multimeter (T2), or equivalent, check re- pump housing is a resistance type thermobulb which
sistance between contacts of electrical receptacle on top monitors engine oil temperature and transmits varying
of transducer. voltage signals to engine oil temperautre of indi-
cator. Refer to figure 8-1 for equipment loca-
b. Resistance readings across the four-pin connec- tions. Refer to paragraph F-9 in Appendix F for
tor should be as follows: equipment locations chart.
8-18 Change 22
TM 55-1520-236-23
8-77. CLEANING - ENGINE OIL (1) Remove oil temperature bulb to be checked
TEMPERATURE BULB. and allow sufficient time to adjust to ambient
temperature.
a. Remove moisture and loose dirt with a clean,
(2) W i t h r e s i s t a n c e b r i d g e ( T 6 2 ) o r ( T 6 3 )
soft cloth.
measure resistance of temperature bulb between pin
A and B. Ambient temperature test points and
tolerances are listed in following chart:
Cleaning solvent is flammable and toxic. AMBIENT
Provide adequate ventilation. Avoid TEMPERATURE
prolonged breathing of solvent vapors TEST POINT RESISTANCE TOLERANCE
and contact with skin or eyes. DEGREES (OHMS) (OHMS)
b. Remove oil, grease, fungus and ground-in dirt -20 Celsius (-4F) 83.77 ko.4
with a clean, lint-free cloth dampened with dry -10 Celsius (14F) 87.04 *(3.4
cleaning solvent (C112). 0 Celsius (32F) 90.38 *0.4
+100 Celsius (50F) 93.80 50.4
c. Remove dirt from electrical connectors with a +20 Celsius (68 F) 97.80 ?0.4
bristle brush. +300 Celsius (86 F) 100.91 *(). 4
+400 Celsius (1040F) 104.60 @.4
8-78. INSPECTION, - ENGINE OIL
TEMPERATURE BULB. b. P e r f o r m i n s u l a t i o n leakage test. With
temperature bulb subjected to a 100 volt potential
a. Inspect temperature bulb for cracks, leaks, between any electrical pin and bulb housing, the
security and proper mounting. minimum resistance shall be 5 megohms.
b. Inspect electrical connector for damaged or c. Reinstall temperature bulb.
bent pins and cracked inserts.
8-79. R E M O V A L - ENGINE OIL 8-82. INSTALLATION - ENGINE OIL
TEMPERATURE BULB. TEMPERATURE BULB.
a. C u t l o c k w i r e and disconnect electrical a. Coat threads and gasket with lubricating oil (79
connector. or 80) when installing gasket on temperature bulb.
b. R e m o v e l o c k w i r e and unscrew temperature b. I n s t a l l t e m p e r a t u r e b u l b a n d g a s k e t in
bulb from oil manifold. manifold.
c. Remove gasket. c. Lockwire (137) to adjacent bolt head on
manifold.
8-80. REPAIR - ENGINE OIL
TEMPERATURE BULB. d. C o n n e c t and lockwire (C137) electrical
connector.
a. Repair damaged electrical connectors.
8-83. TURBINE GAS TEMPERATURE
b. Replace damaged or worn gasket. INDICATING SYSTEM.
c. R e p l a c e t e m p e r a t u r e b u l b i f c r a c k e d o r 8-84. DESCRIPTION - TURBINE GAS
damaged. TEMPERATURE INDICATING SYSTEM.
8-81. FUNCTIONAL TEST - ENGINE OIL The turbine gas temperature (TGT) indicating system
TEMPERATURE BULB - BENCH (AVIM). includes pilot and gunner turbine gas temperature
indicators and turbine temperature thermocouple.
a. Perform resistance check as follows: The system requires 28 Vdc power, which is provided
8-19
TM 55-1520-236-23
by the essential dc bus through TGT IND circuit d. Remove resistance bridge from pins T and U of
breaker (1CB17). plug 1M1P1 and connect it to pins T and U of plug
1M11P1. Repeat circuit resistance check of previous
8-85. TESTING - T U R B I N E G A S step c.
TEMPERATURE INDICATING SYSTEM.
e. Remove resistance bridge and reconnect the
NOTE plugs to each indicator. Check that connectors are
properly mated and secure.
Anytime any component of the turbine gas
temperature indicating system is replaced
perform a system calibration test.
a. Disconnect plug 1P5 from receptacle 1J5 8-86. TROUBLESHOOTING - TURBINE
Connect resistance bridge (T62 or T63) to pins A and B GAS TEMPERATURE INDICATING
of 1P5 and measure resistance of the thermocouple SYSTEM.
loop in engine. Check that resistance of hermocouple
loop is within 1.225 thru 1.8 ohms for the engine. a. q ~ Use table 8-3 and perform necessary
checks to isolate trouble. Refer to figure 8-1 for
b. Remove resistance bridge leads and reconnect equipment location and paragraph F-9 in Appendix F
plug 1P5 to 1J5. Check that connector is properly for wiring diagram. Broken or shorted wiring is
mated, tight and secure. always a probable cause of malfunction or failure and
has not been included.
c. Disconnect plug 1M1P1 from pilot turbine gas
temperature indicator. Disconnect plug 1M11P1 b. ~ Use table 8-3 and perform necessary
from gunner turbine gas temperature indicator. checks to isolate trouble. Refer to paragraph F-9 in
Connect resistance bridge (T62 or T63) to pins T and U Appendix F for wiring diagram and equipment
of plug 1M1P1. Check that total turbine gas location chart. Broken or shorted wiring is always a
temperature circuit resistance is 5 TO 100 ohms at probable cause of malfunction or failure and has not
normal room temperature. been included.
NOTE
Before you use this table, be sure you
have performed all normal operational
checks. If you have a malfunction which
is not listed in this table, notify the next
higher level of maintenance.
Table 8-3. Troubleshooting Turbine Gas Temperature Indicating System
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. Indicator fails to respond.
STEP 1. Determine if indicator is defective by substitution of known good indicator or perform functional
test in accordance with paragraph 8-91.
Replace indicator if defective (paragraph 8-1).
STEP 2. Check for open thermocouple lead or defective thermocouple in accordance with TM 55-2840-
229-23.
Replace thermocouple if defective.
8-20 Change 16
TM 55-1520-236-23
Table 8-3. Troubleshooting Turbine Gas Temperature Indicating System (Cont)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
STEP 3. Determine if TGT IND circuit breaker is defective by use of multimeter or substitution of known
good circuit breaker.
Replace circuit breaker if defective (paragraph 9-23).
2. Indicator operates erratic or incorrectly.
STEP 1. Check for defective thermocouple leads in accordance with paragraph 8-85.
Replace defective leads and retest system.
STEP 2. Check for defective indicator by substitution of known good indicator.
Replace indicator if defective (paragraph 8-1).
STEP 3. Check for defective exhaust thermocouple in accordance with TM 55-2840-229-23.
Replace thermocouple and retest system (paragraph 8-85).
8-87. TURBINE GAS TEMPERATURE 8-89. CLEANING - TURBINE GAS
INDICATORS. TEMPERATURE INDICATORS.
8-88. DESCRIPTION - TURBINE GAS Clean turbine gas temperature indicators in
TEMPERATURE INDICATORS. accordance with paragraph 8-3.
The pilot and gunner turbine gas temperature 8-90. INSPECTION - T U R B I N E GAS
indicators, located on respective instrument panel, TEMPERATURE INDICATORS.
indicate turbine gas temperature in degrees celsius.
The indicators operate on electrical potential from the Inspect turbine gas temperature indicators in
thermocouple harness assembly, mounted on first accordance with paragraph 8-4.
stage power turbine nozzle of combustor turbine
assembly.
Change 16 8-21
TM 55-1520-236-23
8-91. FUNCTIONAL TEST - TURBINE GAS 8-94. INSTALLATION - TURBINE GAS
TEMPERATURE INDICATORS. TEMPERATURE INDICATORS.
Install turbine gas temperature indicators in
NOTE accordance with paragraph 8-7.
Refer to TM 55-2840-229-23 for ther- 8-95. TORQUE PRESSURE
mocouple harness assembly resistance INDICATING SYSTEM.
check.
8-96. D E S C R I P T I O N - TORQUE
NOTE PRESSURE INDICATING SYSTEM.
The following notification must be imple- The torque pressure indicating system includes the
mented when a Penn Airborne Turbine Gas pilot and gunner torque pressure indicators and
respective torque pressure transducers. The torque
Temperature Indicator, P/N 209-075-651-3
pressure indicators indicate engine output shaft
and PIN 9A1290, is tested on a Howell In-
torque pressure in percent torque by means of
struments Tester Exhaust Gas Temperature,
respective torque pressure transducers. The system
P/N BH112JB53, with a Temperature In-
is powered by 28 Vdc essential bus and is protected by
dicator Adapter, P/N BH16492: Ground the
a 5 ampere TRQ IND circuit breaker. Regulated 10Vdc
negative simulated thermocouple lead, Pin
is furnished by the indicator to the transducer.
U in the BH16492 adapter, to a suitable
ground.
a. Remove plug 1M1P1 from back of pilot turbine
8-97. TROUBLESHOOTING - TORQUE
gas temperature indicator. Remove plug 1M11P1
PRESSURE INDICATING SYSTEM.
from back of gunner turbine gas temperature
indicator. Check each indicator for proper operation
a.~ ~ Use table 8-4 and perform necessary
and accuracy using test set (T68) and observing
checks to isolate trouble. Refer to figure 8-1 for
appropriate tester operating instruction. Indicators
equipment location and paragraph F-9 in Appendix F
should read within +10C of correct temperature for wiring diagram. Broken or shorted wiring is
at 810C and 866C. always a probable cause of malfunction or failure and
has not been included.
b. Remove test set (T68) and reconnect plugs
b. ~ Use table 8-4 and perform necessary
1M1P1 and 1M11P1 to pilot and gunner turbine gas
temperature indicators, respectively. Check that checks to isolate trouble. Refer to paragraph F-9 in
Appendix F for wiring diagram and equipment
connectors are properly mated and secure.
location chart. Broken or shorted wiring is always a
probable cause of malfunction or failure and has not
8-92. R E M O V A L - TURBINE GAS been included.
TEMPERATURE INDICATORS.
Remove turbine gas temperature indicators in
accordance with paragraph 8-5.
8-93. R E P A I R - TURBINE GAS
TEMPERATURE INDICATORS.
Repair turbine gas temperature indicators in
accordance with paragraph 8-6.
8-22 Change 16
TM 55-1520-236-23
NOTE
Before you use this table, be sure you
have performed all normal operational
checks. If you have a malfunction which
is not listed in this table, notify the next
higher level of maintenance.
Table 8-4. Troubleshooting Torque Pressure Indicating System
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. Either indicator has inaccurate or sticking pressure indication.
STEP 1. Check for defective indicator by substitution of known good indicator.
Replace indicator if defective (paragraph 8-1).
2. Indicator has sluggish pressure indication.
STEP 1. Check for sludge in pressure line in accordance with paragraph 8-102.
Bleed pressure line.
Change 16 8-22.1 /(8-22.2 blank)
TM 55-1520-238-23
Table 8-4. Troubleshooting Torque Pressure Indicating System (cont)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
3. Both indicators have no or low reading.
STEP 1. Check for kinked or obstructed pressure line.
Replace or dean Iine.
STEP 2. Determine if transducers are defective by substitution of known good transducer or
perform functional test in accordance with paragraph 8-102.
Replace transducer if defective (paragraph 8-106).
STEP 3. Check for open circuit between transducer end indicator.
Make continuity check and replace or repair leads.
STEP 4. Check for defective pressure metering valve.
Replace metering valve in accordance with TM 55-2840-229-24.
4. Indicator has fluctuating pressure indication.
STEP 1. Check for loose electrical connections, or instrument damped too tight
Check connections and/or re-adjust damp.
STEP 2. Determine if incorrect restrictor is installed in system.
Install correct restrictor Incorrect (0.025 to 0.027 hole opening).
5. Indicator has high reading.
STEP 1. Check main rotor blade for excess paint since the extra drag can increase engine torque.
Remove excess paint and repaint.
8-98. TORQUE PRESSURE INDICATORS. 8-100. CLEANING TORQUE PRESSURE
INDICATORS.
8-99. DESCRIPTION TORQUE PRES-
Clean torque pressure indicators in accordance with
SURE INDICATORS. paragraph 8-3.
8-101. INSPECTION TORQUE PRESSURE
INDICATORS.
Inspect torque pressure indicators in accordance with
paragraph 8-4.
Change 22 8-23
TM 55-1520-236-23
8-102. FUNCTIONAL TEST TORQUE 8-107. DESCRIPTION TORQUE
PRESSURE INDICATORS. PRESSURE TRANSDUCER.
a. Close TRQ IND circuit breaker. The pilot and gunner torque pressure transducer,
mounted on a bracket in transmission compartment,
b. Disconnect the pressure line from the monitors engine output shaft torque and transmits
engine at the bulkhead tee fitting. varying voltage signals to the respective torque
pressure indicator. Refer to figure 8-1 for
c. Connect a pressure line from the tester, equipment location. Refer to paragraph F-9 in
pressure gage (MP-1) to the bulkhead tee fitting. Appendix F for equipment location chart.
Slowly apply pressure to the transducers until 56
psig is indicated on the master gage (MP-1). 8-108. CLEANING TORQUE PRESSURE
TRANSDUCER.
d. Record the percent readings on both the
gunner and pilot indicators. The indicators must a. Remove moisture and loose dirt with a clean,
read 100 plus or minus 2 percent. soft cloth.
NOTE
If one of the readings is fairly close to
the acceptable 98 to 102 percent range,
Cleaning solvent is flammable and toxic,
reverse the electrical cannon plug leads
Provide adequate ventilation. Avoid
from one transducer to the other and
prolonged breathing of solvent vapors
repeat the pressure test. This switching
and contact with skin or eyes.
utilizes the differences between the sen-
sitivities of each electrical system and
could make use of otherwise unservice-
able equipment. b. Remove oil, grease, fungus, and ground-in dirt
with a clean lint-free cloth dampened with dry
e. By part substitution, replace the faulty cleaning solvent (C112).
pressure transducer or indicator.
c. Remove dirt from electrical connectors with a
f. Open TRQ IND circuit breaker and recon- bristle brush.
nect the torque pressure lines.
8-109. INSPECTION TORQUE
PRESSURE TRANSDUCER.
8-103. REMOVAL TORQUE PRESSURE
INDICATORS. a. Inspect pressure transducer for cracks, secure
and proper mounting, and proper operation.
Remove torque pressure indicators in accordance
with paragraph 8-5. b. Inspect oil line and fitting connection for leaks
and proper installation.
8-104. REPAIR TORQUE PRESSURE
INDICATORS. c. Inspect electrical connector for damaged or
bent pins and cracked inserts.
Repair torque pressure indicators in accordance with
paragraph 8-6.
8-110. FUNCTIONAL TEST TORQUE
PRESSURE TRANSDUCER.
8-105. INSTALLATION TORQUE
PRESSURE INDICATORS. Test torque pressure transducer in accordance with
paragraph 8-102.
Install torque pressure indicators in accordance with
paragraph 8-7.
8-111. REMOVAL TORQUE PRESSURE
TRANSDUCER.
8-106. TORQUE PRESSURE
TRANSDUCER. a. Remove cowling from transmission.
8-24 Change 5
TM 55-1520-236-23
b. Disconnect electrical connector, hose, and oil 8-112. REPAIR - TORQUE PRESSURE
line from transducer to be removed. TRANSDUCER.
c. Cap openings of oil line and protect electrical a. Repair damaged electrical connectors.
connector with electrical tape (C121).
b. Tighten loose oil line or fitting connection.
d. Remove nut and washer. Remove transducer
from helicopter.
Change 5 8-24.1 /(8-24.2 blank)
TM 55-1520-236-23
c. Replace defective or damaged oil line or fitting. 8-113. INSTALLATION - TORQUE PRESSURE
TRANSDUCER.
d. Replace pressure transducer if cracked or
damaged. a. Position transducer in bracket and install with
washer and nut.
e. Reinstall improperly mounted pressure
transducer. b. Remove protective covers and connect oil line,
hose and electrical connector to transducer. Install
cowling.
SECTION Ill. FLIGHT INSTRUMENTS
8-114. FLIGHT INSTRUMENTS. NOTE
8-115. DESCRIPTION - FLIGHT INSTRUMENTS. Except for the use of system drain, a
functional check of the pitot-static
Flight instruments include the pitot-static system, system and pitot-static instruments will
airspeed indicators, altimeters, attitude indicating be performed following any opening and
system, and vertical speed indicator. closing of the pitot-static system.
8-116. PITOT - STATIC SYSTEM. 8-117.1. FUNCTIONAL CHECK - PITOT STATIC
SYSTEM.
8-117. DESCRIPTION - PITOT-STATIC SYSTEM.
a. Pitot Line Leak Check.
The pitot-static system (figure 8-2) consists of the
electrically heated pitot tube, two static ports, pitot and (1) Seal pitot tube drain holes air tight with
static drains, and pitot and static lines necessary to pressure sensitive tape (C123).
connect to airspeed indicators, altimeters, vertical
speed indicator, and air data pressure transducer. (The (2) Hook up airspeed outlet of pitot-static tester
air data pressure transducer is a component of the turret to pitot system in accordance with figure 8-2.1. Open
system, refer to q TM 9-1090-203 or q q TM vacuum and up and down valves, close pressure up and
9-1090-206 series maintenance manuals.) The pitot down valves. Rotate airspeed selector valve to open.
tube is mounted on upper left side of forward pylon Valve is located on top of test set. Rotate pressure
fairing. The static ports are located one on each side of selector valve to airspeed indicator position. Apply
pitot section, in line with instrument panel. Information power to the test set.
pertaining to pitot heater electrical system is contained
in paragraph 9-384. (3) Slowly apply pressure to pitot line until the
airspeed indicator reads 120 knots.
CAUTION (4) Tap instrument to remove friction effects.
When indicator pointer drops more than 10 mph (8.7
Do not apply suction to pitot lines or knots) in one minute, a leak is indicated. Slowly
pressure to static lines except as decrease pressure to return tester airspeed indicator to
instructed in paragraph 8-117.1. zero, repair any faults if necessary and repeat step
above.
NOTE b. Airspeed Indicator Functional Check.
Assure pitot static tester has a current (1) Slowly apply pressure to pitot line to obtain
calibration label (DA Form 80). Use airspeed readings in table 8-4.1. Indicator should be
appropriate power supply in accordance gently tapped prior to reading. Check need not exceed
with pitot static tester requirements. 120 knots.
Change 18 8-25
TM 55-1520-236-23
Table 8-4.1. TOLERANCE ( KNOTS)
MS28045 MS28021 MS28046
Airspeed Check 10 to 150 20 to 250 40 to 400
Points (Knots) 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
(2) If readings are not within tolerance of table (3) Adjust test set and aircraft altimeter
8-4.1, slowly relieve pressure on pitot line until airspeed barometric scales to read 29.92. Gently tap test set
indicator reads zero. Replace indicator with serviceable altimeter, and check to insure that aircraft altimeters
one and repeat steps b(1) and (2) above. read within 70 feet of test set altimeter and report of
calibration data card located across the top of tester
(3) Airspeed indicators that fail test shall be outlet valve cover.
turned in for overhaul.
(4) If aircraft altimeters fail to meet this check,
(4) Bleed pitot-static tester pressure system. remove and install a serviceable instrument and repeat
step c(3) above.
c. Static Line Leak Check.
(5) Open pitot pressure up and down valves.
(1) Hook up pitot-static tester, rate of climb and Close vacuum up and down valves. Close airspeed
altimeter outlet, to pitot and static system in accordance valve at top of test set. Rotate vacuum selector valve to
with figure 8-2.2 altimeter position. Apply power to test set. Slowly apply
vacuum to pitot and static lines (figure 8-2.2) until the
CAUTION altimeter reads 1000 feet above reading obtained from
step c(3). Close vacuum source and gently tap altimeter
Make sure that both aircraft pitot and at same time until rate of climb indicator stabilizes at
static lines are connected to airspeed zero. After stabilization, the altimeter should not drop
indicator to prevent possible damage to more than 100 feet in one minute. Slowly decrease
airspeed indicator. vacuum until rate of climb stabilizes at zero. Repair any
faults if necessary and repeat this step.
NOTE d. Vertical Speed Indicator Functional Check.
Hooking up the pitot line to the tester (1) Slowly apply vacuum to aircraft system to
vacuum source will only be done during obtain rate of climb readings in table 8-4.2. After vertical
the following check to equalize the speed indicator stabilizes at desired reading, instrument
pressure in the airspeed indicator case to shall be subjected to gentle tapping, and readings
prevent damage to its diaphragm. compared to report of calibration data card across the
top of tester. After completion of checks, close both pitot
(2) Tape all unused static ports. static tester vacuum valves.
8-26 Change 18
TM 55-1520-236-23
Table 8-4.2. Vertical Speed Tolerance Feet Scale Accuracy
Standard Altitude Check Rate Tolerance
Check Interval Ascent or Descent Scale Error
(Feet) (fpm) (fpm)
2000 to 2500 500 100
2000 to 3000 1000 200
2000 to 4000 2000 300
2000 to 5000 3000 300
15,000 to 17,000 2000 300
(2) Slowly decrease vacuum until desired rate of e. Altimeter Functional Check.
descent is obtained from table 8-4.2. After vertical
speed indicator stabilizes at desired readings, subject (1) Apply 28 volt power to aircraft electrical
instrument to gentle tapping and compare readings to system to provide electrical power for counter drum
tester rate of climb indicator and calibration data card. altimeter vibrators.
(3) Instruments that fail check and tolerances (2) Slowly apply vacuum to aircraft system at a
shall be replaced with a serviceable unit and steps d(1) rate not to exceed 3000 feet per minute. Continue to
and (2) above repeated. apply vacuum until altimeter readings reach the next
higher reading on table 8-4.3 above altimeter altitude
(4) Vertical speed indicators that fail check will indicated when barometric scale is set at 29.92.
be turned in for overhaul.
Table 8-4.3. Altimeter Scale Error
Altitude (feet) Tolerance (i feet)
0 70
500 70
1,000 70
2,000 70
3,000 70
5,000 100
10,000 130
15,000 140
(3) Close vacuum valve and keep altimeter at NOTE
this setting for at Ieast one minute, but not more than
five minutes, then gently tap three-pointer type Altimeters that do not pass the perfor-
altimeters before reading. Assure that vibrators are mance requirements of table 8-4.3 shall be
operative on counter drum altimeters before readings removed from aircraft and shop tested in
are compared to tolerance shown in table 8-4.3. accordance with the test procedures in TM
55-1500-204-23 (Series) to verify malfunc-
(4) Compare the readings of the installed tions. Install serviceable altimeter and
instruments against readings on the tester and repeat steps (3) and (4).
calibration data card at the check points shown in table
8-4.3. (5) Remove pitot static tester and all tape from
pitot/static lines and openings. Check hoses for
adequate clearance after removal of the tape from the
static ports.
Change 18 8-26.1
TM 55-1520-236-23
8-118. TROUBLESHOOTING - PITOT-STATIC a. Disconnect pitot and static lines from airspeed
SYSTEM. indicators and air data pressure transducer. Disconnect
static lines from altimeters and vertical velocity indicator.
Refer to applicable portions of airspeed indicators, Cap openings in indicators and pressure transducer to
altimeters, and vertical speed indicator troubleshooting prevent entrance of foreign material.
procedures.
b. Remove caps and open pitot drain valve and
8-119. PITOT-STATIC PIPING AND FITTINGS. static drain valve.
8-120. DESCRIPTION - PITOT-STATIC PIPING
AND FITTINGS.
The pitot-static piping and fittings consist of flexible
piping lines routed from the pitot tube and static ports CAUTION
to airspeed indicators, altimeters, vertical speed
indicator, and air data pressure transducer. The piping Disconnect air data pressure transducer
lines are connected with nylon fittings and contain a and all instruments that use pitot or static
pitot drain and static drain (figure 8-2). air pressure before blowing lines clear.
8-121. CLEANING - PITOT-STATIC PIPING AND
FlTTNGS.
c. Blow all lines clean with filtered, compressed air.
NOTE
d. Uncap openings in indicators and transducer and
The air data pressure transducer is reconnect all lines.
located above and aft of left ammunition
bay door, and is connected to pitot-static
system.
8-26.2 Change 5
TM 55-1520-236-23
1. Static drain 10. Altimeter (pilots) 19. Air data pressure transducer
2. Pitot drain 11. Vertical speed 20. Restrictor tee
3. Union tee indicator (pilots) (pitot drain)
4. Altimeter (gunners) 12. Airspeed indicator 21. Pipe tee
5. Vertical speed (pilots) 22, Free air temperature gage case
indicator (gunners) 13. Pitot tube 23. Case washer
6. Airspeed indicator 14. Pipe elbow 24. Dished washer
(9unners) 15. Pipe union 25. Grommet
7. Standby compass 16. Pipe tee 26. Sunshield
8. Static Dort 17. Pipe tee
9. Pipe tee 18. Static port 209075-317D
Figure 8-2. Pitot-Static System (Typical)
Change 5 8-26.3
TM 55-1520-236-23
Figure 8-2-1. Connection for Pitot Leak Check (Typical)
8-26.4
TM 55-1520-236-23
Figure 8-2-2. Connections for Static Leak Check (Typical)
Change 18 8-26.5/(8-26.6 Blank)
TM 55-1520-236-23
e. Assemble nylon fittings as follows: b. Tighten or properly install fittings and clamps.
(1) Install coupling nut on nylon tubing. c. Replace defective or damaged nylon fittings or
clamps.
(2) Install insert into end of nylon tubing.
8-127. INSTALLATION - PITOT-STATIC
(3) Apply silicone compound (C110) to threads PIPING AND FITTINGS.
of nylon nut and fitting.
a. Route pitot and static lines through clamps in
(4) Connect coupling nut to fitting and torque place. Tighten clamps, Connect pitot and static lines
nut fingertight. to indicators and air data pressure transducer.
f. Close pitot and static drain valves and install b. Apply silicone compound (C110) to threads of
drain caps. fitting couplings.
8-122. INSPECTION - PITOT-STATIC c. Connect nylon fittings. Torque coupling nuts
PIPING AND FlTTINGS. fingertight.
a. Inspect pitot and static piping and fittings for d. C o n d u c t f u n c t i o n a l c h e c k i n a c c o r d a n c e
leaks, chafing, crimping, or other visible damage. with paragraph 8-117.1.
b. Inspect system for improperly installed fittings
8-128. PITOT TUBE HEAD.
and clamps.
8-129. DESCRIPTION - PITOT TUBE
8-123. FUNCTIONAL CHECK - PITOT- HEAD.
STATIC PIPING AND FITTINGS.
Perform functional test in accordance with
paragraph 8-117.1.
8-124. TROUBLESHOOTING - PITOT- Serious burns may result if contact is
STATIC PIPING AND FITTINGS. made with pitot tube when pitot heater is
ON.
Refer to applicable portions of airspeed indicator,
altimeters, and vertical speed indicator
The electrically heated pitot tube head and mount is
troubleshooting procedures. (See figure 8-2.)
located on upper left side of forward pylon fairing
(figure 8-2). Information pertaining to the pitot heater
8-125. R E M O V A L - PITOT-STATIC
electrical system is contained in paragraph 9-384.
PIPING AND FITTINGS.
a. D i s c o n n e c t p i t o t a n d s t a t i c l i n e s f r o m 8-130. CLEANING - PITOT TUBE HEAD.
indicators and air data pressure transducer. Cap
openings in indicators and pressure transducer to
prevent entrance of foreign material.
b. D i s c o n n e c t a p p l i c a b l e n y l o n f i t t i n g s a n d Cleaning solvent is flammable and toxic.
clamps. Provide adequate ventilation. Avoid
prolonged breathing of solvent vapors
c. Remove pitot and static lines. and contact with skin or eyes.
8 - 1 2 6 . R E P A I R - PITOT-STATIC PIPING a. Clean pitot tube head with a clean, lint-free
AND FlTTINGS. cloth dampened with dry cleaning solvent (C112).
a. Replace defective or damaged pitot and static b. C l e a n m o u n t w i t h a c l e a n , l i n t - f r e e c l o t h
lines. dampened with dry cleaning solvent (C112)
Change 5 8-27
TM 55-1520-236-23
8-131. INSPECTION - PITOTTUBE HEAD. b. Apply silicone compound (C110) to threads of
coupling.
a. Inspect pitot tube for clogged or obstructed
inlet opening, and clogged drain hole on bottom of c. Connect pitot line coupling to adapter. Torque
tube (figure 8-2). coupling fingertight.
b. Inspect pitot tube for cracks or damage. d. Connect electrical connector to pitot tube head
connector.
c. If pitot tube head is removed, inspect electrical
receptacle, pins, and sockets for damage. e. Carefully position pitot tube into mount and
install three mounting screws and lockwashers.
8-132. REMOVAL - PITOT TUBE HEAD.
f. From inside left forward pylon fairing, remove
a. Check that system electrical power is OFF. protective caps from union and nut. Apply silicone
compound (C110) to threads of union.
b. Open access door on left center pylon fairing.
g. Connect union assembly. Torque union nut
c. From inside the left forward pylon fairing, fingertight. Install pitot line clamp and electrical
remove the clamps securing the pitot line and pitot clamp.
heater electrical wires.
h. Close pylon fairing access door.
d. D i s c o n n e c t u n i o n a s s e m b l y a n d i n s t a l l
protective caps on open ends.
8-135. AIRSPEED INDICATORS.
e. From outside the helicopter, remove the three
screws and lockwashers attaching pitot tube head to
mount. 8-136. DESCRIPTION - AIRSPEED
INDICATORS.
f. Carefully pull pitot tube from mount to expose
electrical connector and pitot line coupling.
Disconnect electrical connector. Disconnect coupling The pilot and gunner airspeed indicators, located on
from adapter. Cap open adapter and tape electrical respective instrument panel, are standard pitot-static
connector to prevent entrance of foreign material. instruments. The single-scale indicator provides
airspeed indication of 20 to 250 knots by measuring
8-133. REPAIR - PITOT TUBE HEAD. differences between impact air pressure from the
pitot tube and atmospheric pressure from the static
a. Replace pitot tube head if inlet opening is pressure ports.~ q Refer to figures 8-1 and 8-2 for
clogged or obstructed, drain hole is clogged, or equipment locations. ~ Refer to figure 8-2 and
electrical connector is damaged. paragraph F-9 in Appendix F for equipment location.
b. Replace pitot tube head if cracked or damaged
to the extent it would restrict impact air pressure. 8-137. C L E A N I N G - AIRSPEED
INDICATORS.
c. Replace defective or damaged pitot electrical
connector.
Clean airspeed indicators in accordance with
d. Tighten or properly install fittings. paragraph 8-3.
8-134. INSTALLATION - PITOT TUBE 8-138. INSPECTION - AIRSPEED
HEAD. INDICATORS.
a. At pitot tube mount, remove protective cap
Inspect airspeed indicators in accordance with
from adapter and remove tape from electrical
paragraph 8-4.
connector.
8-28
TM 55-1520-236-23
8-139. FUNCTIONAL CHECK - AIR- 8-140. TROUBLESHOOTING - AIRSPEED
SPEED INDICATORS. INDICATORS.
Check airspeed indicators in accordance with Use table 8-5 and perform necessary checks to isolate
paragraph 8-117.1. trouble.
NOTE
Before you use this table, be sure you
have performed all normal operational
checks. If you have a malfunction which
is not listed in this table, notify the next
higher level of maintenance.
Table 8-5. Troubleshooting Airspeed Indicators
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. Indicators fail to respond.
STEP 1. Check for pressure line not connected.
Connect line.
2. Indicator pointer indicates incorrectly.
STEP 1. Check for lines clogged by water or dirt.
Disconnect and blow lines clear, while actuating drain valve
STEP 2. Determine if indicator is defective or leaking by substitution of known good indicator or perform
functional check in accordance with paragraph 8-117.1.
Replace indicator if defective (paragraph 8-1).
8-141. REMOVAL - AIRSPEED Repair airspeed indicators in accordance with
INDICATORS. paragraph 8-6.
Remove airspeed indicators in accordance with 8-143. INSTALLATION - AIRSPEED
paragraph 8-5. INDICATORS.
8-142. R E P A I R - AIRSPEED Install airspeed indicators in accordance with
INDICATORS. paragraph 8-7.
Change 5 8-29
TM 55-1520-236-23
8-144. ALTIMETERS. 8-146. CLEANING - ALTIMETERS.
Clean altimeters in accordance with paragraph 8-3.
8-145. DESCRIPTION - ALTIMETERS. 8-147. INSPECTION - ALTIMETERS.
The pilot and gunner altimeters, located on respective Inspect altimeters in accordance with paragraph 8-4.
instrument panel, furnish direct readings of
helicopter height in feet above sea level. The 8-148. FUNCTIONAL CHECK - ALTIM-
altimeters are connected through piping to static ETERS.
pressure ports to sense atmospheric pressure. An
external adjustment knob is provided to make Functional check altimeters in accordance with
compensation for variations of prevailing barometric paragraph 8-117.1.
pressure. The altimeters are equipped with vibrators
to eliminate pointer sticking due to friction error. The
8-149. TROUBLE SHOOTING -
vibrators are operated by 28 Vdc through the ALTM
ALTIMETERS.
circuit breaker. ~a Refer to figures 8-1 and 8-2 for
equipment location. ~Refer to figure 8-2 and Use table 8-6 and perform necessary checks to isolate
paragraph F-9 in Appendix F for equipment location. trouble. AA-32A encoding altimeter; code off flag will not
drop and mode C will not test, see figure F-47.
NOTE
Before you use this table, be sure you
have performed all normal operational
checks. If you have a malfunction which
is not listed in this table, notify the next
higher level of maintenance.
Table 8-6. Troubleshooting Altimeters
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. Indicator has incorrect reading.
STEP 1. Check for leaks in static pressure line in accordance with paragraph 8-117.1.
Correct leaks in line.
STEP 2. Check for clogged static port or piping.
Clean port or piping.
STEP 3. Determine if indicator is defective by substitution of known good indicator or perform functional
check in accordance with paragraph 8-117.1.
Replace indicator if defective (paragraph 8-1).
8-30 Change 16
TM 55-1520-236-23
Table 8-7. Troubleshooting Attitude Indicators (Cont)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
STEP 2. Check for defective circuit breaker by use of multimeter or substitution of known good circuit
breaker.
Replace circuit breaker if defective (paragraph 9-23).
STEP 3. Check for defective attitude gyro in accordance with TM 11-1520-236-20.
Replace gyro if defective in accordance with TM 11-1520-236-20.
2. Either pilot or gunner indicator display fails to erect to within *2 degrees in pitch and roll within 3 minutes
after turn on.
STEP 1. Check for defective indicator by substitution of known good indicator.
Replace indicator if defective (paragraph 8-1).
3. System functions properly, but gunner power OFF flag does not lift.
STEP 1. Check for defective indicator by substitution of known good indicator.
Replace indicator if defective (paragraph 8-1).
8-163. REMOVAL - ATTITUDE 8-166. TURN AND SLIP INDICATING
INDICATORS. SYSTEM.
Remove attitude indicators in accordance with 8-167. DESCRIPTION - TURN AND SLIP
paragraph 8-5. INDICATING SYSTEM.
8-164. R E P A I R - ATTITUDE Turn and slip portion of the pilot and copilot attitude
INDICATORS. indicators consist of a rate of turn pointer (on pilot
indicator only) and an inclinometer (ball) which
Repair attitude indicators in accordance with operate independently of each other. Rate of turn
paragraph 8-6. pointer is controlled by an electrically actuated dc
powered rate gyro and is protected by TURN SLIP
8-165- INSTALLATION - ATTITUDE circuit breaker. Rate of turn pointer indicates in which
INDICATORS. direction and at what rate helicopter is turning.
Inclinometer (ball) indicates when helicopter is in
Install attitude indicators in accordance with directional balance either in a turn or in straight and
paragraph 8-7. level flight. If helicopter is yawing or slipping, ball will
8-33
TM 55-1520-236-23
be off center.~~Refer to figure 8-1 for equipment 8-170. CLEANING - VERTICAL SPEED
location and paragraph F-9 in Appendix F for wiring INDICATORS.
diagram.~ Refer to paragraph F-9 in Appendix F
for equipment location chart and wiring diagram. Clean vertical speed indicators in accordance with
paragraph 8-3.
8-171. INSPECTION - VERTICAL SPEED
8-168. VERTICAL S P E E D
INDICATORS.
INDICATORS.
Inspect vertical speed indicators in accordance with
paragraph 8-4.
8-169. DESCRIPTION - VERTICAL
SPEED INDICATORS. 8-172. FUNCTIONAL CHECK - VER-
TICAL SPEED INDICATORS.
The pilot and gunner vertical speed indicators, Functional check vertical speed indicators in ac-
mounted in the respective instrument panels are cordance with paragraph 8-117.1.
connected to the static air system to sense the rate of
atmospheric pressure change. The indicators register 8-173. TROUBLESHOOTING - VERTICAL
ascent or descent in feet per minute~ Refer to SPEED INDICATORS.
figure 8-1 and 8-2 for equipment locations.
% Refer
to figure 8-2 and paragraph F-9 in Appendix F for Use table 8-8 and perform necessary checks to isolate
equipment location. trouble.
NOTE
Before you use this table, be sure you
have performed all normal operational
checks. If you have a malfunction which
is not listed in this table, notify the next
higher level of maintenance.
Table 8-8. Troubleshooting Vertical Speed Indicators
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. Indicator points off zero.
STEP 1. Determine if mechanism shifted by substitution of known good indicator.
Return pointer to zero by turning adjustment screw on face of instrument; tap face of indicator
lightly while adjusting.
2. Indicator has inaccurate readings.
STEP 1. Check for defective indicator by substitution of known good indicator.
Replace indicator if defective (paragraph 8-1).
8-34 Change 5
TM 55-1520-236-23
Table 8-8. Troubleshooting Vertical Speed Indicators (Cont)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
STEP 2. Check for loose connection in static line.
Tighten connections.
STEP 3. Determine if indicator case leaks by substitution of known good indicator or in accordance with
paragraph 8-117.1.
Replace indicator if defective (paragraph 8-1).
3. Indicator has excessive pointer oscillation.
STEP 1. Check for leaks in static line in accordance with paragraph 8-117.1.
Tighten connections; replace leaky lines.
STEP 2. Check for defective indicator by substitution of known good indicator.
Replace indicator if defective (paragraph 8-1).
8-174. REMOVAL - VERTICAL SPEED The ADS consists of a wind direction, speed, and
INDICATORS. temperature detector (AADS), a signal processor unit
(EPU), and an airspeed and direction indicator (LA1).
Remove vertical speed indicators in accordance with The ADS provides helicopter subsystems with air
paragraph 8-5. data information to aid flight safety at low airspeeds,
to contribute to accurate fire control, and to provide
8-175. REPAIR - VERTICAL SPEED backup navigation capability. The ADS displays
INDICATORS. forward, aft, and lateral components of airspeed up to
50 knots in any direction and also supplies electronic
Repair vertical speed indicators in accordance with signals to the fire control computer and doppler
paragraph 8-6. navigation system. Refer to TM 9-1270-219-13 for
description, operational check, troubleshooting, and
8-176. INSTALLATION - VERTICAL maintenance of the ADS.
SPEED INDICATORS.
8-179. m WIND DIRECTION, SPEED,
Install vertical speed indicators in accordance with AND TEMPERATURE DETECTOR
paragraph 8-7. (AADS).
8-177. ~ FIRE AND FLIGHT AIR 8-180. ~ DESCRIPTION - WIND
DATA SUBSYSTEM (ADS). DIRECTION, SPEED, AND TEMPERATURE
DETECTOR (AADS).
8-178. ~ DESCRIPTION - FIRE AND The AADS is a part of the ADS. The AADS is a
FLIGHT AIR DATA SUBSYSTEM (ADS). swiveling pitot-static probe which samples local
Change 5 8-35
TM 55-1520-236-23
airflow pitot and static pressures, the angles of that AADS and radar altimeter. The EPU converts these
airflow relative to the aircraft, and the free stream air signals into airspeed, temperature, and pressure
temperature. Pneumatic pressure outputs are fed output signals for the LAI, fire control computer, and
through the aircraft plumbing to the EPU and doppler navigation system. Refer to TM 9-1270-219-
converted into analog electronic signals. Electronic 13 for description, operationaI check,
signals representing airflow angle and temperature troubleshooting, and maintenance of the EPU.
are also fed to the EPU. Component airspeed outputs
from the EPU are displayed on the low airspeed 8-183. ~ A I R S P E E D AND
indicator. Refer to TM9-1270-219-13 for description, DIRECTION INDICATOR (LAl).
operational check, troubleshooting, and maintenance
of the AADS. 8-184. DESCRIPTION - AIRSPEED
AND DIRECTION INDICATOR (LAI).
8-181. m SIGNAL PROCESSOR UNIT
(EPU). The LAI is a part of the ADS. The indicator displays
forward, aft, and lateral components of airspeed up to
8-182. ~ DESCRIPTION - SIGNAL 50 knots in any direction. A three-position flag is
PROCESSOR UNIT (EPU). provided to indicate system operational, system
failure, or an over-range condition. Refer to TM
The EPU, located on bulkhead behind pilot seat, 9-1270-219-13 for description, operational check,
receives pneumatic and electronic signals from the troubleshooting, and maintenance of the LAI.
SECTION IV. NAVIGATION INSTRUMENTS
8-185. NAVIGATION INSTRUMENTS. 8-189. RADIO MAGNETIC
INDICATOR.
8-186. DESCRIPTION - NAVIGATION
INSTRUMENTS. 8-190. DESCRIPTION - RADIO
MAGNETIC INDICATOR.
Navigation instruments include the horizontal
situation indicator, radio magnetic indicator, and The radio magnetic indicator (RMI) is mounted in
standby compass. gunner instrument panel. The indicator gives
gyromagnetic (AN/ASN-43) compass heading.
Pointer number 1 indicates magnetic bearing of ADF
8-187. HORIZONTAL SITUATION (AN/ARN-89B). Pointer number 2 indicates magnetic
INDICATOR. bearing of VOR(AN/ARN-123). Referto TM 11-1520-
236 series manual for description, operational check,
8-188. DESCRIPTION - HORIZONTAL troubleshooting, and maintenance o f s y s t e m
SITUATION INDICATOR. components.
The horizontal situation indicator is located in the 8-191. STANDBY MAGNETIC
pilot instrument panel. The indicator is used in COMPASS.
conjunction with Gyro-magnetic Compass System
(AN/ASN-43), ADF (AN/ARN -89B), VHF-FM Radio 8-192. DESCRIPTION - STANDBY
(AN/ARC-114A) operating in homing mode, and MAGNETIC COMPASS.
VOR-LOC-GS-MB System (AN/ARN-123).
Navigation functions of the indicator are controlled by One standby compass of standard magnetic type is
HSI Display Control Panel. Refer to TM 11-1520-236 mounted on right windshield support. The standby
series manuals for description, operational check, compass is utilized by both pilot and gunner. The
troubleshooting, and maintenance o f s y s t e m compass correction card is located adjacent to the
components. compass. Refer to figure 8-2 for equipment locations.
8-36
TM 55-1520-236-23
8-193. CLEANING - STANDBY MAGNETIC 8-197.1. QGPS T R I M P A C K .
COMPASS.
8-197.2. .2.~DESCRIPTION - GPS TRIMPACK.
Clean standby magnetic compass in accordance
with paragraph 8-3. The GPS trimpack is mounted on the left side of the
pilot glare shield. The trimpack is a GPS navigation
8-194. INSPECTION - STANDBY MAGNETIC receiver which provides world-wide, day/night, all
COMPASS. weather position and velocity.
Inspect standby magnetic compass in accordance 8-197.3. .3.~CLEANING - GPS TRIMPACK.
with paragraph 8-4.
Clean GPS trimpack in accordance with 8-3.
8-195. COMPENSATION (SWINGING) -
STANDBY MAGNETIC COMPASS. 8-197.4. .4.~lNSPECTION - GPS TRIMPACK.
The standby magnetic compass may be calibrated Inspect GPS trimpack in accordance with 8-4.
concurrently with the ASN-43 compass system.
8-197.5. .5.~REMOVAL - GPS TRIMPACK.
Refer to TM 11-1520-236 series maintenance
manuals. Remove GPS trimpack in accordance with 8-6.
8-196. REMOVAL - STANDBY MAGNETIC 8-197.6. INSTALLATION - GPS TRIMPACK.
COMPASS.
Install GPS trimpack in accordance with 8-7.
Remove standby magnetic compass in accordance
with paragraph 8-6.
8-197. INSTALLATION - STANDBY
MAGNETIC COMPASS.
Install standby magnetic compass in accordance
with paragraph 8-7.
Change 19 8-37
TM 55-1520-236-23
SECTION V. MISCELLANEOUS INSTRUMENTS
8-198. MISCELLANEOUS 8-203. INSPECTION - FREE AIR
INSTRUMENTS. TEMPERATURE GAGE.
8-199. DESCRIPTION Inspect and replace free air temeprature gage if any of
MISCELLANEOUS INSTRUMENTS. the following conditions exist:
The miscellaneous instruments include the free air a. D i s c o l o r a t i o n .
temperature gage, fuel quantity indicating system,
transmission oil temperature and pressure indicating b. Leaking seals.
system, voltmeter/ammeter, clock, ~ q pilot
steering indicator (PSl), ~ head up display (HUD), c. Temperature indication reading does not agree
radar warning system and ~ proximity warning with that of a standard indicator.
system.
8-200. FREE AIR TEMPERATURE 8-204. FUNCTIONAL TEST - FREE AIR
GAGE. TEMPERATURE GAGE.
8 - 2 0 1 . DESCRIPTION - FREE AIR Check temperature reading with that of a standard
TEMPERATURE GAGE. indicator known to be correct. (Refer to TM 55-1500-
204-25/1). Replace gage if readings do not agree.
The free air temperature gage is a bimetallic, probe
type thermometer mounted on the left side of pilot
compartment. The probe portion is exposed to outside
temperatures through a rubber grommet mounted on
skin of helicopter. The indicator is calibrated in
degrees celsius. Refer to figure 8-2 for equipment
locations.
8-202. C L E A N I N G - FREE AIR 8-205. TROUBLESHOOTING - FREE AIR
TEMPERATURE GAGE. TEMPERATURE GAGE.
Clean free air temperature gage in accordance with Use table 8-9 and perform necessary checks to isolate
paragraph 8-3. trouble.
8-38 Change 19
TM 55-1520-236-23
NOTE
Before you use this table, be sure you
have performed all normal operational
checks. If you have a malfunction which
is not listed in this table, notify the next
higher level of maintenance.
Table 8-9. Troubleshooting Free Air Temperature Gage
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. Gage has reading upscale of free air temperature.
STEP 1. Check for missing or improperly installed sunshield.
Properfy install sunshield.
STEP 2. Determine if gage is defective in accordance with TM 1-1500-204-23 Series.
Replace gage if defective (paragraph 8-200).
2. Gage has reading downscale of free air temperature.
STEP 1. Check for defective gage in accordance with TM 1-1500-204-23 Series.
Replace gage if defective (paragraph 8-200).
8-206. REMOVAL - FREE AIR a. H o l d w a s h e r s a n d t h e r m o m e t e r c a s e i n
TEMPERATURE GAGE. position at mounting flange (figure 8-2).
a. U n s c r e w a n d r e m o v e s u n s h i e l d , d i s h e d b. Insert probe through grommet and mounting
washer, and one case washer from outer end of flange.
thermometer.
c. Place sunshield over thermometer probe and
b. Remove thermometer and other case washer tighten.
from inside of pilot compartment.
8-209. FUEL QUANTITY INDICATING
8-207. R E P A I R - FREE AIR SYSTEM.
TEMPERATURE GAGE.
8-210. DESCRIPTION - FUEL QUANTITY
Replace gage if any of the inspection requirements INDICATING SYSTEM.
are not met.
The fuel quantity indicating system is a bridge
8-208. lNSTALLATION - FREE AIR capacitance, balance type system which includes a
TEMPERATURE GAGE. fuel quantity indicator, located on pilot instrument
8-38.1/(8-38.2 blank)
TM 55-1520-236-23
panel, and two fuel quantity transmitters; one located 8-211. TROUBLESHOOTING FUEL
in forward fuel cell, and the other located in aft fuel QUANTITY INDICATING SYSTEM.
cell. The system is powered from the 115 Vac bus,
and is protected by a 1 ampere FUEL QTY IND circuit
breaker. Pressing FUEL GAUGE TEST SWITCH,
located on the pilot miscellaneous control panel,
checks the fuel quantity indicator for zero return. Fuel Use table 8-10 and perform necessary checks to
quantity indicator in pilot instrument paneI registers isolate trouble. Refer to paragraph F-9 in Appendix F
fuel quantity in pounds. ~ Refer to figure 8-1 for for wiring diagram. Broken or shorted wiring is
equipment locations. aRefer to paragraph F-9 in always a probable cause of malfunction or failure and
Appendix F for equipment location chart. has not been included.
NOTE
Before you use this table, be sure you
have performed all normal operational
checks. If you have a malfunction which
is not listed in this table, notify the next
higher level of maintenance.
Table 8-10. Troubleshooting - Fuel Quantity Indicating System
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. Fuel quantity indicator reads low.
STEP 1. Determine if system is out of adjustment in accordance with paragraph 8-212 (AVIM).
Perform adjustment procedures (AVIM).
STEP 2. Check tank unit for low capacitance in accordance with paragraph 8-212 (AVIM).
Replace tank unit if faulty (paragraph 8-220).
STEP 3. Check for compensator capacitance too high in accordance with paragraph 8-212 (AVIM).
Replace tank unit if faulty (paragraph 8-220).
2. Fuel quantity indicator reads high.
STEP 1. Determine if system is out of adjustment in accordance with paragraph 8-212 (AVIM).
Perform adjustment procedures (AVIM).
STEP 2. Check tank unit for high capacitance in accordance with paragraph 8-212 (AVIM).
Change tank unit if faulty (paragraph 8-220).
8-39
TM 55-1520-236-23
Table 8-10. Troubleshooting - Fuel Quantity Indicating System (Cont)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
STEP 3. Check for open lead on compensator circuit.
Repair wiring if defective.
STEP 4. Check for compensator section of tank unit open in accordance with paragraph 8-212 (AVIM).
Change tank unit if faulty (paragraph 8-220).
3. Indicator remains at one point on scale.
STEP 1. Check for no power in accordance with paragraph 9-131.
Repair 115 Vac power system (paragraph 9-125).
STEP 2. Check for defective indicator by substitution of known good indicator in accordance with paragraph
8-212 (AVIM).
Replace indicator if defective (paragraph 8-1).
STEP 3. Check for grounded coaxial lead.
Check wiring and/or replace indicator assembly.
4. Indicator remains at zero or below.
STEP 1. Check for open wiring.
Repair or replace wiring.
STEP 2. Check for defective indicator by substitution of known good indicator or in accordance with
paragraph 8-212 (AVIM).
Replace indicator if defective (paragraph 8-1).
5. Indicator operation is sluggish.
STEP 1. Check for low insulation of the circuit in accordance with paragraph 8-212 (AVIM).
Repair or replace wiring and/or tank unit (paragraph 8-220).
8-40
TM 55-1520-236-23
8-212. FUNCTIONAL TEST - FUEL QUAN- c. Indicator Test.
TITY INDICATING SYSTEM - BENCH
(1) Set up test circuit (figure 8-4).
(AVIM).
NOTE (2) Set up capacitance of 223.8 pF on tank unit
section of tester and 50.7 pF on compensator section.
Refer to paragraph 8-212.1 when using Adjust empty control until pointer reads zero.
Tester T79.1.
(3) Set tank unit section of tester to 480.0 pF and
leave compensator section set at 50.7 pF. Adjust full
a. Tank Unit Capacitance Test. Use capacitance
control until pointer reads 1975 pounds.
bridge section of field calibration unit (T79), or equivalent,
to measure capacitance between the coaxial and 400 (4) With compensator section set at 50.7 pF, vary
Hertz receptacles, and also between the coaxial and tank unit section of tester so that pointer reads at gradua-
compensator receptacles. When measuring the tank tions shown. Capacitance must be as shown opposite
unit section on 381075-008 tank unit, ground compen- indicator reading.
sator 400 Hertz connection. When measuring the com-
pensator section, ground tank unit 400 Hertz connection.
Ground tank unit flange to the measuring device while
measuring capacitance. The unit capacitances should
be as shown below. (Refer to figure 8-3).
Tolerance of measuring equipment must
be taken into consideration in making all
capacitance measurements
b. Tank Unit Insulation Resistance Test. Using
the three wire insulation resistance tester, or insulation
resistance section of field calibration unit (179), mea-
sured insulation resistance between points listed below. (5) Cause Minor to travel from 0 to 1975
The mounting flange is considered ground. pounds and from 1975 to 0 pounds. The travel time must
not be more than 30 seconds.
(1) Center of coaxial connector to ground - not
less than one megohm. (6) Adjust tester so that indicator is upscale.
Close test switch. Indicator should go to zero. Release
(2) Center of 400 Hertz connector to ground - not test switch. Pointer should go back to its original posi-
less than one megohm. tion.
(3) Center of compensator connector to ground - d insulation Resistance Test. After all tank units
not less than one megohm. and wiring have been installed in helicopter, test the
insulation resistance of circuits. Use a three-wire insula-
(4) Center of coaxial connector to center of 400 tion resistance tester and make the following insulation
Hertz connector of tank unit 381075-008- not less than resistance tests at the amphenol connector. Disconnect
650 megohms. connector from indicator prior to making tests and recon-
nect after tests are completed.
(5) Center of coaxial connector to center of 400
Hertz connector of tank unit 381065-007- not less than (1) Between compensator (Pin D) and ground (pin
850 megohms. J) - not less than one megohm.
(6) Center of maxial connector to center of com- (2) Between coaxial and ground - not less than
pensator connector - not less than 3500 megohms. one megohm.
Change 21 8-41
TM 55-1520-236-23
209475-373
Figure 8-3. Test Circuit Setup For Fuel Tank Unit Capacitance and Resistance Tests
8-42 Change 7
TM 55-1520-236-23
(3) Between 400 Hertz (pin H) and ground - not Table 8-11. Fuel Tank Table of Limits
less than one megohm.
a. Tank Unit Empty Capacitance Values.
(4) Between coaxial and 400 Hertz (Pin H) - not
less than 350 megohms. Circuit Capacitance
(5) Between coaxial and compensator (Pin D) - Tank Unit (Dry) 223.8 2.3 pF
not less than 3000 megohms.
Compensator Section (Dry) 25.0 0.5 pF
(6) Between 400 Hertz (Pin H and
compensator (pin D) - not less than 10 megohms. b. Added and Full Capacitance Values.
(7) Use bridge section of field calibration unit
(T79), or equivalent, to measure capacitance of tank Capacitance Indicator Readings
circuit. Ground compensator lead (Pin D) at indicator
when measuring tank section, and ground tank Added Full (Pounds)
section (Pin H) at indicator when measuring the
compensator. The values should be as listed in Table 256.2 480.0 1975
8-11.
e. Adjustment Procedure - Preferred Method (3) Turn EMPTY control until indicator reads
With Fuel Tanks Empty. Adjust fuel tank gage as exactly zero.
follows:
(1) Check that all connecting cables and units (4) Connect field calibration unit (T79), or
have been installed properly, and connections are equivalent, in parallel with helicopter wiring (figure
tight. 8-5).
(2) Make sure all tanks are empty and turn on
(5) Set compensator section of tester to 25.7
power.
pF and the tank unit section to 256.2 pF.
(6) Adjust "FULL control on indicator to cause
pointer to read at last dial division (1975 pounds).
(7) Disconnect adapter cable and reconnect
airframe wiring to indicator.
f. Adjustment Procedure - Alternate Method
With Fuel in Tanks.
(1) Disconnect amphenol connector at
indicator and insert adapter cable (figure 8-5).
Connect field calibration unit (T79) and leave cables
marked 1, 2, and 3 disconnected.
(2) Set compensator section of tester to 50.7
pF and tank unit section to 223.8 PF. Adjust the
EMPTY control on indicator to cause pointer to read
zero.
Figure 8-4. Test Circuit Setup For
(3) Leave compensator section set at 50.7 pF
Fuel Quantity Indicator Bench Test and set tank unit section to 480.0 pF. Adjust FULL
Change 9 8-43
TM 55-1520-236-23
Figure 8-5. Circuit Arrangement and Adapter Cable for Fuel Quantity Adjustment
Procedures On Installed System
control so that indicator pointer reads at last dial NOTE
division (1975 pounds).
The fuel quantity system operational
8-212.1. Test/Adjust-Fuel Quantity check can be used in either of two
ways. The preferred method shall be
System (AVIM). used when the fuel tanks can be
drained. The alternate method will be
used when conditions do not allow
fuel tanks to be drained i.e. combat/
mobilization. Though the alternate
Do not use any fuel quantity tester method is considered adequate it is
other than the PSD60-1AF with this possible for resdue to be trapped in
procedure. the probe area which could indicate
a false quantity.
a. Capacitance Test Using Tester (T79.1) and
"T" cable (T79.2) Preferred Method Empty Tanks.
Never connect a fuel gauge or signal (1) Ground aircraft to earth ground.
conditioner unit (SCU) to an electri-
cally live connector. (2) Completely drain sump and fuel tank(s) to
be calibrated.
(3) Verify that inverter which powers fuel
quantity indicator is turned off.
If a circuit breaker pops during cal-
ibration or troubleshooting, a short
circuit is indicated. Correct fault be-
fore reapplying power. Always ground the tester to a good,
clean aircraft ground Do not connect
ground wire behind circuit breaker
panels or near any exposed power
termination.
Use only authorized test equipment (4) Connect tester chassis jack (J-7, fiigure
to test, troubleshoot and calibrate 8-5.1) to airframe ground using ground leads-
the fuel quantity system. Shop tes- plied with tester.
ters including multimeters and meg/
ohmeters, are not certified safe for (4) Lift to unlock tester ON-OFF switch and
use on any wiring to the fuel tank. turn to "ON" position. If words LO BAT appear in
8-44 Change 21
TM 55-1520-236-23
upper left-hand comer of LCD display (D-3) re- NOTE
place batteries in tester.
If tank capacitance is out of toler-
ance, check for trapped fuel at fuel
(6) Allow tester to warm up for at least 3 min-
drain.
utes before using.
(18) The tank unit capacitance should be as
(7) Connect "T cable (figure 8-5.2) LOZ, shown below:
HIZ, and Comp leads to TANK UNITS terminals
(J-4, J-5, and J-6 figure 8-5.1) respectively on
tester.
(8). Rotate tester FUNCT switch (S-2) to
MEASURE EXT position.
(9) Rotate tester SELECT switch(S-3) to
"TU" POSITION.
(10) Switch TANK IN/OUT switch on "T" cable
to the IN position.
(19) Rotate SELECT switch (S-3) on tester to
NOTE "COMP" position. Read capactiance of compensa-
tor PIUS cable capacitance on tester LCD. Record
Worksheet figure 6-5.3 is to be local-
on worksheet line 4.
Iy reproduced.
(20) Subtract cable capacitance measured in
(11) Read capacitance of "TU" test leads. If step 12 above from reading in step 19. Compensa-
reading is over.5 pf, repair or replace cable. Record tor capacitance must be between 24.5 pf and 25.5
capacitance on worksheet, line 1. pf. Record COMP capacitance on worksheet line 5.
(12) Rotate SELECT switch (S-3, figure (21) Rotate SELECT switch (S-3) on tester to
8-5.1) to COMP position. Read capacitance of "LOZ-HIZ" position.
COMP leads. If reading is over .5 pf, repair or re-
place cable. Record capactiance on worksheet, line NOTE
2.
(13) Loosen damp holding fuel quantity gauge
in instrument panel and remove gauge from panel.
(22) Verify that the tester LCD reads over 20
megohms in LOZ-HIZ position. Record reading
on line 7 of worksheet.
(23) Rotate SELECT switch (S-3) to the fol-
When disconnecting aircraft vviring lowing positions and verify that the tester LCD reads
cable from indicator hold cable to over 1 megohm in each position:
prevent retraction behind instrument
panel. LOZ-SHLD LOZ-GND
HIZ-SHLD HIZ-GND
(14) Disconnect aircraft wiring cable from fuel
Record reachings on fine 8 of worksheet.
quantity gauge.
(24) Rotate SELECT switch (S-3) to SHLD-
(15) Connect (J-1) of "T" cable to aircraft wir- GND position. Verify that LCD read-out indicates
ing connector removed from gauge. Do not connect O megohms.
to gauge.
(25) Disconnect T cable leads from tester
(16) Read capacitance of empty tank plus TANK UNITS terminals and connect to lNDlCA-
cable and record on worksheet line 3. TOR LOZ, HE and COMP terminals respec-
tively.
(17) Subtract capacitance of cable measured
in step 11 above from reaching in step 16. Capac- (26) Rotate tester FUNCT switch (S-2) to
tance must be between 221.5 pf and 226.5 pf. MEASURE INT" position.
Change 21 8-44.1
TM 55-1520-236-23
(27) Rotate SELECT switch (S-3) to the (46) Reconnect indicator aircraft wiring and
COMP position. reinstall in panel.
(28) Set COMP simulator decade (D-2) to b. Capacitance Test Using Tester (T79.1) and
read 00. "T" cable (179.2) Alternate Method Fuel In Tanks.
(1) Ground aircraft to earth ground.
(29) Adjust COMP vernier (V-2) to read 25.7
pf on tester LCD display. (2) Verify that inverter which powers fuel
quantity indicator is turned off.
(30) Rotate SELECT switch (S-3) to "TU"
position.
(31) Set TU simulator decade (D-1) to read
023.
Always ground the tester to a good,
(32) Adjust TU vernier (V-1) to read 256.2 pf clean aircraft ground. Do not connect
on tester LCD display. ground wire behind circuit breaker
panels or near any exposed power
(33) Rotate FUNCT switch (S-2) to AIR- termination.
CRAFT ONLY position.
(3) Connect tester chassis jack (J-7, figure
(34) Connect T cable (P-1) to fuel quantity 8-5.1) to airframe ground using ground lead sup-
indicator. plied with tester.
(4) Lift to unlock tester ON-OFF switch and
(35) Turn on inverter to power indicator.
turn to ON position. If words LO BATT appear in
upper left-hand comer of LCD display (D-3) re-
place batteries in tester.
(5) Allow tester to warmup for at least 3 min-
If a circuit breaker pops during cal- utes before using.
ibration or troubleshooting, a short
circuit Is indicated. Correct fault be- (6) Connect "T" cable (figure 8-5.2) "LOZ",
fore reapplying power. HIZ, and Comp Ieds to TANK UNITS terminals
(J-4, J-5, and J-8, figure 8-5.1) respectively on
(36) Press and release indicator test switch on tester.
instrument panel.
(7) Rotate tester FUNCT switch (S-2) to
(37) Adjust E trimmer at lower left (viewed "MEASURE EXT" position.
from front of gauge) until pointer reads 0 lb.
(8) Rotate tester SELECT switch (S-3) to
(36) Repeat steps 36 and 37 above until point- "TU" POSITION.
er returns to 0 lb. (9) Switch TANK IN/OUT switch on "T" cable
to the IN position.
(39) Rotate FUNCT SWITCH (S-2) on tester
to SIM TU & COMP position. NOTE
(40) Adjust F trimmer at lower right (viewed Worksheet figure 8-5.3 is to be local-
from front of gauge) until pointer reads 1975 lb. Iy reproduced.
(41) Press and release indicator test switch on (10) Read capacitance of "TU" test leads. If
instrument panel. realing is over .5 pf, repair or replaceable. Record
capacitance on worksheet, line 1.
(42) Repeat steps 40 and 41 until pointer re-
turns 1975 lb. (11) Rotate SELECT switch (S-3, figure
8-5.1) to COMP position. Red capacitance of
(43) Repeat steps 32 through 36 above. COMP leak. If reading is over .5 pf, repair or re-
place cable. Record capacitance on worksheet, line
(44) Turn inverter off. 2.
(45) Disconnect "T" cable from gauge and (12) Loosen damp holding fuel quantity gauge
from aircraft wiring. in instrument panel and remove gauge from panel.
8-44.2 Change 21
TM 55-1520-236-23
(26) Adjust TU vernier (V-1) to read 223.8 pf
on tester LCD display.
When disconnecting aircraft wiring (27) Rotate FUNCT switch (S-2) to "SIM TU
cable from indicator hold cable to & COMP" position.
prevent retraction behind instrument (28) Connect "T" cable (P-1) to fuel quantity
panel.
indicator.
(13) Disconnect aircraft wiring cable from fuel
(29) Switch the TANK IN/OUT switch on the
quantity gauge.
interface cable to the "OUT" position.
(14) Connect (J-1) of "T" cable to aircraft wir-
ing connector removed from gauge. Do not connect (30) Turn on inverter to power indicator.
to gauge.
(15) Rotate SELECT switch (S-3) on tester to
LOZ-HIZ position.
If a circuit breaker pops during cal-
NOTE
ibration or troubleshooting, a short
circuit is indicated. Correct fault be-
fore reapplying power.
(31) Press and release indicator test switch on
instrument panel.
(16) Verify that the tester LCD reads over 20
megohms in LOZ-HIZ position. Record readings (32) Adjust E trimmer at lower left (viewed
on line 3 of worksheet from front of gauge) until pointer reads 0 lb.
(17) Rotate SELECT switch (S-3) to the fol- (33) Repeat steps 31 and 32 above until point-
lowing positions and verify that the tester LCD reads er returns to 0 lb.
over 1 megohm in each position:
(34) Rotate FUNCT switch (S-2) on tester to
"LOZ-SHLD" "LOZ-GND" MEASURE INT position.
HIZ-SHLD HIZ-GND
(35) Set TU simulator decade (D-1) to red
Record readings on line 4 of work- "046".
sheet
(36) Adjust TU vernier (V-1) to read 460.0 pf
(18) Rotate SELECT switch (S-3) to SHLD- on tester LCD display.
GND position. Verify that LCD read-out indicates
0 megohms. (37) Rotate FUNCT switch (S-2) to SIM TU
& COMP position.
(19) Disconnect "T" cable leads from tester
TANK UNITS terminals and connect to INDlCA- (38) Adjust F" trimmer at lower right (viewed
TOR LOZ, HIZ and COMP terminals respec- from front of gauge) until pointer reads 1975 lb.
tively.
(39) Press and release indicator test switch on
(20) Rotate tester FUNCT switch (S-2) to instrument panel.
MEASURE INT position.
(40) Repeat steps 38 end 39 until pointer re-
(21) Rotate SELECT switch (S-3) to the turns to 1975 lb.
COMP position.
(41) Rotate FUNCT switch (S-2) on tester to
(22) Set COMP simulator decade (D-2) to MEASURE INT" position.
read "03".
(42) Repeat steps 25 through 32 above.
(23) Adjust COMP vernier (V-2) to read 50.7
pf on tester LCD display. (43) Turn inverter off.
(24) Rotate SELECT switch (S-3) to "TU" (44) Disconnect "T" cable from gauge and
position. from aircraft wiring.
(25) Set TU simulator decade (D-1) to read (45) Reconnect indicator to aircraft wiring and
"020". reinstall in panel.
Change 21 8-44.3
TM 55-1520-236-23
J-1 LoZ output to indicator S-1 Power ON-OFF switch
J-2 HiZ output to indicator S-2 Function select switch
J-3 Comp LoZ out to indicator S-3 Cap-Meg select switch
J-4 Tank Unit Loz input S-4 Lid-close power OFF sw
J-5 Tank Unit HiZ input S-5 Press for 2-terminal
J-6 Tank Unit Comp input megger readings
J-7 Airframe ground jack S-6 X-10 range switch
D-1 Tank Unit simulator decade V-1 TU simulator vernier
D-2 Compressor sim decade V-2 TU simulator vernier
D-3 Liquid Crystal Display (LCD)
Figure 8-5.1 Fuel Quantity Test Set P/N PSD60-1AF
8-44.4 Change 21
TM 55-1520-236-23
Figure 8-5.2 Fuel Quantity T Cable P/N PSDAF-537
Change 21 8-44.5
TM 55-1520-236-23
FIGURE 8-5.3 FUEL QUANTITY CALIBRATION WORKSHEET
8-44.6 Change 21
TM 55-1520-236-23
8-213. FUEL QUANTITY INDICATOR. 8-218. REPAIR - FUEL QUANTITY lNDlCA-
TOR.
8-214. Description-Fuel Quantity Indicator. The fuel
quantity indicator provides indications of fuel quantity in Repair fuel quantity indicator in accordance with para-
total pounds. The indicator is connected to two fuel quan- graph 8-6.
tity transmitters and powered by 115 Vac essential bus.
figure 8-1
8-219. INSTALLATION - FUEL QUANTITY
Refer to paragraph F-9 in Appendix F for equipment
INDICATOR.
location chart.
Install fuel quantity indicator in accordance with para-
8-215. CLEANING - FUEL QUANTITY INDl- graph 8-7.
CATOR.
Clean fuel quantity indicator in accordance with para- 8-220. FUEL QUANTITY TRANSMITTERS.
graph 8-3.
8-221. DESCRIPTION - FUEL QUANTITY
8-216. INSPECTION - FUEL QUANTITY lN- TRANSMITTERS.
DICATOR. Two fuel quantity transmitter probes are installed, one
Inspect fuel quantity indicator in accordance with para- each in the forward and aft fuel cells, and are electrically
graph 8-4. connected to the fuel quantity indicating system. Exter-
nal ends of the transmitters are located in the hydraulic
reservoir compartment at left side, and in the transmis-
8-217. REMOVAL - FUEL QUANTITY lNDl-
sion compartment deck below the induction baffle and
CATOR. figure 8-1
paragraph F-9
Remove fuel quantity indicator in accordance with para-
graph 8-5. Appendix F for equipment Iocation chart.
Change 21 8-44.7/(8-44.8 blank)
8-222. CLEANING - FUEL QUANTITY f. Open transmission cowling and remove air
TRANSMlTTERS. induction baffle for access to aft fuel quantity
transmitter.
a. Remove moisture and loose dirt with a clear
soft cloth. g. Remove transmitter in same manner as for
forward unit. (Refer to steps (b), (c), and (e).)
8-225. REPAIR - FUEL QUANTITY
TRANSMITTERS.
a. Repair damaged electrical connections.
Cleaning solvent is flammable and toxic.
Provide adequate ventilation. Avoid
b. Replace transmitter if cracked.
prolonged breathing of solvent vapors
and contact with skin or eyes.
c. Reinstall improperly mounted transmitter.
b. Remove oil, grease, fungus, and ground-in dirt 8-226. INSTALLATION - FUEL QUANTITY
with a clean, lint-free cloth dampened with dry TRANSMITTERS.
cleaning solvent (C112).
NOTE
c. Remove dirt from electrical connectors with a
bristle brush. Forward and aft transmitters install in the
d. Carefully clean the flange and connector housing same manner, except for location and
of any residue pro-seal. parts removed for, access.
a. Uncover fuel cell port. Place a new pack-
8-223. INSPECTION - FUEL QUANTITY ing i n g r o o v e o f t r a n s m i t t e r mounting
TRANSMlTTERS. flange. Insert transmitter carefully into
cell. Install frangible clips for aft cell at aft and
right side bolts. On forward fuel cell install
a. Inspect pressure transmitter for cracks, secure
frangible clips a t f o r w a r d a n d r i g h t s i d e
and proper mounting, and proper operation. bolts. Install bolts and washers. Add bead of
sealant around periphery of part.
b. Inspect fuel line and fitting connection for leaks
and proper, installation. b. 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 s t o t r a n s m i t -
ter. Perform a functional fuel quantity in-
dicating system test. (Refer to paragraph 8-212.)
c. Inspect electrical connector for damaged or
bent pins and cracked inserts. c. Apply a bead of pro-seal (C105) at the mating sur-
face of the connector housing and the flange.
8-224. REMOVAL - FUEL QUANTITY d. Reinstall parts removed for access. Close cowling
TRANSMlTTERS. or access doors.
a. O p e n l e f t d o o r o f h y d r a u l i c r e s e r v o i r 8-227. TRANSMISSION OIL
compartment for access to forward fuel quantity TEMPERATURE AND PRESSURE
transmitter. INDICATING SYSTEM.
b. D i s c o n n e c t electrical connectors from 8-228. DESCRIPTION - TRANSMISSION
transmitter. OIL TEMPERATURE AND PRESSURE
INDICATING SYSTEM.
c. Remove ram air intake duct.
The transmission oil temperature and pressure
d. Move ECU as required (paragraph 13-5). indicating system consists of the transmission oil
temperature and pressure indicator, transmission oil
e . Remove four bolts and washers from mounting pressure transducer, and an electrical resistance type
flange, and remove the two frangible clips. Carefully thermobulb. The system is powered from the 28 Vdc
withdraw transmitter upward from fuel cell, tilting as essential bus and protected by a 5 ampere TEMP IND
necessary for clearance. Cover open port. ENG/XMSN circuit breaker.
Change 9 8-45
TM 55-1520-236-23
8-229. TROUBLESHOOTING - 8-237. INSTALLATION - TRANSMISSION
TRANSMISSION OIL TEMPERATURE AND OIL TEMPERATURE AND PRESSURE
PRESSURE INDICATING SYSTEM. INDICATOR.
Troubleshoot system in accordance with procedures Install indicator in accordance with paragraph 8-7.
contained in Table 8-2.
8-238. TRANSMISSION OIL
8-230. TRANSMISSION OIL PRESSURE TRANSDUCER.
TEMPERATURE AND PRESSURE
INDICATOR. 8-239. DESCRIPTION - TRANSMISSION
OIL PRESSURE TRANSDUCER.
8-231. DESCRIPTION - TRANSMISSION
The transmission oil pressure transducer, located on
OIL TEMPERATURE AND PRESSURE
right side of transmission, monitors transmission oil
INDICATOR.
pressure and transmits voltage signals to the
The transmission oil temperature and pressure transmission oil pressure indicator. ~ Refer to
indicator, located in pilot instrument panel, indicates figure 8-1 for equipment locations. @ Refer to
transmission oil pressure in psi and oil temperature in paragraph F-9 in Appendix F for equipment location
degrees celsius. The indicator is powered from the 28 chart.
Vdc essential bus and protected by a 5 ampere TEMP
IND ENG/XMSN circuit breaker. 8-240. CLEANING - TRANSMISSION OIL
PRESSURE TRANSDUCER.
8-232. CLEANING - TRANSMISSION OIL Clean transducer in accordance with paragraph 8-69.
TEMPERATURE AND PRESSURE
INDICATOR. 8-241. INSPECTION TRANSMISSION OIL
PRESSURE TRANSDUCER.
Clean indicator in accordance with paragraph 8-3.
Inspect transducer in accordance with paragraph
8-233. INSPECTION TRANSMISSION OIL 8-70.
TEMPERATURE AND PRESSURE
INDICATOR. 8-242. FUNCTIONAL TEST -
TRANSMISSION OIL PRESSURE
Inspect indicator in accordance with paragraph 8-4. TRANSDUCER.
Functional test transducer in accordance with
8-234. FUNCTIONAL TEST paragraph 8-71.
TRANSMISSION OIL TEMPERATURE AND
PRESSURE INDICATOR. 8-243. REMOVAL - TRANSMISSION OIL
PRESSURE TRANSDUCER.
Functional test indicator in accordance with
paragraphs 8-62 and 8-63. a. Remove cowling from transmission.
8-235. REMOVAL - TRANSMISSION OIL b. Disconnect electrical connector.
TEMPERATURE AND PRESSURE
INDICATOR. c. Cut Iockwire and remove transducer.
Remove indicator in accordance with paragraph 8-5. d. Cap openings in manifold and protect electrical
connector with cap or tape.
8-236. REPAIR - T R A N S M I S S I O N O I L
TEMPERATURE AND PRESSURE 8-244. REPAIR - T R A N S M I S S I O N O I L
INDICATOR. PRESSURE TRANSDUCER.
Repair indicator in accordance with paragraph 8-6. a. Repair damaged electrical connectors.
8-46
TM 55-1520-236-23
b. Replace pressure transducer if cracked or 8-251. REPAIR - TRANSMISSION OIL
damaged. TEMPERATURE BULB.
c. R e i n s t a l l improperly mounted pressure Repair temperature bulb in accordance with
transducer. paragraph 8-80.
8-252. FUNCTIONAL TEST -
8-245. INSTALLATION - TRANSMISSION TRANSMISSION OIL TEMPERATURE BULB
OIL PRESSURE TRANSDUCER. - BENCH (AVIM).
a. Install packing and lubricate with oil (C88 or Functional test transmission bulb in accordance with
C89). paragraph 8-81.
b. Remove protective caps or tape and install 8-253. INSTALLATION - TRANSMISSION
transducer. OIL TEMPERATURE BULB.
c. Install Iockwire (137). Install temperature bulb in accordance with
paragraph 8-82.
d. Connect electrical connector.
8-254. VOLTEMETER/AMMETER.
e. Install cowling.
8-255. DESCRIPTION - VOLTMETER/
AMMETER.
8-246. TRANSMISSION OIL
TEMPERATURE BULB. The dc voltmeter, which is in the same case with
ammeter, monitors and indicates voltage of the 28
8-247. DESCRIPTION - TRANSMISSION Vdc essential bus. The dc voltmeter is protected by a 5
OIL TEMPERATURE BULB. ampere DC VM circuit breaker. The dc ammeter
indicates output in amperes of the generator portion
The transmission oil temperature bulb, installed in
of starter-generator. The dc ammeter is protected by
transmission oil manifold, monitors transmission oil
two 5 ampere circuit breakers, one wired in series
temperature and transmits voltage signals to the
with positive lead, and the other wired in series with
transmission oil temperature and pressure indicator. negative lead. The two dc ammeter circuit breakers
Refer to figure 8-1 for equipment locations.
are located in aft compartment below the generator-
IF f e r t o p a r a g r a p h F - 9 i n A p p e n d i x F f o r
R e
ammeter shunt.
equipment location chart.
8-256. CLEANING - VOLTMETER/
8-248. CLEANING - TRANSMISSION OIL AMMETER.
TEMPERATURE BULB.
Clean voltmeter/ammeter in accordance with
Clean temperature bulb in accordance with paragraph 8-3.
paragraph 8-77.
8-257. INSPECTION - VOLTMETER/
AMMETER.
8-249. INSPECTION - TRANMISSION OIL Inspect voltmeter/ammeter in accordance with
TEMPERATURE BULB. paragraph 8-4.
Inspect temperature bulb in accordance with 8-258. TROUBLESHOOTING -
paragraph 8-78. VOLTMETER/ AMMETER.
8-250. REMOVAL - TRANSMISSION OIL Use table 8-12 and perform necessary checks to
TEMPERATURE BULB. isolate trouble. Refer to paragraph F-9 for wiring
diagram. Broken or shorted wiring is always a
Remove temperature bulb in accordance with probable cause of malfunction or failure and has not
paragraph 8-79. been included.
8-47
TM 55-1520-236-23
NOTE
Before you use this table, be sure you
have performed all normal operational
checks. If you have a malfunction which
is not listed in this table, notify the next
higher level of maintenance,
Table 8-12. Troubleshooting Voltmeter/Ammeter
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. Indicator has no reading or erratic reading.
STEP 1. Check for open or short circuit in instrument by substitution of known good instrument.
Replace indicator if defective (paragraph 8-1).
STEP 2. Check for dirty or worn mechanism in instrument by substitution of known good instrument.
Replace indicator if defective (paragraph 8-1).
STEP 3. Check for instrument scale error in accordance with paragraph 8-261 (AVIM).
Make adjustments to indicator (paragraph 8-261).
8-259. REMOVAL - VOLTMETER/ (2) Dc millivoltmeter, 0 to 50 millivolts with
AMMETER. 1/2 millivolt accuracy or better.
Remove voltmeter/ammeter in accordance with (3) Variable dc voltage source, 0 to 30 volts and
paragraph 8-5. sufficient current capability to drive the reference
meter.
8-260. R E P A I R - VOLTMETER/
AMMETER.
b. Test Procedure.
Repair voltmeter/ammeter in accordance with
paragraph 8-6. (1) Connect the equipment as shown in figure
8-6.
8-261. FUNCTIONAL TEST
VOLTMETER/ AMMETER - BENCH (AVIM). (2) With zero input to the voltmeter, adjust the
mechanical zero adjustment so that it indicates zero.
a. Test Equipment Required (figure 8-6). (For P/N 260173 only.)
(1) Dc voltmeter, 0 to 30 volt with 1/4 volt (3) With 50 millivolts input to ammeter, adjust
accuracy or better. mechanical zero adjustment so that it indicates 3 0 0
amperes. (For P/N 260173 only.)
8-48 Change 16
TM 55-1520-236-23
Figure 8-6. Volt-Ammeter Test Set-Up
c. Movement Balance Test. 8-262. INSTALLATION - VOLTMETER/
AMMETER.
(1) Adjust voltage source so that volt-ammeter
indicates any convenient reading on scale. Install voltmeter/ammeter in accordance with
paragraph 8-7.
(2) Rotate instrument so that pointer is vertical
and note indication. 8-263. CLOCK.
(3) R o t a t e i n s t r u m e n t s o t h a t p o i n t e r i s 8-264. DESCRIPTION - CLOCK.
horizontal and note indication.
The clock, located on pilot instrument panel, is an 8
(4) The difference between indications noted in day clock with added stopwatch feature for elapsed
steps (b) and (c) should not exceed two percent of full time. The clock has a sweep-second pointer and a
scale. minute totalizer hand to indicate elapsed time. A
control knob on the case starts pointers when
d. Friction Test. Vary voltage source so that pressed, stops both pointers when pressed a second
indication of the volt-ammeter varies from zero to full time, and returns to 12 oclock when pressed a third
scale. If any signs of pointers sticking are observed, time. A separate control knob winds and sets the
stop and note indication before and after tapping clock.
meter. The friction error should not exceed two
percent of full scale.
8-265. CLEANING - CLOCK.
e. Scale Error Test.
Clean clock in accordance with paragraph 8-3.
NOTE
8-266. INSPECTION - CLOCK.
Support instrument in its normal
operating position and tap or vibrate Inspect clock in accordance with paragraph 8-4.
instrument before each reading.
(1) Adjust voltage source so that master meter 8-267. REMOVAL - CLOCK.
indicates a convenient value. Note indication of the
volt-ammeter; it should not exceed two percent of Remove clock in accordance with paragraph 8-5.
master meter indication.
8-268. INSTALLATION - CLOCK.
(2) Repeat step (1) above at a minimum of five
equally spaced intervals over range of volt-ammeter. Install clock in accordance with paragraph 8-7.
8-49
TM 55-1520-236-23
8-269. ~ q PILOT STEERING TOW missile subsystem. The pilot steering indicator
INDICATOR (PSI). provides pilot with steering information for prelaunch
helicopter alignment or postlaunch maneuver. The
8-270. ~ D E S C R I P T I O N - PILOT PSI also indicates status of attack and constraint
STEERING INDICATOR (PSI). boundaries. The visual display indicators and their
functions are as follows:
The pilot steering indicator, mounted on top center of
pilot instrument panel, is a component of the M65
Indicator Function
ATTK annunciator. Indicates when M65 is in attack mode.
RDY annunciator. Indicates when M65 is in fire mode and pilot is flying within
prelaunch constraints.
FIRE annunciator. Indicates that gunner has initiated missile launch sequence.
Sightline position bars. Vertical and horizontal bars indicate azimuth and elevation
position of sightline with respect to helicopter reference
axis and the prelaunch constraints boundary.
Reference ring. Indicates helicopter reference axis.
Azimuth angle markers. Fixed TSU azimuth angle limit references.
Course scale azimuth pointer. Indicates TSU angular azimuth position within fixed angle limit
references
Ascend-descend pointers Indicates to pilot how to fly the pitch plane of helicopter in
prelaunch condition. When helicopter flight path needs correction, only
pointer which indicates correction sense will be displayed.
Prelaunch constraint boundary. Indicates boundary within which pilot must keep sightline position
bars during attack and fire modes.
Postlaunch constraint boundary. Indicates boundary within which pilot must keep sightline position bars
during maneuver mode.
The PSI visual display indicators are energized and 8 - 2 7 2 . ~~ I N S P E C T I O N - P I L O T
actuated by the stabilization control amplifier (SCA). STEERING INDICATOR (PSI).
For additional information of M65 TOW missile
subsystem, refer to TM 9-1425-473 series a. Inspect for loose, cracked, or broken cover
maintenance manuals. glass.
8-271. ~ q CLEANING - PILOT b. Inspect for security of mounting.
STEERING INDICATOR (PSI).
8-273. m~ FUNCTIONAL TEST - PILOT
a. Remove dust and clean indicator cover glass STEERING INDICATOR (PSI).
with a clean, soft, lint-free cloth.
The PSI operational check is conducted asa portion of
b. Remove moisture with a clean, lint-free, dry the M65 TOW missile subsystem operational test
cloth. procedures. Refer to paragraph 9-427, 9-464.
8-50
TM 55-1520-236-23
8-274. ~ ~ T R O U B L E S H O O T I N G - Use table 8-13 and perform necessary checks to
PILOT STEERING INDICATOR (PSI). isolate trouble. Refer to paragraph F-9 in Appendix F
for wiring diagram.
NOTE
Before you use this table, be sure you
have performed all normal operational
checks, If you have a malfunction which
is not listed in this table, notify the next
higher level of maintenance.
Table 8-13. ~ ~ Troubleshooting Pilot Steering Indicator (PSI)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. One or more visual indicators inoperative.
STEP 1. Check for defective wiring from PSI to SCA
Check continuity of wiring; repair defective wiring.
STEP 2. Check for defective connector at PSI, tailboom disconnect, or SCA.
Repair or replace defective connectors.
STEP 3. Check for defective PSI by substitution of known good indicator or perform test in accordance with
paragraph 8-273.
Replace indicator if defective (paragraph 8-1).
8 - 2 7 5 . ~~ R E M O V A L - PILOT 8-276. ~ ~ REPAIR - PILOT STEERING
STEERING INDICATOR (PSI). INDICATOR (PSI).
a. Replace indicator if cover is loose, cracked, or
a. Ensure all system power is off. broken.
b. Remove mounting screws and carefully lift b. Replace indicator if inoperative, defective, or
indicator out of shroud just far enough to expose damaged.
electrical connector at rear of indicator.
8-277. ~ ~ I N S T A L L A T I O N - P I L O T
STEERING INDICATOR (PSI).
c. Disconnect electrical connector.
a. Remove protective cap from electrical
d. Cap electrical connector on indicator and connector on indicator and remove protective tape
protect disconnected plug with electrical tape (C121). from indicator plug.
8-51
TM 55-1520-236-23
b. Connect indicator plug to PSI and carefully 8-284. n DESCRIPTION - PROXIMITY
position PSI in place in mounting shroud. WARNING SYSTEM.
c. Install mounting screws. The proximity warning system consists of a receiver-
transponder (YG-1054), two antennas, and a
8-278. ~ HEAD UP DISPLAY connection to the helicopter static air line. This
SUBSYSTEM (HUDS). system provides the pilot and gunner with
audio/visual intrusion indications if a similarly
8-279. ~ DESCRIPTION - HEAD UP equipped aircraft is within a radius of 5000 feet and
DISPLAY SUBSYSTEM (HUDS). within an altitude band of plus or minus 300 feet. The
transmitter-receiver operates on a frequency of 5.08
The HUDS display helicopter situation and weapons GHz. A visual display consisting of flashing arrows
firing information in the pilot forward field of view. indicates the altitude of the intruding aircraft relative
The HUDS functions automatically asa part of the fire to the altitude of the helicopter. An audio signal from
control system. Operator control is limited to the proximity warning system is connected directly to
ON/OFF, day/night viewing settings, and mode the helicopter intercommunication system and will
selection. Refer to TM 9-1270-220-13 for be heard in all headsets. (Refer to TM 11-1520-236
description, operational check, troubleshooting, and series manuals for detailed description, operational
maintenance of the HUDS. check, troubleshooting, and maintenance of
proximity warning system components.)
8-280. ROUNDS REMAINING
INDICATOR. 8-284.1 ~ DESCRIPTION - LASER
DETECTOR SET (AN/AVR-2) (AFTER
Refer to TM 9-1090-203-12 series manuals. MWO 55-1520-236-50-23).
8-281. RADAR WARNING SYSTEM The laser detecting system consists of fiie components:
(AN/APR-39) (PROVISIONS). four Sensors and a Comparator. The system interfaces
with the Radar Warning System (APR-39) and receives
8-282. DESCRIPTION - RADAR power-on and self-test commands from the radar
WARNING SYSTEM. warning control. Laser threat and missile alert
information is displayed on the radar warning indicator
Provisions for the radar warning system is provided (CRT). The AVR-2 comparator monitors and processes
for pilot. The radar warning system provides pilot with
signal lines from the APR-39 and controls information
both visual and audible warning when a high radar
displayed on the radar warning indicator. In the event of
threat environment is encountered. The system is
effectively operated by use of a control (located on simultaneous warnings from both radar warning and
pilot right console) and an indicator on instrument laser detecting sets, the laser detecting signals have
panel. Refer to TM 11-1520-236-20 for description, priority. Together the two systems provide early warning
operational check, troubleshooting, and maintenance against radar and laser threats. Refer to TM 11-1520-
of system components. Refer to paragraphs 8-3 236-23 for detailed description, operational check,
through 8-7 for instrument maintenance. troubleshooting, and maintenance of system
components.
8-283. ~ PROXIMITY WARNING
SYSTEM.
SECTION VI. INSTRUMENT PANELS
8-285. INSTRUMENT PANELS. center section of respective console and contain
instruments for pilot and gunner. Each instrument
8-286. DESCRIPTION - INSTRUMENT panel is mounted to the formed center section of the
PANELS. respective console by mounting screws or shock
mounts, located around edge of panel. No adjustment
The instrument panels are mounted on forward of instrument panel is required.
8-52
TM 55-1520-236-23
8-287. CLEANING - INSTRUMENT d. Cover openings in instruments.
PANELS.
e. Remove mounting hardware and lift panel from
a. Remove moisture and loose dirt with a clean, helicopter.
soft cloth.
8-290. REPAIR - INSTRUMENT PANELS.
a. Repair cracks in accordance with TM 55-1500-
204-25/1.
Cleaning solvent is flammable and toxic.
b. Replace shock mount if warped.
Provide adequate ventilation. Avoid
prolonged breathing of solvent vapors
and contact with skin or eyes. c. Replace loose or worn mounting screws.
b. Remove grease, fungus, and ground-in dirt d. Touchup paint if damaged or deteriorated,
with a clean, lint-free cloth dampened with dry using primer (C88) and lacquer (C65) in accordance
cleaning solvent (C112). with TB 746-93-2.
8-288. INSPECTION - INSTRUMENT
PANELS. 8-291. INSTALLATION - INSTRUMENT
PANELS.
Visually inspect panels for surface scratches,
warpage, cracks, and loose mounting screws. a. Install shock mounts if removed.
8-289. REMOVAL - INSTRUMENT b. Position panel in place on console and install
PANELS. mounting hardware.
a. Ensure all electrical power is off. c. Connect electrical receptacles to instruments.
b. Disconnect all electrical receptacles and hoses d. Apply silicone compound (C110) to threads of
from instruments. pitot-static fittings.
c. Cover all receptacles and hoses to prevent e. Connect nylon fittings, Torque coupling nuts
entrance of foreign particles. finger tight.
U.S. GOVERNMENT PRINTING OFFICE: 1992- 654-029/65055 Change 17 8-53/(8-54 blank)
TM 55-1520-236-23
CHAPTER 9
ELECTRICAL SYSTEMS
SECTION I. ELECTRICAL SYSTEMS MAINTENANCE
9-1. ELECTRICAL SYSTEMS 9-3. q EMERGENCY DC POWER.
MAINTENANCE.
In the event of starter-generator failure, dc power is
supplied by the 24 volt, 22 ampere/hour battery
(2BT1). The battery, assuming an 85 percent charge,
can supply the essential loads under emergency
Ensure armament system is safe conditions for a period of approximately 20 minutes.
before performing electrical
operational checks. (Refer to
WARNING page.)
9-4. EMERGENCY AC POWER.
a. q In the event of main inverter failure, ac
power is supplied by the 115 volt, 250 volt/ampere,
Before performing any maintenance 4 0 0 H z , r o t a r y , single-phase standby inverter
checks on electrical panel which re- (3MG1), The standby inverter is powered from the
quire power be applied to the panel, non-essential 28 volt dc bus.
open the panel before applying power
and ensure no contact of energized b . ~ ~ I n t h e e v e n t of transmission driven
panel is made with cutside frame. alternator failure, emergency ac power is supplied by
the 115 volt, 750 Volt/ampere, 400 Hz, solid state,
three phase, wye connected inverter (3PS1), powered
NOTE
from the power transfer bus.
Power loading charts and detail system
wiring diagrams are contained in 9-5. ELECTRICAL BUS WIRING
Appendix F. Aviation Unit SCHEMATIC.
Maintenance activites shall request
Intermediate Maintenance assistance a. ~ A single-line, simplified electrical bus wiring
for electrical system repairs in schematic of the electrical power system is shown on
accordance with the maintenance figure 9-1. Primary power is distributed bya dual-bus
allocation chart, Appendix B. arrangement so that non-essential dc loads are
automatically de-energized in the event of a starter-
9-2. PRIMARY ELECTRICAL POWER. generator failure. A bus-reset feature is provided to
permit reactivation of these loads at pilot discretion.
a. ~ The primary dc electrical power on the
helicopter is a 28 volt direct current system supplied
b. H~ A single line simplified electrical power
by the engine driven 30 volt, 300 ampere starter-
distribution schematic of the electrical power system
generator (1MG1) derated to 200 amperes. Primary
is shown on figure 9-2.
ac power is supplied by the 115 volt, 750
volt/ampere, 400 hertz, solid state, three-phase,
delta-connected main inverter (3PS1), powered from
9-6. STARTING POWER.
the essential 28 volt dc bus.
Starting power is supplied by the 24 volt, 22
b. ~~ The primary dc electrical power on the amp/hour battery or by an external ground power
helicopter is provided by the engine driven 30 volt, source.
(regulated to 28 volts) 200 ampere starter-generator
(1MG1) and the 28 Vdc, 200 ampere transformer- 9-7. CONTROL PANELS AND
rectifier unit (TRU), The primary ac electrical power is MISCELLANEOUS EQUIPMENT.
supplied by the 120/208 Volt, 3 phase wye
connected 10 kva, 400HZ transmission driven The control panels for the acand dc electrical systems
alternator. are located in the pilot and gunner consoles. The ac
9-1
TM 55-1520-236-23
Figure 9-1. q Simplified Electrical Bus Wiring Schematic
9-2
TM 55-1520-236-23
Figure 9-2. ~ Simplified Electrical Bus Wiring Schematic
and dc circuit breaker panels are located in the pilot tools and equipment contained in
console. Control relays, power relays, voltage electronic equipment tool kit (T20) and
regulator, transformers, and other equipment multimeter (T2) or equivalent.
required to control, regulate, effect power transfer
and for malfunction monitoring are located in the NOTE
gunner and pilot sections (right and left wells) and aft
compartment. Refer to figures 2-2 and 2-3 for To measure voltage or resistance at
location of access panels and doors. See figures 9-3 terminal boards, switches, and relays
through 9-6 for configuration q and figures 9-7 with environmental type connectors,
through 9-10 for configuration ~ equipment remove wire from connector and insert a
location. Refer to paragraph F-9 in Appendix F for locally fabricated tool in series as shown
configuration q equipment location charts. in figure 9-11. Measurements may then
be taken from clip to airframe ground,
etc.
9-8. GENERAL MAINTENANCE
PROCEDURES. 9-9. VISUAL INSPECTION - ELECTRICAL
EQUIPMENT.
NOTE Inspect electrical and electronic equipment for dirt
and corrosion. The surfaces should be free of dirt,
T h r o u g h o u t t h i s c h a p t e r , unless grease, and fungus.
otherwise specified, electrical
maintenance, testing, and trouble- a. Remove moisture, dust, and loose dirt with a
shooting procedures will utilize only clean soft cloth.
Change 11 9 - 3
TM 55-1520-236-23
Sheet 1
Figure 9-3.
9-4
TM 55-1520-236-23
CODE
ITEM DESCRIPTION
8A4 PC Board - NVG
8A5 PC Board - NVG
8A6 PC Board - NVG
8K1 Relay - Gunner NVG
8K3 Relay - Pilot NVG
8K4 Relay - Pilot NVG
8PS1 Power Supply - Gunner Instrument Light
8PS2 Power Supply - Pilot_Tactical Instrument Light
8PS3 Power Supply - Pilot Flight Instrument Light
8PS4 Power Supply - Pilot Engine Instrument Light
8Q1 Transistor - NVG
8Q2 Transistor - NVG
8Q3 Transistor - NVG
8Q4 Transistor - NVG
8Q5 Transistor - NVG
8Q6 Transistor - NVG
8TB6 Terminal Board - Pilot NVG Lighting
8TB7 Terminal Board - Pilot NVG Lighting
8TB8 Terminal Board - Gunner NVG Lighting
209475-380-2A
Figure 9-3. ~ Electrical Equipment Location - Forward Section (Sheet 2 of 2)
9-5
TM 55-1520-236-23
Figure 9-4. q Electrical Equipment Location - pilots section (sheet 1 of 2)
9-6
TM 55-1520-236-23
CODE cODE
ITEM DESCRIPTION ITEM DESCRIPTION
1A1 Panel assembly, engine control 421 Gyro, attitude
1TB10 Terminal board, attitude indicator 4Z2 Transmitter, rate gyro
1Z3 RPM limit detector TDR 3905 Panel assembly, pilots caution
2A1 Panel assembly, DC circuit breaker 8DS13 Light, pilots cockpit
2A2 Panel assembly, electric power 8T83 Terminal board, pilot instrument ground
3A1 Panel assembly, AC circuit breaker 8TB4 Terminal board, lighting and caution
3C1 Capacitor, power factor correction 821 Flasher, NAV light
3C2 Capacitor, power factor correction 9A1 Panel assembly, SCAS control
3T1 Transformer, reference 10A1 Panel assembly, pilots lighting/ECS
3T2 Transformer, 11 5/28 Vac 22A1 Panel assembly, pilots miscellaneous
Figure 9-4. ~ Electrical Equipment Location - Pilots Section (Sheet 2 of 2)
9-7
TM 55-1520-236-23
CODE
ITEM DESCRIPTION
20A4 Panel, tow control
8A3 Panel, Gunners caution
1A2 Panel, gunners miscellaneous control
Figure 9-5. q Electrical Equipment Location - Gunners Section (Sheet 1 of 2)
9-8
TM 55-1520-236-23
CODE
ITEM DESCRIPTION
21K2 Relay, jettison control
3J1 Receptacle, engine vibration meter
8Z2 Unit, fire detection
8TB5 Terminal board, gunners lighting
9L1 Brake, anti-torque mag brake
Figure 9-5. q Electrical Equipment Location - Gunners Section (Sheet 2 of 2)
9-9
TM 55-1520-236-23
CODE
ITEM DESCRIPTION
1K3 Relay, starter
1K4 Relay, emergency hydraulic power
1S24 Sensor, emergency hydraulic pump overload
2K1 Relay, external power
2K2 Relay, battery
2K3 Relay, turret power
2K4 Relay, nonessential bus
2K5 Relay, reverse current
2K6 Relay, generator field
2R1 Shunt
2VR1 Regulator, voltage
3K1 Ralay, main inverter power
3K2 Relay, standby inverter Power
3S2 Switch, main inverter overload
3S3 Sensor, standby invarter overload
8S6 Switch, external power door
2TB1 Terminal board, external powar
2J1 Receptacle, external Power
Figure 9-6. q Electrical Equipment Location Aft Section (Sheet 1 of 3)
9-10
TM 55-1520-236-23
CODE
ITEM DESCRIPTION
1K3 Relay, starter
2BT1 Battery
2K1 Relay, external power
2K5 Relay, reverse current
2K6 Relay, generator field
2R1 Shunt
3MG1 Inverter, standby
3PS1 Inverter, main
8S6 Switch, external power door
Figure 9-6. q Electrical Equipment Location - Aft Section (Sheet 2 of 3)
9-11
TM 55-1520-236-23
CODE
ITEM DESCRIPTION
2K7 Reley, bus control
3K3 Relay, AC power control
3K4 Reley, inverter three phase
3K5 Relay, main AC fail
3K6 Relay, inverter select
3K7 Relay, standby AC fail
3K8 Relay, main inverter light
3TB1 Terminal board, AC
10K2 Relay, heater control
10S5 Sensor, tow overload
Figure 9-6. ~ Electrical Equipment Location - Aft Section (Sheet 3 of 3)
9-12
TM 55-1520-236-23
Figure 9-7. q Electrical Equipment Location - Forward Section (Sheet 1 of 2).
Change 19 9-13
TM 55-1520-236-23
CODE CODE
DESCRIPTION DESCRIPTION
ITEM ITEM
8A4 PC Board -- NVG 8Q1 Transistor -- NVG
8A5 PC Board -- NVG 8Q2 Transistor -- NVG
8A6 PC Board -- NVG 8Q3 Transistor -- NVG
8K1 Relay -- Gunner NVG 8Q4 Transistor -- NVG
8K3 Relay -- Pilot NVG 8Q5 Transistor -- NVG
8K4 Relay -- Pilot NVG 8Q6 Transistor -- NVG
8PS1 Power Supply - Gunner Instrument Light 8TB6 Terminal Board - Pilot NVG Lighting
8PS2 Power Supply - Pilot Tactical Light 8TB7 Terminal Board - Pilot NVG Lighting
8PS3 Power Supply - Pilot Flight Instrument Light 8TB6 Terminal Board - Gunner NVG Lighting
8PS4 Power Supply - Pilot Engine Instrument Light
Figure 9-7. ~ Electrical Equipment Location - Forward Section (Sheet 2 of 2)
9-14 Change 19
TM 55-1520-236-23
Figure 9-8. = Electrical Equipment Location - Pilot Section (Sheet 1 of 3)
Change 20 9-15
TM 55-1520-236-23
Figure 9-8. q Electrical Equipment Location - Pilot Section (Sheet 2 of 3)
9-16
TM 55-1520-236-23
CODE DESCRIPTION CODE DESCRIPTION
ITEM ITEM
1A1 Panel, pilot engine control 8A3 Power module, ODDS
1TB3 Terminal board, engine instrument junction 8DS13 Light, pilot cockpit
1TB10 Terminal board, attitude indicator 8DS15 Light, gunner cockpit
1Z3 Detector, RPM 8R1 Resistor, navigation light
2A1 Panel, DC circuit breaker 8TB3 Terminal board, pilot instrument ground
2A2 Panel, pilot electrical control 8TB4 Terminal board. lighting/caution
2K18 Relay, SCAS 8Z1 Flasher, navigation light
3A1 Panel, AC/armament circuit breaker 9CR1 Diode, arc suppressor
3C1 Capacitor, power factor correction 9A1 Panel. SCAS control
3C2 Capacitor, power factor correction 9L2 Brake, lateral magnetic
3T1 Transformer, reference 9L3 Brake, fore/aft magnetic
3T2 Transformer, 115/28 VAC 9MT1 Motion transducer, pitch
4A2 Stick, pilot collective 9MT2 Motion transducer. roll
4Z1 Gyro, attitude 9R 1 Resistor, rate gyro
4Z2 Transmitter, rate gyro 10A1 Panel, pilot lighting/ECS
8A2 Panel, pilot caution 10C1 Capacitor, radio blower
22A1 Panel, pilot miscellaneous
Figure 9-8. = Electrical Equipment Location - Pilot Section (Sheet 3 of 3)
(4) Faulty circuit breakers (will not remain closed
when pressed) serving normal loads.
Cleaning solvent is flammable and (5) Switches (rotary, sliding, tumbler, push-pull
toxic. Provide adequate ventilation. types) with loose mounting, weak position detents, and
Avoid prolonged -breathing of intermittent circuit connection.
solvent vapors and contact with
skin or eyes. (6) Panels with poor legibility of switch and selector
setting markings and lighting.
b. Remove grease, fungus, and ground-in dirt from
the equipment cases and mountings; use a cloth (7) Loose knobs on control panels.
dampened (not wet) with approved dry cleaning solvent
(C112). (8) Burned panel lights.
c. Before performing operational procedures on an (9) Faulty (cracked, corroded, intermittent) or loose
electrical system, visually inspector check that the connectors and mounting.
installation is free of DEFECTS or DAMAGE. If any of
the following c o n d i t i o n s e x i s t o n t h e a f f e c t e d (10) Burned, discolored, corroded, cracked, and
components or equipment, make necessary repairs broken components (diodes, resistors, capacitors,
(using standard practice) or replace. inductors, transistors, relays, etc.).
d. The term DEFECT primarily includes the following (11) Relays (dented, cracked, or corroded
conditions: connectors) loose in r e c e p t a c l e o r mounting,
intermittent when lightly tapped with hand or small
(1) Connectors with corroded or bent pins. insulated object.
(2) Connectors with broken safety wire. (12) Loose terminal boards and faulty mounted
components (components that are cracked, dented,
(3) Frayed or broken insulation on conductors chipped, discolored from overload or open circuit
or interconnecting cabling. including resistor, diodes, and condensers).
Change 20 9-17
TM 55-1520-236-23
209475-439-1A
CODE DESCRIPTION
ITEM
1A2 Panel, gunner miscellaneous control
1M10 Indicator, altimeter
1M11 Indicator, gunner turbine gas temperature
1M12 Indicator, gas producer
1M13 Indicator. dual tachometer
1M14 Indicator, torque
1M21 Indicator, gunner airspeed
1M22 Indicator, gunner vertical speed
5M1 Indicator, gunner attitude
20A4 Panel, TOW control
8A3 Panel, gunners caution
Figure 9-9. q Electrical Equipment Location - Gunner Section (Sheet 1 of 2)
9-18
TM 55-1520-236-23
CODE DESCRIPTION CODE DESCRIPTION
ITEM ITEM
1K5 Relay, emergency hydraulic control 8A3 Panel, gunner caution
1M10 Indicator, altimeter 8Z2 Flasher, navigation light
1M14 Indicator, torque 9L1 Brake, anti-torque magnetic
1M22 Indicator, vertical speed - gunner 10K1 Relay, heater control
3J1 Receptacle, engine vibration meter 21K2 Relay, jettison control
5A2 Cyclic stick gunner 8TB5 Terminal board, gunners lighting
Figure 9-9. q Electrical Equipment Location - Gunner Section (Sheet 2 of 2)
9-19
TM 55-1520-236-23
CODE DESCRIPTION
ITEM
1K3 Relay, starter
1K4 Relay, emergency hydraulic pump
2BT1 Battery
2J1 Receptacle, external power
2K1 Relay, external power
2K2 Ralay, battery
2K3 Ralay, battery control
2K6 Relay, reverse current
2K6 Relay, generator field
2K8 Relay, battery control
2K14 Relay, reverse currant control
2K15 Relay, transformer rectifier unit (TRU) control
2K16 Relay, external power
2K17 Reley, armament control
2TB1 Terminal board, relay interface
2VR1 Regulator, voltage
3CB6 Circuit breaker, transformer rectifier
3PS1 Inverter
3PS2 Unit, transformer rectifier
3VR1 Control, alternator
8S6 Switch, external powar door
Figure 9-10. q Electrical Equipment Location - Aft Section (Sheet 1 of 3)
9-20
TM 55-1520-236-23
CODE DESCRIPTION
ITEM
1K3 Relay, starter
1K4 Relay, emergency hydraulic pump
1S24 Switch, emergency hydraulic pump overload
2J1 Receptacle, external power
2K1 Relay, external power
2K2 Relay, battery
2K4 Relay, nonessential
2K5 Relay, reverse current
2K9 Relay, essential
2K10 Relay, transformer rectifier unit (TRU) essential
2K11 Relay, transformer rectifier unit (TRU) nonessential
2K12 Relay, transformer rectifier unit (TRU) armament
2K13 Relay, armament
2R1 Shunt
2VR1 Regulator, voltage
3CB7 Circuit breaker, inverter
8S6 Switch, external power door
10K2 Relay, tow blower
10S5 Sensor, tow blower overload
19K7 Relay, turret power
Figure 9-10. q Electrical Equipment Location - Aft Section (Sheet 2 of 3)
9-21
TM 55-1520-236-23
CODE DESCRIPTION
ITEM
2BT1 Battery
3CB6 Circuit breaker, transformer rectifier
3K1 Relay, source
3PS2 Unit, transformer rectifier
3T3 Transformer, current
Figure 9-10. q Electrical Equipment Location - Aft Section (Sheet 3 of 3)
9-22
TM 55-1520-236-23
Figure 9-11. Environmental Connector Test Adapter
The term DAMAGE primarily includes the a. Perform voltage measurements (ac and dc)
following conditions: where applicable if equipment and airframe compo-
nent(s) of the respective system malfunctions while
(1) Broken connectors, terminal boards, and conducting the operational procedures.
conductors.
b. Check voltage of respective systems at test
(2) Corroded, dented, cracked, or broken
points and terminal boards on the airframe in accor-
equipment and/or mountings.
dance with system wiring diagrams.
f. Coat all exposed electrical and electronic
equipment with either MIL-C-16173 (C43.1) or c. Check the primary voltage input on load side
MIL-C-85054 (C44.3). of respective circuit breaker in accordance with sys-
tem wiring diagrams.
9-10. VOLTAGE MEASUREMENTS.
9-11. CONTINUITY TRACE.
NOTE
Ensure multimeter (T2) or equivalent Is Conduct resistance measurement (continuity trace)
In normal operating condition. Select using resistance selection on multimeter (T77), or
applicable voltage range for the moat equivalent, with primary electrical power removed
accurate reading to match the value from the helicopter. Conduct continuity trace
given on the respective electrical sys- for localization of INVISIBLE defects of connec-
tem wiring diagrams tors, conductors, terminal boards, diodes, resistors,
Change 22 9-23
TM 55-1520-236-23
capacitors, transistors, relays, inductors, switches, f. Check capacitors for retention factor (deflection
selectors, and equipments. For a logical approach to a and rate of return of multimeter pointer).
rapid analysis of faulty airframe conductors and
components within an electrical system, that cannot
be determined by visual inspection, follow the 9-12. GENERAL REPAIR TECHNIQUES.
suggested sequential steps below:
NOTE
If respective system does not perform
normally during operational test
procedures, remove dc power from
helicopter and conduct continuity trace Ensure that the battery is disconnected
to suspected components and/or before attempting any removal or
equipment within the circuitry. replacement procedures.
Under certain conditions of component
a. Repair of the electrical configuration, with
and/or equipment malfunction it maybe
certain exceptions, consists of removal of defective
necessary to make voltage
components and replacement of these components
measurements and/or continuity trace
with known serviceable components from
combinations to pinpoint the trouble.
maintenance stocks. When removal and replacement
of an electrical component or other repair procedures
a. Analyze the respective system wiring diagram
require performing repairs on the airframe, helicopter
for airframe interunit conductor paths (single,
engine controls, or other items that directly affect the
paralleled, and series); consider resistors, diodes and
flight of the helicopter, the repair effort must be
relay holding coils, etc., which may alter the sum total
performed by or coordinated with the helicopter crew
resistance of conductor paths.
chief.
NOTE
b. When a troubleshooting procedure indicates
that a component is defective, follow the applicable
On multimeter, check that meter
removal procedures in this section. Replace the
movement is free and that ohms
removed component with a known serviceable
selection and ranges will zero with ohms
equivalent component. After the component has
adjust knob.
been replaced, install Iockwire (C137), as required, on
the mounting hardware and electrical connectors.
NOTE
When performing resistance
9-13. OPERATIONAL CHECKS
measurements, select the range to give
ELECTRICAL.
the most accurate reading of the path
(conductor, resistor, diode, relay holding
Utilize system wiring diagrams in accomplishing
coil, transistor, and capacitor) selected
functional tests of electrical circuits and components.
from - the electrical system wiring
Conduct tests after installation, repair, or
diagram.
replacement of equipment.
b. Check continuity and resistance of individual
conductors within the respective interconnecting
9-14. C O M M O N E L E C T R I C A L
cabling.
COMPONENTS.
c. Check continuity and resistance of individual
conductors for abnormal conductivity with adjacent 9-15. DESCRIPTION COMMON
conductors, shielding and common ground. ELECTRICAL COMPONENTS.
d. Check resistors for normal value. Common electrical components consist of
miscellaneous electrical components, circuit
e. Check diodes for front-to-back ratio. breakers, and control panels.
9-24
TM 55-1520-236-23
9-16. MISCELLANEOUS ELECTRICAL f. Inspect shunts and bus bars for corrosion,
COMPONENTS. security, deep scratches, physical damage, deformity,
and discoloration (indicating excessive overloading).
9-17. DESCRIPTION - MISCELLANEOUS
ELECTRICAL COMPONENTS. g. Inspect shock mounts for binding,
compression, retention, security, cracks, distortion,
Miscellaneous electrical components included in this and corroded bonding.
category are capacitors, conduits, connectors, diodes,
leads, panel lights, plugs, receptacles, relays, h. Inspect relays for loose connections, damaged
rheostats, shock mounts, shunts, switches, and or broken contact pins or terminals, damage to case or
wiring. insulation between contact pins, and evidence of
corrosion, pits, or discoloration (indicating arcing due
9-18. CLEANING - MISCELLANEOUS to loose connections, internal shorting, or excessive
ELECTRICAL COMPONENTS (GENERAL). overload).
j. Inspect panel lights for faulty bulbs, security,
a. Remove moisture, dust, and loose dirt with a
and corrosion.
clean, soft cloth.
k. Visually check capacitors for loose
connections, security of mounting, seeping dielectic,
and apparent damage.
Cleaning solvent is flammable and toxic.
l. Visually check diodes for loose connection and
Provide adequate ventilation. Avoid broken leads. Check suspected faulty diode front to
prolonged breathing of solvent vapors back conductivity ratio with standard ohmmeter.
and contact with skin or eyes.
m. Visually check transistor mount for security.
b. Remove grease, fungus, and ground-in dirt Check suspected faulty transistor by voltmeter.
from the equipment cases and mountings; use a cloth
n. Inspect NVG flip filters for security, pro-
dampened (not wet) with dry cleaning solvent (C112).
per operation and cracked or broken lenses.
9-19. INSPECTION - MISCELLANEOUS 9-20. REMOVAL - MISCELLANEOUS
ELECTRICAL COMPONENTS. ELECTRICAL COMPONENTS.
a. I n s p e c t r h e o s t a t s f o r s e c u r i t y , c o r r o s i o n ,
burned element, damaged wiper, cracks, and correct
resistance.
Before removing or adjusting any
b. Inspect switches for weak detents, security, electrical component, disconnect
corrosion, faulty operation, and continuity in ON and battery to prevent damage to equipment.
infinity in OFF position. `
a. R e m o v e a t t a c h i n g h a r d w a r e , c l a m p s ,
c. Inspect plugs, connectors and receptacles for connectors or conductors; identify connectors and/or
security, contact corrosion, damaged contacts, conductors.
broken wires, faulty contacts, insert cracks, and faulty
insulation. b. Remove component.
d. Inspect leads and wiring for loose terminals, 9-21. R E P A I R - MISCELLANEOUS
chafing, corrosion or deteriorated condition, faulty or ELECTRICAL COMPONENTS.
damaged insulation, excessive mechanical stress,
broken strands, damaged shielding, shorted a. Tighten loose terminal connectors, mounting
shielding, routing and mounting conditions. and attachments of electrical components.
e. Inspect conduits for security, surface damage, b. Replace miscellaneous electrical components
cracks, dents, corrosion, and deterioration. that fail to meet inspection requirements.
Change 10 9-25
TM 55-1520-236-23
9-22. I N S T A L L A T I O N - a. Position breaker in panel assembly and install
MISCELLANEOUS ELECTRICAL mounting hardware.
COMPONENTS.
b. Remove cover from wire ends and connect to
a. Install component and secure with attaching breaker.
hardware or clamps.
9-30. CONTROL PANELS.
b. Attach identified terminals and/or connectors.
9-31. DESCRIPTION - CONTROL
9-23. CIRCUIT BREAKERS. PANELS.
9-24. D E S C R I P T I O N - CIRCUIT The control panels are mounted in the consoles at the
BREAKERS. pilot and gunner stations.
The circuit breakers are mounted in the AC/ARMT 9-32. CLEANING - CONTROL PANELS.
and dc circuit breaker panels in the pilot side console.
Circuits can be opened and closed by operating these Clean control panels in accordance with
trip-free, puch-pull circuit breakers. (Some armament paragraph 9-18.
circuit breakers may be toggle circuit breakers.)
9-33. INSPECTION - CONTROL PANELS.
9-25. CLEANING - CIRCUIT BREAKERS.
Visually inspect for scratches, chipped edges, faulty
Clean circuit breakers in accordance with paragraph edge light panels and bulbs, broken edge light panels,
9-18. damaged or faulty switches, loose or damaged wiring
and connectors, and broken or missing mounting
fasteners.
9-26. INSPECTION - CIRCUIT
BREAKERS.
9-34. REMOVAL - CONTROL PANELS.
Inspect circuit breakers for reset retention, actuation
for circuit power ON and power OFF, faulty operation, NOTE
corrosion and security.
The removal procedures for all electrical
9-27. REMOVAL - CIRCUIT BREAKERS. control paneIs are relatively the same. A
single removal procedure may be used
a. Be sure all electrical power is OFF. Disconnect for any electrical control panel.
battery.
a. Ensure all electrical power is OFF.
b. Disconnect wiring to appropriate breaker and
cover wire ends with electrical tape. b. Disengage fasteners holding panel mounting.
c. Remove mounting hardware and lift breaker c. Carefully lift panel from mount.
from panel assembly.
d. Disconnect electrical connector(s).
9-28. REPAIR - CIRCUIT BREAKERS.
9-35. REPAIR - CONTROL PANELS.
a. Repair is limited to tightening or properly
installing any loose or improperly installed mounting a. Repair any scratches or chipped edge light
hardware and connectors. panels.
b. Replace circuit breaker if any other inspection NOTE
requirements are not met.
Failure of integrally lit panels to
9-29. INSTALLATION - CIRCUIT illuminate will require replacement of
BREAKERS. control panel.
9-26
TM 55-1520-236-23
b. Replace control panel if any other inspection b. Position panel in mount; being careful not to
requirements are not met. damage wiring. Engage fasteners.
9-36. INSTALLATION - CONTROL
PANELS.
c. Apply power and check components for proper
a. Connect electrical connector(s). operation.
SECTION Il. DIRECT CURRENT POWER DISTRIBUTION S Y S T E M
9-37. DIRECT CURRENT POWER operation. (TRU requires 3 phase, 115 Vac input
DISTRIBUTION SYSTEM. power from alternator).
9-38. DESCRIPTION - DIRECT CURRENT The three distribution buses are the essential bus
POWER DISTRIBUTION SYSTEM. (ESS BUS), the non essential bus (NON ESS BUS),
and the armament bus (ARMT BUS). BUS
a. ~ The direct c u r r e n t p o w e r d i s t r i b u t i o n interconnect logic circuits control power transfer
system provides all basic power for operation of from the PWR XFR BUS and TRU BUS to the three
electrical components installed in the helicopter and distribution buses, as required, depending on crew
consists of the battery; external power, generator, station control switch settings and power source
and dc bus systems. operation status.
b. q q T h e d i r e c t c u r r e n t p o w e r s y s t e m Any distribution bus can be supplied with power from
provides the direct current (dc) electrical power any power source, depending on operating mode,
required for operation of the electrical equipment except that the battery alone cannot supply the ARMT
installed in the helicopter. It also provides for utilizing BUS. Interlock logic prevents incompatible power
external power for engine starting and checkout of source interconnection. A b a t t e r y ( 2 B T 1 ) a n d
electrical, avionics and armament systems. provisions for using external power connect directly
to the essential load distribution bus. The
The direct current power system consists of the interconnect logic circuits also control application of
following: power from these sources as required for engine
starting and ground checkout operations. Battery
(a) Three installed power sources charging from any other power source is possible
when proper conditions for battery charging exist,
(b) One power transfer bus and one TRU bus Pilot station controls are battery switch (2S1),
generator switch (2S3), non-essential bus switch
(c) Three distribution buses (2S2), master arm switch (19S12), and gunner
station pilot override armament switch (19S7). The
(d) Interconnecting relays electrical power emergency switch allows gunner to
shut off all electrical power to the helicopter in an
(e) Interconnect logic relays emergency situation. The pilot override armament
switch permits gunner to energize the ARMT BUS
(f) Crew station control switches and fire weapons in case of pilot incapacitation in
certain modes of operation.
(g) External power provisions
Normal operation: In flight, both the starter-
The three power sources are a starter-generator generator and the TRU are energized. If the armament
(1MG1), a transformer-rectifier unit (TRU) (3PS2), system is off, starter-generator power is applied
and a battery (2BT1). The starter-generator supplies through the PWR XFR BUS to the ESS BUS and TRU
power directly to the PWR XFR BUS. The TRU supplies power is applied through the TRU BUS to the NON-
power directly to the TRU BUS when alternator is in ESS BUS. When the armament system is energized,
9-27
TM 55-1520-236-23
starter-generator power is applied through the PWR essential bus relay (2K4) is energized when the NON-
XFR BUS to the ARMT BUS and ESS BUS. TRU power ESNTL BUS switch (2S2) on the pilot electrical power
is applied through the TRU BUStothe NON-ESS BUS. control panel is set to MANUAL and battery power is
applied through the contacts of (2K4) to the non-
In-flight or ground run without external power, essential bus. Thevolt/loadmeter (2M1) monitors the
battery power is applied to the ESS BUS with battery essential bus battery voltage when DC VM circuit
switch in START or RUN. The NON-ESS BUS may be breaker (2CB5) is closed. This voltage will be
energized by placing the NON-ESS BUS switch in approximately 24 Vdc when the battery is reasonably
MANUAL position. well charged. After the battery has been used for
engine starting and the starter-generator becomes
With EXT PWR applied, ESS and NON/ESS buses are operational, the volt/loadmeter will indicate high
energized and the ARMT BUS may be energized by current (dependent upon state of charge of the
placing the master arm switch in STBY or ARM or by battery). As the battery becomes recharged, the
placing the pilot override switch in PLT ORIDE. volt/loadmeter reading will decrease gradually until
the battery becomes completely recharged. When
Operation with inoperable power source: With the battery is completely recharged, there will be no
TRU inoperable and with the armament system off, perceptible difference (5 amperes or less differential)
the starter-generator supplies power through the in volt/loadmeter reading when BAT switch is moved
PWR XFR BUS to both the ESS BUS and the NON-ESS from ON to OFF.
BUS. With the armament system on, the starter-
generator supplies the NON-ESS BUS and ARMT (2) Due to the high current demand of turret
BUS. With the starter-generator inoperable and with weapons, battery power is used to supply the left and
the armament system off, the TRU supplies the ESS right turret weapons speed controllers, and the
BUS and NON-ESS BUS through the TRU BUS. With battery is isolated from the main dc bus during turret
the armament system on, the TRU supplies the ESS firing. Gun clearing relay (19K1) is energized when
BUS, NON-ESS BUS and the ARMT BUS through the cyclic stick trigger is depressed. This de-energizes
TRU BUS, (opens) battery relay (2K2), removing the battery from
the main dc bus and energizes (closes) turret power
With both TRU (or ALT) and starter-generator relay (2K3), thereby energizing feeder wires which
inoperable, the BAT supplies the ESS BUS and, at the supply power to the turret weapons speed controllers
pilot option, the NON-ESS BUS. for gun drive power. When the cyclic trigger is
released, r e l a y ( 1 9 K 1 ) r e m a i n s e n e r g i z e d f o r
approximately one-half second (to allow for gun
9-39. BATTERY SYSTEM. clearing), then opens. This action de-energizes
(opens) relay (2K3) removing power from speed
9-40. DESCRIPTION - BATTERY controllers; and energizes relay (2K2) reconnecting
SYSTEM. battery to the main dc bus for recharging.
a. q The battery system is comprised of the
battery (2BT1), battery relay (2K2), BAT switch (2S1) b. ~ The battery system is comprised of the
and utilizes the ELEC PWR position of the gunners battery (2BT1), battery relay (2K2), BATTERY switch
ELEC PWR - EMER OFF selector switch (2S4). The (2S1) ELEC PWR switch (2S4), battery relay (2K3) and
battery weapons power system is comprised of the SCAS relay (2K18). The battery system is actuated by
WPNS FIRE circuit breaker (19CB3), gun clearing placing the pilot BATTERY switch (2S1) to START
relay (19K1), and turret power relay (2K3). position. This completes a ground circuit from the
NEG terminal of the battery relay (2K2) through
(1) The battery circuit is actuated by placing the closed contacts of ELEC PWR EMER OFF switch
pilot BAT switch to the ON position and the gunner (2S4). (The emergency power switch (2S4) is
ELEC PWR - EMER OFF selector switch to the ELEC normally locked in the ELEC PWR position. )Whenthe
PWR position (the ELEC PWR - EMER OFF selector ground circuit is completed to the NEG terminal, the
switch is normally locked in the ELEC PWR position). contacts of battery relay (2K2) close, connecting the
Battery relay (2K2) is energized through the contacts battery (2BT1) to the 28 VDC ESS BUS. The battery
of gun clearing relay (19K1) and battery power is will then provide power to the ESS BUS for
transferred through the contacts of battery relay emergency power or for checkout of equipment. If
(2K2) to the main and essential dc buses. The non- ESS BUS is energized by external power or from the
9-28
TM 55-1520-236-23
PWR XFR BUS or TRU BUS, charging of the battery (switch toggle must be pulled out to actuate switch).
will occur.
9-41. FUNCTIONAL TEST BATTERY START. Check that voltrmeter indicates no voltage.
SYSTEM.
d. Place gunner ELEC PWR EMER OFF
The following tests of the battery circuitry shall be switch (2S4) to ELEC PWR. Check that voltmeter now
performed using the installed 24 Vdc battery as a indicates battery or external power source voltage.
power source, or alternatively, an external 24 Vdc
power source connected to the battery connector.
a. Before connecting power to battery circuitry,
open all circuit breakers and place all switches to their
open positions. Check that an open circuit exists 9-42. TROUBLESHOOTING BATTERY
between positive terminals of the battery quick-discon- SYSTEM.
nect and ground.
Use Table 9-1 and perform checks necessary to
b. Check all battery circuitry connections for isolate trouble. Refer to paragraph F-9 in Appendix F
tightness and correct polarity. for wiring diagrams.
c. Connect the battery or external power source. In the fallowing table, tripped circuit breakers am
Close DC circuit bakers in aft eIectrical compartment omitted from indications of trouble. Such trouble is
and on DC circuit breaker panel in pilots cockpit. Posi- usually easily detected and corrected. Broken wiring is
tion ELEC PWR EMER OFF switch (2S4) on always a probable cause of circuit malfunction or
gunners miscellaneous control panel, to EMER OFF failure and has not been induced.
NOTE
Before you use this table, be sure you have
performed all normal operational checks. If
you have a malfunction which is not listed in
this table, notify the next higher Ievel of
maintenance.
Table 9-1. Troubleshooting Battery System
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. Voltmeter indicates zero volts with DC VM circuit breaker closed, ELEC PWR EMER OFF switch on
STEP 1. With multimeter (T77), or equivalent, determine if voltage is present on 28 Vdc essential bus.
If voltage is present on essential bus continue with Step 2. If voltage is not present continue
with Step 4.
STEP 2. Check for bus voltage on voltmeter side of DC VM circuit breaker.
Replace circult breaker If defective (paragraph 9-23).
Change 22 9-29
TM 55-1520-236-23
Table 9-1. Troubleshooting Battery System (Cont)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
STEP 3. Check for bus voltage at pins A and G of volt/ Ioadmeter connector (2M1P1).
Replace volt/loadmeter (2M1) if voltage is present (paragraph 8-1).
Replace switch if defective (paragraph 9-16).
STEP 5. Ensure that ground potential is present at terminal 2 of ELEC PWR EMER OFF switch (2S4).
Check for ground potential at terminal 1.
Replace switch if defective (paragraph 9-16).
available at pin D. Temporarily place a jumper between pin D and pin H and check for voltage on 28 Vdc bus,
Replace gun clearing relay (19K1) if voltage is present on 28 Vdc bus (paragraph 9-16).
terminal X1 of battery relay (2K2).
Replace battery relay if defective (paragraph 9-16).
terminal BAT of battery relay (2K2).
Replace battery relay if defective (paragraph 9-16).
2. Voltmeter indicates plus 28 volts dc with ELEC PWR EMER OFF switch in the EMER OFF position, DC VM
STEP 1. Check for continuity between terminals 1 and 2 with ELEC PWR EMER OFF switch in EMER OFF
posit ion.
Replace switch if defective (paragraph 9-16).
3.
PWR, BAT switch set to ON, NON-ESNTL BUS switch (2S2) set to MANUAL position, and GEN BUS RESET
circuit breaker closed.
STEP 1. With a multimeter (T77), or equivalent, determine if voltage is present on 28 Vdc essential bus.
If voltage is present on essential bus, continue with Step 2, If voltage is not present on essential
bus, accomplish Steps 4 through 7 of condition 1.
9-30
TM 55-1520-236-23
Table 9-1. Troubleshooting Battery System (Cont)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
STEP 2. Check for bus voltage on switch side of GEN BUS RESET circuit breaker
Replace circuit breaker if defective (paragraph 9-23).
STEP 3. Check for bus voltage at terminals 1 and 2 of NON-ESNTL BUS switch (2S2).
Replace switch if defective (paragraph 9-16).
STEP 4. Ensure that ground potential is present at terminal X2 and check for bus voltage at terminal X1 of
non-essential bus relay (2K4).
Replace non-essential bus relay if actuating voltage is present and relay is not actuated
(paragraph 9-16).
9-43. BATTERY. 9-45. CLEANING BATTERY.
a. Clean battery in accordance with procedures
9-44. DESCRIPTION - BATTERY.
contained in TM 11-6140-203-14-2.
The 24-volt, 22-ampere/hour nickel-cadmium type b. Clean battery compartment in accordance with
battery is installed in the aft electrical compartment. procedures contained in TM 55-1500-333-24.
The battery provides engine starting power, back-up
emergency power, and ~ gun drive power during 9-46. INSPECTION - BATTERY.
firing of the turret weapons. The battery installation
includes vent tubes, eyebolts for attaching tiedown Accomplish inspection of battery in accordance with
rods, and battery cables. procedures contained in TM 11-6140-203-14-2.
Change 3 9-31
TM 55-1520-236-23
9-47. CONDITION - BATTERY.
A fullv charged batterv can be determined only by
moving BAT ~~ BATTERY switch from ~ ON
~ RUN to OFF and observing the effect on the Take every possible step to keep the
generator Ioadmeter. If the change in indications is nickel-cadmium battery as far away as
less than 5 amperes, the battery is fully charged. possible from the lead-acid type battery.
Do not use the same tools and materials
9-48, SERVICE - BATTERY. (screwdrivers, wrenches, gloves, apron,
etc.) for both types of batteries.
Service battery in accordance with procedures
contained in TM11-6140-203-14-2. Anything associated with the lead-acid
battery, even the air, must never come in
contact with the nickel-cadmium battery
9-49. REMOVAL - BATTERY. or its electrolyte. Even a traca of sulfuric
acid fumes from a lead-acid battery may
result in damage to the nickel-cadmium
battery. I f s u l f u r i c a c i d h a s b e e n
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.
The electrolyte used in nickel-cadmium
batteries contains potassium hydroxide a. Check that BAT ~ q BATTERY switch is
(KOH), which is a caustic chemical agent. OFF, and external power is not applied. Open
Serious and deep burns of body tissue will compartment door.
result if the electrolyte comes in contact
with the eyes or any part of the body. b. Disconnect battery cable connector by turning
knob counterclockwise.
c. Disconnect two vent tubes from battery case.
Use rubber gloves, rubber apron, and d. Open tiedown clamps and disengage rods from
protective eye covering when handling battery cover. Lift battery from compartment.
the battery. If accidental contact with the
electrolyte is made, use ONLY clean e. Close compartment door.
water and immediately (seconds count).
Flush contaminated areas. Continue 9-50. REPAIR - BATTERY.
flushing with large quantities of clean
water. Seek medical attention Repair battery in accordance with procedures
immediately. contained in TM 11-6140-203-14-2.
9-51. INSTALLATION - BATTERY.
a. Open compartment door.
Before removing or installing the battery, b. Place battery on shelf, aligned for connections.
ensure that the battery switch is off and Engage tiedown rods to strap on cover. Secure with
the ~ battery h a s c o o l e d d o w n i f Iockwire (C137).
overheated. Removal or installation of c. Check vent line for obstruction. Connect two vent
the battery connector while the battery is tubes to battery case and tighten clamps fingertight.
under load may result in explosion,
electrical arcing and possible severe d. Insert cable connector in battery receptacle
burns to personnel. and secure by turning knob clockwise.
9-32 Change 16
TM 55-1520-236-23
e. E n s u r e t h a t D C V M c i r c u i t b r e a k e r a n d to the essential bus through an external power
Ioadmeter circuit breakers are closed. receptacle (2J1), located on the aft left side of the
fuselage, and an external power relay (2K1). If the
f. P o s i t i o n ~ B A T ~ ~ B A T T E R Y s w i t c h t o external power is of correct polarity, the external
H ON ~~ RUN. Check that battery voltage is power relay closes automatically which connects the
indicated on voltmeter. external power to the essential bus. If external power
polarity is incorrect, diode (2CR5) in external power
g. Check voltage regulator output. (Refer to para- relay ground circuit prevents actuation of the external
graph 9-94 for proper output.) power relay. This protects installed equipment from
being damaged by inadvertent application of power of
wrong polarity. Helicopter circuits are not protected
9-52. BATTERY RELAY.
against overvoltage when operating on external
power.
9-53. DESCRIPTION - BATTERY RELAY.
The battery relay is located in the aft compartment 9-60. FUNCTIONAL TEST - EXTERNAL
and serves to control battery power as described in POWER SYSTEM .
paragraph 9-40. (Refer to paragraphs 9-18 through 9-
22 for maintenance procedures.) a. Before connecting external power, open all
circuit breakers.
9-54. q T U R R E T P O W E R R E L A Y .
b. Apply an isolated source 28 Vdc of reverse
polarity between the small pin on the external power
9-55. q DESCRIPTION - TURRET
receptacle and the frame of the helicopter. Check that
POWER RELAY.
the external power relay does not close. Remove 28
The turret power relay (2K3) is located in the aft Vdc reverse polarity.
compartment and serves to control battery power as
described in paragraph 9-40. (Refer to paragraph 9- c. Connect a 28 Vdc external power source to the
18 through 9-22 for maintenance procedures.) helicopter external power receptacle (2J1). Energize
power source. Close DC VM circuit breaker. The dc
voltmeter should indicate external power on the
9-56. q G U N C L E A R I N G R E L A Y .
essential bus.
9-57. m DESCRIPTION - GUN
CLEARING RELAY. 9-61. TROUBLESHOOTING - EXTERNAL
POWER SYSTEM.
The gun clearing relay (19K1) is located in pilot
Use Table 9-2 and perform checks as necessary to
section left well and serves to control battery power to
isolate trouble. Refer to paragraph F-9 in Appendix F
turret system. (Refer to paragraphs 9-18 through 9-
for wiring diagrams. In the following table, tripped
22 for maintenance procedures.)
circuit breakers are omitted from indications of
trouble. Such trouble is usually easily detected and
9-58. EXTERNAL POWER SYSTEM.
corrected. Broken wiring is always a probable cause
EXTERNAL of circuit malfunction or failure and has not been
9-59. DESCRIPTION -
included.
POWER SYSTEM.
External power may be used for system checkout or
other ground operations. External power is connected
Change 7 9-33
TM 55-1520-236-23
NOTE
Before you use this table, be sure you
have performed all normal operational
checks. If you have a malfunction which
is not listed in this table, notify the next
higher level of maintenance.
Table 9-2. Troubleshooting External Power System
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. Lack of power when external power plug is inserted into connector (2J1).
STEP 1. Ensure that connection between external power plug and connector (2J1) is tight. Check for
reversed polarity in external power pIug connections at external power source.
Reconnect power cable at external power source attachment points if reversed.
STEP 2. Check external power source for correct output voltage.
Adjust external power source for correct output voltage.
STEP 3. Ensure that ground potential is present at terminal X2 and actuating voltage is present at terminal
X1 of external power relay (2K1). Check that relay (2K1) is actuated.
Replace external power relay if defective (paragraph 9-16).
2. Voltmeter indicates zero voltage with DC VM circuit breaker closed, caution lights circuit breaker closed, and
external power applied to helicopter.
STEP 1. Ensure that ground potential is present at terminal X2 and actuating voltage is present at terminal
X1 of external power relay (2K1). Check that relay (2K1) is actuated.
Replace external power relay if defective (paragraph 9-16).
STEP 2. Determine if diode (2CR5) across terminals 3 and 4 of terminal board (2TB1) is defective.
Replace diode if defective (paragraph 9-16).
3. Voltmeter indicates zero voltage, EXT PWR caution light is illuminated; DC VM circuit breaker closed; caution
lights circuit breaker closed; and external power is applied to helicopter.
STEP 1. Check for essential bus voltage at pins A and G of connector (2M1P1).
Replace volt-loadmeter (2M1) if defective (paragraph 8-1).
STEP 2. Check for essential bus voltage on volt-loadmeter side of DC VM circuit breaker.
Replace circuit breaker if defective (paragraph 9-23).
9-34
TM 55-1520-236-23
Table 9-2. Troubleshooting External Power System (Cont)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
4. External power relay is energized with reverse polarity voltage applied to external power receptacle.
STEP 1. Determine if diode (2CR5) across terminals 3 and 4 of terminal board (2TB1) is defective or
installed incorrectly.
Replace diode (2CR5) if defective. Reverse diode (2CR5) if installed incorrectly (paragraph
9-16).
9-62. EXTERNAL POWER b. Remove nuts and washers from terminal posts
RECEPTACLE. of receptacle, identify and remove wires to receptacle
from bracket. Cover wire ends with electrical tape.
9-63. DESCRIPTION - EXTERNAL (C121).
POWER RECEPTACLE.
c. Remove mounting screws and lift receptacle
The external power receptacle (2J1) provides from bracket.
connection of an external power source to the
helicopter. The receptacle is covered by an access 9-67. REPAIR - EXTERNAL POWER
door. RECEPTACLE.
NOTE Repair external power receptacle in accordance with
paragraph 9-21.
External power should be utilized for
engine start to prevent excessive battery 9-68. I N S T A L L A T I O N - EXTERNAL
drain. POWER RECEPTACLE.
9-64. CLEANING - EXTERNAL POWER a. Position receptacle on bracket and install
RECEPTACLE. mounting screws.
Clean external power receptacle in accordance with b. Remove protective tape from electrical wires,
paragraph 9-18. and connect wires to respective receptacle terminals. -
9-65. INSPECTION - EXTERNAL POWER 9-69. EXTERNAL POWER RELAY.
RECEPTACLE.
9-70. DESCRIPTION - EXTERNAL
Inspect external power receptacle in accordance with POWER RELAY.
paragraph 9-19.
The external power relay (2K1) connects an external
9-66. REMOVAL - EXTERNAL POWER power source through the external power receptacle
RECEPTACLE. to the electrical system of the helicopter. A diode
(2CR5), mounted on (2TB1), is located near the relay
a. Ensure all electrical power is OFF. and serves to complete ground return for the holding
9-35
TM 55-1520-236-23
coil and prevents the application of reverse polarity to to the ON position. Check that DC GEN caution lights
the helicopter electrical system. (Refer to paragraphs on pilot and gunner caution panels are illuminated.
9-18 through 9-22 for maintenance procedures.)
9-71. GENERATOR AND DC BUS e. Return BAT switch (2S1) to OFF position.
SYSTEM.
f. Place GEN switch (2S3) to ON position. Reverse
9-72. DESCRIPTION - GENERATOR current relay (2K5) should close and both essential
AND DC BUS SYSTEM. and non-essential buses should be energized. Check
that DC GEN Iights on pilot and gunner caution panels
The dc bus system supplies power for all de electrical are not illuminated.
components of the helicopter. This system is fed by
external power, battery (2BT1), or the self-excited g. Close both ammeter circuit breakers.
starter-generator (1MG1), which normally switches Momentarily turn on a load, such as the main
onto the main 28 Vdc bus after the engine start inverter, and check that ammeter on pilot instrument
procedure when the generated voltage exceeds the panel reads upscale.
voltage on the bus by 0.30 TO 0.42 volt. The
application and regulation of power to the bus system h. Slowly increase voltage of the power source.
is controlled by the generator shunt (2R1), reverse At 31 TO 33 volts, over-voltage relay in generator
current relay (2K5), non-essential bus relay (2K4), voltage regulator should actuate, causing field relay
generator field relay (2K6), voltage regulator (2VR1), (2K6) to trip and reverse current relay (2K5) to open
and the bus control relay (2K7), all of which are and thus remove voltage from all buses. Do not
located in the aft compartment. exceed 33 volts. Reduce voltage to 28 volts. Position
BAT switch (2S1) to ON. Reset generator system by
9-73. FUNCTIONAL TEST - placing GEN switch (2S3) to RESET position and then
GENERATOR AND DC BUS SYSTEM. to OFF. Return BAT switch (2S1) to OFF. Position GEN
switch (2S3) to ON. Field relay (2K6) should reset and
a. Open ail circuit breakers. reverse current relay (2K5) should reclose, again
energizing both de buses. Open all circuit breakers
b. Disconnect wires P26A1 and P26C4 from and reconnect wires to their proper terminals.
positive terminal B, and disconnect wires K5A1 and
K5C4 from negative terminal E on the starter- 9-74. TROUBLESHOOTING -
generator, Observing proper polarity, connect these GENERATOR AND DC BUS SYSTEM.
wires to an adjustable de power source (26 TO 33
volts). Set voltage to 28 volts. Refer to paragraph F-9 in Appendix F for wiring
diagram. Use table 9-3 and perform checks as
c. Energize the power source. Check that there is necessary to isolate trouble. In the following table,
no voltage on the main 28 Vdc bus in the electrical tripped circuit breakers are omitted from indications
compartment or on terminal A1 of starter relay (1K3). of trouble. Such trouble is usually easily detected and
corrected. Broken wiring is always a probable cause
d. Close GEN FIELD, GEN BUS RESET, DC VM, of circuit malfunction or failure and has not been
and CAUT LT circuit breakers. Place BAT switch (2S1) included.
9-36
TM 55-1520-236-23
NOTE
Before you use this table, be sure you
have performed all normal operational
checks. If you have a malfunction which
is not listed in this table, notify the next
higher level of maintenance.
Table 9-3. Troubleshooting Generator and DC Bus System
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. DC GEN caution lights fail to illuminate with caution lights circuit breaker closed; BAT switch set to ON;
voltmeter indicating battery voltage.
STEP 1. Check for defective lights.
Replace lights if defective (paragraph 9-282).
STEP 2. Ensure that ground potential is present at terminal A2 and check for continuity between terminals
A2 and A3 of bus control relay (2K7).
Replace relay if defective (paragraph 9-16).
2. DC GEN caution lights do not go out and non-essential dc bus is not energized under these conditions: GEN
BUS RESET circuit breaker closed; CAUT LT circuit breaker closed; BAT switch set to ON; helicopter engine
running; GEN FIELD circuit breaker closed; NON-ESNTL BUS switch set to NORMAL.
STEP 1. Ensure that actuating voltage is present at terminal X1 and ground potential is present at terminal
X2 of bus control relay (2K7). Determine if relay is actuated.
Replace relay if defective (paragraph 9-16).
STEP 2. Check for dc voltage on SW terminal of reverse current relay (2K5). Determine if relay is actuated.
Replace relay if defective (paragraph 9-16).
STEP 3. Determine if generator field relay (2K6) is tripped or defective.
Replace relay if defective (paragraph 9-16).
STEP 4. Check for proper operation of GEN switch (2S3).
Replace switch if defective (paragraph 9-16).
STEP 5. Determine if ELECT PWR - EMER OFF switch (2S4) is defective.
Replace switch if defective (paragraph 9-16).
9-37
TM 55-1520-236-23
Table 9-3. Troubleshooting Generator and DC Bus System (Cont)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
STEP 6. Determine if generator is defective.
Replace starter-generator (1MG1) if defective (paragraph 9-79).
3. DC GEN caution lights are not illuminated with essential dc bus energized; NON-ESNTL BUS switch in
NORM position; ELEC PWR - EMER OFF switch in ELEC PWR position; GEN BUS RESET circuit breaker
closed; GEN FIELD circuit breaker closed; CAUT LT circuit breaker closed and helicopter engine running.
STEP 1. Ensure that actuating voltage is present at terminal X1 and ground potential is present at terminal
X2 of bus control relay (2K7). Determine if relay is actuated.
Replace relay if defective (paragraph 9-16).
STEP 2. Check for bus voltage on switch side of GEN BUS RESET circuit breaker.
Replace circuit breaker if defective (paragraph 9-23).
STEP 3. Check NON-ESNTL BUS switch for proper operation.
Replace switch if defective (paragraph 9-16).
4. Conditions same as described in condition 3 above, except DC GEN caution light is illuminated and GEN
switch (2S3) has been positioned to RESET and returned to ON.
STEP 1. Ensure that actuating voltage is present at SWterminal of reverse current relay (2K5) and check for
defective relay.
Replace relay if defective (paragraph 9-16).
STEP 2. Determine if generator field relay (2K6) is tripped.
Replace relay if defective (paragraph 9-16).
STEP 3. Check for defective GEN switch (2S3).
Replace switch if defective (paragraph 9-16).
STEP 4. Check for bus voltage on switch side of GEN BUS RESET circuit breaker (2CB3).
Replace circuit breaker if defective (paragraph 9-23).
STEP 5. Check for defective ELEC PWR - EMER OFF switch (2S4).
Replace switch if defective (paragraph 9-16)
9-38
TM 55-1520-236-23
Table 9-3. Troubleshooting Generator and DC Bus System (Cont)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
STEP 6. Check for bus voltage on relay side of GEN FIELD circuit breaker (2CB4).
Replace circuit breaker if defective (paragraph 9-23).
STEP 7. Determine if generator voltage regulator (2VR1) is defective.
Replace generator voltage regulator if defective (paragraph 9-90).
STEP 8. Determine if starter generator is defective.
Replace starter-generator if defective (paragraph 9-79).
5. Loss of dc voltage on non-essential bus. NON-ESNTL BUS switch (2S2) is in NORMAL position.
STEP 1. Determine if starter-generator is defective.
Replace starter-generator if defective (paragraph 9-79).
STEP 2. Ensure that actuating voltage is present on terminal X1 of non-essential bus relay (2K4) and
determine if relay is defective.
Replace relay if defective (paragraph 9-16).
STEP 3. Determine if NON-ESNTL BUS switch (2S2) is defective.
Replace switch if defective (paragraph 9-16).
STEP 4. Ensure that actuating voltage is present on terminal X1 of bus control relay (2K7) and determine if
relay is defective.
Replace relay if defective (paragraph 9-16).
6. Loss of voltage on non-essential bus when NON-ESNTL BUS switch is in MANUAL position and GEN BUS
RESET circuit breaker is closed.
STEP 1. Check for defective NON-ESNTL BUS switch (2S2).
Replace switch if defective (paragraph 9-16).
STEP 2. Ensure that actuating voltage is present on terminal X1 of non-essential bus relay (2K4) and
determine if relay is defective.
Replace relay if defective (paragraph 9-16).
9-39
TM 55-1520-236-23
Table 9-3. Troubleshooting Generator and DC Bus System (Cont)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
STEP 3. Check for bus voltage on switch side of GEN BUS RESET circuit breaker.
Replace circuit breaker if defective (paragraph 9-23).
7. Volt-loadmeter does not indicate proper load with normal loads operating.
STEP 1. Check for defective loadmeter circuit breakers (2CB1 and 2CB2).
Replace circuit breaker if defective (paragraph 9-23).
STEP 2. Determine if volt-loadmeter is defective.
Replace volt-loadmeter if defective (paragraph 8-1).
STEP 3. Check for defective shunt (2R1).
Replace shunt if defective (paragraph 9-16).
9-75. GENERATOR POWER connect the generator output wires to the PWR XFR
SYSTEM. BUS.
9-76. DESCRIPTION DC 9-77. FUNCTIONAL TEST DC
GENERATOR POWER SYSTEM. GENERATOR POWER SYSTEM.
The DC Generator Power System consists of the a. Open all circuit breakers.
starter-generator (1MG1) operating in generator
mode, generator field relay (2K6), electrical power b. Disconnect wires (P26A1 and P26C4 from
switch (2S4), generator switch (2S3), voltage terminal B(+)andwire K5A1 from terminal E (-) on the
regulator (2VR1), load meter shunt (2R1), and reverse starter-generator. Leave wire K5C4 firmly connected
current relay (2K5). as installed. Connect these disconnected wires to an
adjustable external dc power source, observing
When the GEN FIELD and GEN BUS RESET circuit proper polarity.
breakers are closed, generator field has been reset, c. Energize the power source and set voltage at
GEN switch is in ON position, and generator is 28 Vdc. There should be no voltage on the PWR XFR
rotating at an appropriate speed, a voltage will be BUS or other buses in the electrical compartment.
generated at the output terminals B and E of the
starter generator. (ELEC PWR switch is assumed to be d. Close GEN FIELD, GEN BUS RESET, and DC
locked in the ELEC PWR position.) The generator VM circuit breakers. Position BATTERY switch (2S1)
output voltage is sensed by the reverse current relay. to START. Voltmeter should indicate battery voltage.
When the generator output voltage exceeds the
voltage ontheessential bus by 0.30 T0 0.42 volt, the e. Position GEN switch (2S3) to RESET and
contacts of the reverse current relay close and release. Return battery switch to OFF.
9-40
TM 55-1520-236-23
f. Position GEN switch (2S3) to ON. Reverse i. Start engine and allow to warm up in
current relay (2K5) should close, energizing the PWR accordance with TM 55-1520-236-10. Adjust speed
XFR BUS. to idle speed. Position GEN switch (2S3) to ON and
battery switch to run. Check that generator output
g. Close both Ioadmeter circuit breakers. Check voltage is within normal operating range of 27.5
that Ioadmeter reads upscale. 0.25 volts dc.
j. Increase engine speed to normal flight speed.
NOTE Energize the electrical equipment. Use an accurate
voltmeter to measure and adjust the voltage on the
If power source is not available refer to PWR XFR BUS in accordance with paragraph 9-88.
next higher level of maintenance.
k. De-energize all electrical equipment not
needed for maintaining ground run operation. Check
h. Slowly increase voltage of the power source. that the PWR XFR BUS voltaqe remains essentially
At 31 TO 33 volts, over-voltage relay in generator unchanged.
voltage regulator should actuate, causing field relay
(2K6) to trip and reverse current relay (2K5) to open 9-78. TROUBLESHOOTING - DC
and thus remove voltage from all buses. Do not GENERATOR POWER SYSTEM.
exceed 33 volts. Reduce voltage to 28 volts. Position
BATTERY switch (2S1) to START. Reset generator Refer to paragraph F-9 in Appendix F for wiring
system by placing GEN switch (2S3) to RESET diagrams. Use Table 9-4 and perform checks as
position and then to OFF. Return BATTERY switch necessary to isolate trouble. In the following table,
(2S1) to OFF. Position GEN switch (2S3) to ON. Field tripped circuit breakers are omitted from indications
relay (2K6) should reset and reverse current relay of trouble Such trouble is usually easily detected and
(2K5) should reclose, again energizing both dc buses. corrected Broken wiring is always a probable cause
Open all circuit breakers and reconnect wires to their of circuit malfunction or failure and has not been
proper terminals. included.
NOTE
Before you use this table, be sure you
have performed all normal operational
checks. If you have a malfunction which
is not listed in this table, notify the next
higher level of maintenance.
Table 9-4. Troubleshooting DC Generator Power System
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. DC GEN caution lights remain illuminated, starter-generator is rotating at normal operating speed. GEN
FIELD, GEN BUS RESET, DC VM, CAUTION LT, RVS CUR RLY, and both LOADMETER circuit breakers are
closed. GEN switch is in ON position. BATTERY switch is in RUN position.
STEP 1. Position GEN switch to OFF, then to RESET and back to ON.
If DC GEN caution lights extinguish and remain extinguished, DC generator has been reset and
normal operation resumed.
Change 9 9-41
TM 55-1520-236-23
Table 9-4. ~ ~Troubleshooting DC Generator Power System (Cent)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
If DC GEN caution lights remain illuminated, continue with step 2.
STEP 2. Check for generator voltage (approximately 28 Vdc) on the PWR XFR BUS
If generator voltage is present on PWR XFR BUS, continue with step 3.
If generator voltage is not present on PWR XFR BUS, do step 7.
STEP 3, Check for approximately 28 Vdc on terminal Xl of reverse current control relay (2K1 ;).
If voltage is present, replace relay (2K14) (paragraph 9-1 6).
If voltage is not present, continue with step 4,
STEP 4. Check for 28 Vdc on load side of RVS CUR RLY circuit breaker (2CB 10).
If voltage is present, repair wiring between RVS CUR RLY circuit breaker through terminal board
2TB1-l E and 2TB1-1 D to relay 2K14-X1,
If voltage is not present, continue with step 5.
STEP 5. Check for 28 Vdc on power side of RVS CUR RLY circuit breaker (2CB1 O).
If voltage is present, replace circuit breaker (2CB1 O) (paragraph 9-23).
If voltage is not present, continue with step 6.
STEP 6. Check for 28 Vdc on IND terminal of reverse current relay (2K5).
If voltage is present, repair wiring between 2K5-IND and circuit breaker (2CB1 O).
If voltage is not present, continue with step 7.
STEP 7. Check for generator output voltage on GEN terminal of reverse current relay (2K5).
If voltage is present at 2K5-GEN, continue with step 8.
If voltage is not present, do step 9.
STEP 8, Check for 28 Vdc on terminal SW of reverse current relay (2K5).
If voltage is present, replace reverse current relay (2K5) (paragraph 9-1 6).
If voltage is not present, continue with step 12.
9-42
TM 65-1 S20-236-23
Table 9-4. Troubleshooting DC Generator Power System (Cent)
CONDTION
TEST OR INSPECTION
CORRECTIVE ACTION
STEP 9. Check for approximately 28 Vdc output voltage between terminals B and E (ground) of starter-
generator.
If voltage is present, repair feeder circuit between generator terminal Band reverse current relay
(2K5) terminal GEN.
If voltage is not present, continue with step 10.
STEP 10. Check for a voltage (exact value may vary) on terminal A of starter-generator.
If voltage is present, replace starter-generator (paragraph 4-121 ).
If voltage is not present, continue with step 11.
STEP 11. Check for a voltage (exact value may vary) on pin A of plug 2VR1 P1 on voltage regulator (2VR1 ).
If voltage is present, replace generator field relay (2K6) (paragraph 9-86).
If voltage is not present, continue with step 12.
STEP 12. Check for 28 Vdc on load side of GEN FIELD circuit breaker (2 CB4).
If voltage is present, continue with step 13.
If voltage is not present, replace GEN FIELD circuit breaker (2CB4) (paragraph 9-23).
STEP 13. Check circuit between GEN FIELD circuit breaker (2CB4) through connector 2A1 P2/2Al J2,
terminals 9A, 9B, and 9C or 2TB1, connector 2A 2J1 /2A2P1, contacts 2 and 3 of GEN switch (2S3), contacts
4 and 5 of ELEC PWR switch (2S4), contacts B3 and B2 of generator field relay (2K6) to 2K5-SW.
If circuit continuity does not exist, repair wiring or replace components as required.
. 9-79. DC GENERATOR. 9-81. CLEANING DC GENERATOR.
9-80. DESCRIPTION DC GENERATOR. a. Remove moisture and loose dirt with a clean,
soft cloth.
. The engine driven 30 volt, 300 ampere
starter-generator, derated to 200 ampere, supplies
the primary 28 volt direct current electrical power on
the helicopter.
I WARNING b
Cleaning solvent is flammable and toxic.
b. An engine-driven 30 volt, 200 ampere
starter-generator provides 28 Vdc power to the PWR
XFR BUS.
Provide adequate ventilation. Avoid
prolonged breathing of solvent vapors
and contact with skin or eyes.
9-43
b. Remove grease, fungus, and ground-in dirt,
with a clean, lint-free cloth dampened with dry
cleaning solvent (Cl 1 2).
f. Remove clamp and detach flexible hose duct from
shroud on forward end of starter-generator. Loosen two
clamping bolts at left side of inlet shroud, and slide
shroud aft for access to starter mounting studs. Discon-
nect main fuel line and cap off. I
c. Remove dirt from electrical connectors with a
bristle brush.
g. Loosen nuts and washers on six mounting studs.
Turn starter-generator clockwise and pull straight aft
9-82. INSPECTION DC GENERATOR.
until free of studs and driveshaft engagement. Cover
a. Visually inspect generator for damage. mounting, pad.
NOTE
b. Check terminals for damage and terminal
Observe position of terminal block in
board to ensure that it is not warped or cracked.
relation to engine and reinstall storter-
generatar in same position.
c. Check brush cover for dents and Imse or bent
pins. h. Remove inlet shroud from forward end of
startergenerator.
d. Check brushes for wear and freedom of
movement in brush holders.
e. Check brush springs for proper tension on
brushes.
9-84. REPAIR D C G E N E R A T O R .
f. Check all leads for indication of overheating
and condition of insulation. a. Repair brush cover dents in accordance with
TM55-1 500-204-25/1.
g. Check that proper amount of brush area is
making contact with commutator (100 percent) in b, AVIM Replace brush when cracked, chipped, or
direction of rotation and a minimum of (7S peroent no part of diagonal groove on edge is visible.
axially) and that commutator is not coated with oil or
grease. (1) Loosen screw and remove brush cover
band.
h. Check drive spline for excessive wear by rocking
armature back and forth. If rocking occurs, remove (2) Remove screw from brush pigtail being
generator. (Refer to paragraph 9-83.) careful not to drop screw.
i, Check drive shaft assembly splines for wear by (3) Using needle nose pliers, carefully pull
measuring the tap land of each tooth. If top land brush out of brush holder.
dimension is O.015 inch or less, replace the generator.
(4) Hold brush spring out of the way and insert
9-830 REMOVAL DC 6ENERATORo replacement brush into brush holder. Ensure that
spring seats properly on top of brush.
0. Open engine cowling.
b. Remove gas producer (Nl) t a c h o m e t e r (S) Check brush springs for minimum tension
generator. (Refer to paragraph 8-51.) of 2.8 pounds with a pull scale approximately 7/8
c. Disconnect two engine oil lines located iust inch from center of spring.
below gas producer tachometer generator moun-
ting pod. (6) Install screw to secure brush pigtail.
d. Remove screws to detach forward and aft (7) Install brush cover and tighten screw.
ends of tail rotor driveshoft tunnel from engine
firewalls, allowing tunnel to be lowered. c. Replace warped or cracked terminal boards.
. Disconnect electrical leads from starter-
generator, d. No other repairs are authorized.
Change 16
TM 55-1520-238-23
9-85. INSTALLATION - DC GENERATOR. g. Install gas producer tachometer generator.
a. On a new starter-generator, place inlet shroud (Refer to paragraph 8-54.)
on forward end of starter-generator, far enough aft to
allow access to mounting flange. Install two bolts, h. Close engine cowling.
with washers, at shroud clamping joint. Tighten bolts
to hold temporary position of shroud with inlet point- i. Performoperational and voltage check. Adjust volt-
ing to right. (Refer to figure 4-34.) age regulator as required (paragraph 9-94).
NOTE
Shaft splines maybe aligned by rotat- 9-86. GENERATOR FIELD RELAY.
ing gas producer tachometer genera-
tor drive with one-quarter inch drive
extension and ratchet.
NOTE 9-87. DESCRIPTION-GENERATOR
FIELD RELAY.
Due to the limited accessibility of the
nut and washer at the 11 oclock posi- The generator field relay (2K6) provides control of
tion, this nut and washer may be left generator (1MG1) by opening and closing the gener-
off. ator shunt field. The relay is tripped by the generator
overvoltage applied through the voltage regulator
b. Remove mounting pad cover. Install new gas- (2VR1) and maybe reset by GEN switch (2S3) which
ket. Coat starter-generator shaft and pack female is located on pilot electrical panel (2A2). (Refer to
splines of shaft in gearbox two-thirds (2/3) full with paragraphs 9-16 through 9-22 for maintenance proce-
lubricant (item 85, table 1-3). Lift starter-generator dures.)
to position on studs, meshing shaft splines. Turn
counterclockwise and tighten mounting nuts. 9-88. LOADMETER SHUNT.
c. Slide inlet shroud forward to normal position. 9-89. DESCRIPTION - LOADMETER
Connect flexible duct to inlet and secure by clamp. SHUNT
Tighten two bolts at shroud clamping joint.
The Ioadmeter shunt (2R1) provides a voltage drop,
d. Connect electrical cable leads to starter-gen- proportional to the current, to operate the ammeter.
erator terminals. (Refer to paragraphs 9-18 through 9-22 for mainte-
nance procedures.)
e. Position forward and aft ends of tail rotor
driveshaft tunnel to engine firewalls, and attach 9-90. VOLTAGE REGULATOR.
with screws. Connect main fuel line.
9-91. DESCRIPTION - VOLTAGE REGULA-
f. Reconnect two engine oil lines which were TOR.
disconnected in paragraph 9-83c.
The voltage regulator (2VR1) regulates the voltage of
the generator by increasing or decreasing resistance
Change 19 9-44.1
TM 55-1520-236-23
of the shunt field circuit. The voltage regulator is b. Set BAT switch to ON position.
adjustable from 27.0 to 29.0 Vdc.
c. Set BATTERY switch to RUN position.
9-92. CLEANING -- VOLTAGE REGULATOR.
d. Set GEN switch to ON position.
NOTE
Cleaning solvent is flammable and
toxic. Provide adequate ventilation. Adjust each voltage regulator independent-
Avoid prolonged breathing of solvent ly with other generator(s) turned off.
vapors and contact with skin or eyes.
e. Close (on) all circuit breakers. Ensure all instru-
a. Remove moisture and loose dirt with a clean, ments and communications and navigation equipment
SOft cloth. are on. This will provide a load for the aircraft DC bus.
b. Remove grease, fungus, and ground in dirt with
a clean, lint-free cloth dampened with dry cleaning sol- NOTE
vent (C112).
An AN/UMSM-451 voltmeter or equivalent
c. Remove dirt from electrical connectors with a with a DC voltage scale accuracy of +/- one
bristle brush. percent should be used. If a +/- one percent
voltmeter is not available, an AN/USM-223
9-93. INSPECTION - VOLTAGE REGULATOR. or equivalent multimeter may be used.
However, the voltage regulator should be
Visually inspect regulator case for physical damage readjusted using an AN/USM-451 or equiv-
that could impair normal efficient operation of the unit, alent voltmeter at the earliest possible time.
(cracked case, damaged contact pins). Check for
secure mounting of regulator. f. Connect the positive probe of a voltmeter to
any convenient point on the battery/essential bus.
9-94. ADJUSTMENT - VOLTAGE REGULA- Connect the negative probe to a convenient aircraft
TOR. ground.
Electrical components normally depend upon a con- g. Read and record the voltage.
stant voltage supply from the generator. The genera-
tor voltage output is controlled by the voltage regula- h. Adjust the voltage regulator according to the
tor which requires precision adjustment as follows: seasonal average high (ambient ground level) temper-
ature settings in Table 9-4.1.
a. Run aircraft engine at normal RPM/percent.
TABLE 9-4.1 Voltage Regulator Adjustment Settings
SEASONAL AVERAGE HIGH VOLTAGE REGULATOR
(AMBlENT GROUND LEVEL) SETTING
TEMPERATURE (VOLTS)
Above 80F (26C) 27.0 +/- 0.2
Between 32F (0C) and 28.0 +/- 0.2
80F (26C)
Below 32F (0C) 28.5 +/- 0.2
NOTE
On Standby/Auxiliary 28 VDC electrical system, adjust voltage regulators one volt lower than normal system.
9-44.2 Change 19
TM 55-1520-236-23
i. Turn off all instruments and communications and
navigation equipment. The DC bus voltage reading should
be the same as in step g. above. If the aircraft DC voltage
varies more than +/- 0.5 volt between the two readings,
shut off aircraft engine (refer to TM 55-1520-238-10) and
replace regulator.
9-95. REMOVAL - VOLTAGE REGULATOR.
a. Be sure all electrical power is OFF.
b. Disengage connector from voltage regulator. Cover
connector openings. Remove mounting screws and
remove regulator.
9-96. REPAIR - VOLTAGE REGULATOR.
Other than replacing loose or missing mounting screws, no
other repairs are authorized.
9-97. INSTALLATION - VOLTAGE REGULATOR.
a. Position regulator and secure with mounting
screws.
b. Remove protective covers from plug and recepta-
cle. Engage connector and secure.
9-98. REVERSE CURRENT RELAY.
9-99. DESCRIPTION -- REVERSE. CURRENT
RELAY.
The reverse current relay (2K5) prevents the generator
form being connected to the line until operating voltage is
attained, and prevents reverse current flow and holds gen-
erator on line unless voltage drops to the point where con-
tinued operation would de detrimental electrical equip-
ment. (Refer to paragraphs 9-18 through 9-22 for mainte-
nance procedures.)
Change 19 9-45
TM 55-1520-236-23
9-100. BUS CONTROL RELAY. The TRU power system consists of the transformer-
rectifier unit (TRU) (3PS2) and TRU remote control
9-101 DESCRIPTION - BUS CONTROL circuit breaker (RCCB) (3CB6). When the
RELAY. transmission driven alternator is operating and TRU
circuit breaker is closed, the TRU remote control
The bus control relay (2K7) is actuated from the circuit breaker contacts will close. Closing of the
indicator terminal of the generator reverse current RCCB contacts places 115 Vat, 3. phase, 400 Hz
relay (2K5). It also provides the following functions: power on the input terminals of the TRU. The TRU
energizes the non-essential bus relay (2K4) and output is 26 Vdc power which is connected directly to
allows power to be supplied to non-essential bus from the TRU bus.
either external power or generator. It also completes
the circuit to illuminate DC GEN warning light 9-106. FUNCTIONAL TEST - TRU
segment on caution panels (8A2 and 8A3). (Refer to SYSTEM.
paragraphs 9-18 through 9-22 for maintenance
procedures.) a. Open (off) all circuit breakers.
9-102. NON-ESSENTIAL BUS
REALY. b. Place alternator in operation. Engine ground
run is required. (Refer to TM55-1520-236-10.)
9-103. DESCRIPTION - NON-
ESSENTIAL BUS RELAY. c. Check for 28 Vdc on TRU BUS.
The non-essential bus relay (2K4) is an electrically 9-107. TROUBLESHOOTING - TRU
operated switch between the main 28 VDC bus and POWER SYSTEM.
the non-essential bus. It is controlled by the bus
control relay (2K7) when NON-ESNTL BUS switch Refer to paragraph F-9 in Appendix F for wiring
(2S2) is in NORMAL position. (Refer to paragraphs 9- diagrams. Use Table 9-5 and perform checks as
18 through 3-22 for maintenance procedures.) necessary to isolate trouble. In the following table,
tripped circuit breakers are omitted from indications
9-104. TRU POWER SYSTEM. of trouble. Such trouble is usually easily detected and
corrected. Broken wiring is always a probable cause
9-105. DESCRIPTION - TRU of circuit malfunction or failure and has not been
POWER SYSTEM. included.
NOTE
Before you use this table, be sure you
have performed all normal operational
checks. If you have a malfunction which
is not listed in this table, notify the next
higher level of maintenance.
Table 9-5. Troubleshooting TRU Power System
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. RECT caution lights are illuminated. Alternator and starter-generator operating normally. TRU, CAUT LT and
ARMT BUS circuit breakers are closed.
STEP 1. Check for voltage on TRU BUS.
If voltage is present on TRU BUS, continue with STEP 2. If voltage is not present, continue with
Step 4.
9-46
TM 55-1520-236-23
Table 9-5. Troubleshooting TRU Power System (Cont)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
STEP 2. Check for voltage at terminal X1 of TRU RELAY (2K15).
If voltage is present, replace relay (2K15) (paragraph 9-1 6). If voltage is not present, continue
with Step 3.
STEP 3. Check for voltage on load side of ARMT BUS circuit breaker.
If voltage is present, repair wiring between ARMT BUS circuit breaker through connections on
2B1 -2F and -2A to relay 2K15-X2. Repair wiring. If voltage is not present, replace ARMT BUS
circuit breaker (paragraph 9-23).
STEP 4. Check for approximately 28 Vdc between positive and negative output terminals of TRU (3PS2).
Check for firm ground connection on - terminal.
If voltage is present, repair wiring between positive terminal of TRU and TRU BUS. If voltage is
not present, proceed with Step 5.
STEP 5. Check for 115VAC, 3 phase input power on input connector on TRU (3PS2). Check for solid, firm
ground on terminal of input connector.
If proper AC power is present on input terminals of TRU, replace TRU (3PS2) (paragraph 9-108).
If proper AC power is not present on TRU input terminals, refer to AC power system for additional
troubleshooting procedures.
9 - 1 0 8 . T R A N S F O R M E R -
RECTIFIER UNIT.
9-109. DESCRIPTION - TRANSFORMER-
RECTIFIER UNIT. Cleaning solvent is flammable and toxic.
The transformer-rectifier unit (TRU) requires Provide adequate ventilation. Avoid
200/115V, 3 phase, neutral ground, wye-connected prolonged breathing of solvent vapors
power for operation. The TRU transforms the 3 phase and contact with skin or eyes.
input voltage to a lower voltage, rectifies and filters it
to produce 28 Vdc at its output terminals. Unit is rated
at 200 amperes, 28 Vdc.
b. Remove grease, fungus, and ground-in dirt,
9 - 1 1 0 . C L E A N I N G - with a clean, lint-free cloth dampened with dry
TRANSFORMER-RECTIFIER UNIT. cleaning solvent (C112).
a. Remove moisture and loose dirt with a clean, c. Remove dirt from electrical connectors with a
soft cloth. bristle brush.
9-47
TM 55-1520-236-23
9-111. Deleted. 9-115. DC POWER
DISTRIBUTION AND INTERCONNECT
9-112. REMOVAL LOGIC,
TRANSFORMER-RECTIFIER UNIT.
9-116. DESCRIPTION - DC POWER
a. Be sure all electrical power is off. DISTRIBUTION AND INTERCONNECT
LOGIC.
b. Remove input connector (3PS2P1) and lay
aside. The dc power distribution and interconnect logic
consists of two power transfer buses, three load
distribution buses, six bus interconnection relays,
five interconnect logic relays, and crew station
control switches. The PWR XFR BUS and the TRU
To prevent possible shock hazard, BUS are supplied 28 Vdc power by the starter-
discharge filter capacitor in transformer- generator and TRU, respectively. The three
rectifier unit. distribution buses, essential (ESS), non-essential
(NON ESS) and armament (ARMT) buses are supplied
with power from the PWR XFR BUS andthe TRU BUS,
c. Temporarily short output terminals to as required, depending on crew station control
discharge filter capacitor in output circuit. settings and power plant operation. The bus
interconnection relays (2K4, and 2K9 through 2K13)
d. Remove the two dc output wires. and the interconnect logic relays (2K8 and 2K14
through 2K17) control power transfer from the two 28
e. Remove mounting screws and remove unit Vdc power sources, the battery, and external power to
from helicopter. the load distribution buses. Any load distribution bus
can be supplied with power from any of the ac power
sources, depending on crew station switch settings
9-113. REPAIR - TRANSFORMER- and operating mode, except that the battery alone
RECTIFIER UNIT. cannot supply the ARMT BUS. Interconnect logic
circuits prevent incompatible power source
a. Replace or tighten loose mounting screws, interconnection. Refer to Table 9-6 for a tabulation of
operational modes set up by the interconnect logic
b. Straighten any bent connector pins. circuits under various conditions of crew switch
settings and power source operation.
9-114. INSTALLATION - 9-117. FUNCTIONAL TEST - DC
TRANSFORMER-RECTIFIER UNIT. POWER DISTRIBUTION AND
INTERCONNECT LOGIC.
a. Position TRU in place and secure with
mounting screws. A complete functional test of the dc power
distribution and interconnect logic circuitry requires
b. Connect output leads, observing proper that all three installed dc power sources be
polarity. operational. This requires engine ground run so that
the starter-generator and ac alternator can be
c. Connect plug (3PS2P1) to input receptacle operational. (The TRU requires ac input power from
(3PS2J1). the alternator for operation.)
NOTE
The following functional tests require
helicopter ground-run with engine
operating.
a. Operate helicopter in normal ground run with
engine operating at normal flight rpm in accordance
with TM 55-1520-236-10.
9-46 Change 16
TM 55-1520-236-23
b. Activate each of the three installed dc power c. Refer to Table 9-6. Position crew station
sources; dc generator, TRU, and the battery. Ensure control switches to establish the various conditions
that each source is operating normally and supplying and modes tabulated under the heading of
power to its respective bus. (Refer to paragraph 9-39, CONDITIONS. Check that each of the dc buses is
9-79, and 9-108, for operation and maintenance supplied with dc power from the particular dc power
information for dc generator power system, TRU source indicated under the heading of POWER
power system and battery system, respectively.) SOURCE.
Table 9-6. q g DC Power Distribution Interconnection Logic Chart
9-118. ~~ TROUBLESHOOTING - DC
POWER DISTRIBUTION AND checks as necessary to isolate trouble, In the
INTERCONNECT LOGIC. following table, tripped circuit breakers are omitted
from indications of trouble. Such trouble is usually
Refer to paragraph F-9 in Appendix F for wiring easily detected and corrected. Broken wiring is
diagram and Table 9-6, dc power distribution and always a probable cause of circuit malfunction or
interconnect logic chart. Use Table 9-7 and perform failure and has not been included.
Change 12 9-49
TM 55-1520-236-23
NOTE
Table 9-7 does not address all operating
conditions listed in Table 9-6. Table 9-7
includes only the operating conditions
needed to achieve operation of each
system component, so that any failed
component can be detected.
Before you use this table, be sure you
have performed all normal operational
checks. If you have a malfunction which
is not listed in this table, notify the next
higher level of maintenance.
Table 9-7. ~~ Troubleshooting DC Power Distribution and Interconnect Logic
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. Helicopter is operated in flight or engine ground run without external power applied. BATTERY switch is in
RUN position, MASTER ARM SW is OFF, and GEN switch is ON. ALT, DC GEN, and RECT caution lights are
extinguished. (Reference: Line No. 1 of Table 9-37.) DC VM reads slightly below normal (24V instead of 28).
Battery may become discharged instead of charging. ESS bus is not energized by PWR XFR BUS.
STEP 1. Check for 28 Vdc on terminal X1 of ESS RLY (2K9).
If voltage is not present, replace relay (2K9) (paragraph 9-16).
If voltage is present, do step 2.
STEP 2. Check for voltage on load side of ESS BUS circuit breaker (2CB8) in aft electrical compartment.
If voltage is present, do step 4.
If voltage is not present, continue with step 3.
STEP 3. Check for voltage on bus side of circuit breaker (2CB8).
If voltage is present, replace circuit breaker (2CB8) (paragraph 9-23).
If voltage is not present, check for battery voltage on ESS BUS.
STEP 4. Check for voltage on terminal A2 of RVS CUR CONT RLY (2K14).
If voltage is present, continue with step 5.
If voltage is not present, repair wiring between terminal A2 of relay (2K14) and circuit breaker
(2CB8).
9-50 Change 10
TM 55-1520-236-23
Table 9-7. ~ Troubleshooting DC Power Distribution and Interconnect Logic (Cont)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
STEP 5. Check for voltage on terminal A1 of relay (2K14).
If voltage is present, check for circuit continuity between terminal A2 of relay (2K14) through
normally closed contacts of EXT PWR CONT RLY (2K16), TRU CONT RLY (2K15), BAT CONT
RLY (2K8) to terminal X1 of ESS RLY (2K9).
If voltage is not present, reset generator and check for open DC GEN caution light circuit.
2. Helicopter is operated in flight or engine ground run (No external power applied). BATSW is in RUN position,
MASTER ARM SW is OFF, GEN switch is ON. The ALT, DC GEN, and RECT caution lights are extinguished.
(Reference: Line No. 1 of Table 9-6.) Non-essential bus does not become energized. Generator and TRU are
operating.
STEP 1. Check for approximately 28 Vdc on terminal X1 of TRU NON ESS RLY (2K11).
If voltage is present, replace relay (2K11) (paragraph 9-16).
If voltage is not present, check for voltage at terminal 14 of NON ESS RLY (2K4).
If voltage is present, replace relay (2K4).
If voltage is not present, continue with Step 2.
STEP 2. Check for TRU BUS voltage at load side of TRU BUS circuit breaker (2CB9)
If voltage is present, repair wiring between circuit breaker (2CB9) and NON ESS RLY (2K4),
terminal 14.
If voltage is not present, check for voltage on power side of circuit breaker (2CB9).
If voltage is present, replace circuit breaker (2CB9) (paragraph 9-23).
If voltage is not present, repair wiring between circuit breaker and TRU BUS.
3. Helicopter is operated in flight or engine ground run (No external power applied,). BATTERY switch is in RUN
position, MASTER ARM SW is in STBY position and GEN switch is ON. ALT, DC GEN and RECT caution lights
are extinguished, TRU and generator are in operation. (Reference: Line No. 2 of Table 9-6). Voltmeter
indicates slightly low voltage reading (24 volts instead of 28V) (ESS BUS energized by battery only).
STEP 1. Check for voltage on terminal X1 of TRU ESS RLY (2K10).
If voltage is present, replace relay (2K10) (paragraph 9-16).
9-51
TM 55-1520-236-23
Table 9-7. ~~ Troubleshooting DC Power Distribution and Interconnect Logic (Cont)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
If voltage is not present, check for voltage on terminal 13 of ESS RLY (2K9).
If voltage is present, replace relay (2K9) (paragraph 9-16).
If voltage is not present, continue with Step 2.
STEP 2. Check for TRU BUS voltage at load side of ARMT BUS circuit breaker (2CB9).
If voltage is present, repair wiring between circuit breaker (2CB9) and terminal X1 on TRU ESS
RLY (2K10).
If voltage is not present, check for voltage on power side of circuit breaker (2CB9).
If voltage is present, replace circuit breaker (2CB9) (paragraph 9-23).
If voltage is not present, repair wiring between circuit breaker and TRU BUS.
4. Helicopter is operated in flight or engine ground without external power applied. BATTERY switch is in RUN
position, MASTER ARM SWITCH is in STBY position, and GEN SW is ON. ALT, DC GEN, and RECT caution
lights are extinguished. Generator and TRU are in operation. (Reference: Line No. 2 of Table 9-6). ARMT BUS
is not energized.
STEP 1. Check for voltage on terminal X1 of ARMT RLY (2K13).
If voltage is present, replace relay (2K13) (paragraph 9-16).
If voltage is not present, check for voltage at load side of RVS CUR circuit breaker (2CB10).
If voltage is present, repair wiring between circuit breaker (2CB10) and terminal X1 on ARMT
RLY (2K13).
If voltage is not present, check for voltage on power side of RVS CUR circuit breaker (2CB10).
If voltage is present, replace breaker (2CB10) (paragraph 9-23).
If voltage is not present, repair wiring betwean circuit breaker and IND terminal of RVS CUR RLY
(2K5).
5. Helicopter is operated in flight or engine ground run with no external power applied. BAT switch is in RUN
position, MASTER ARM switch in any position, and GEN switch is ON. DC GEN caution light is extinguished.
Generator is operating but TRU is off. (Reference: Lines 3 and 4 of Table 9-6). NON ESS BUS will not
energize.
STEP 1. Check for voltage on terminal X1 of NON ESS RLY (2K4).
If voltage is present, replace relay (2K4).
9-52
TM 55-1520-236-23
Table 9-7. M ~ Troubleshooting DC Power Distribution and Interconnect Logic (Cont)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
If voltage is not present, check for voltage at load side of ESS BUS circuit breaker (2CB8).
If voltage is present, check and repair wiring between circuit breaker (2CB8), through closed
contacts of TRU CONT RLY (2K15) to terminal X1 of relay (2K4).
If voltage is not present, check for voltage on power side of circuit breaker (2CB8).
If voltage is present, replace circuit breaker (2CB8) (paragraph 9-23).
If voltage is not present, check and repair wiring between circuit breaker (2CB8) and ESS BUS.
6. Helicopter is operated in flight or engine ground run without external power applied. BATTERY switch is in
RUN position, MASTER ARM switch is in STBY, GEN switch is in OFF position. ALTER and RECT caution
lights are extinguished. DC GEN caution light is illuminated. TRU is operational. (Reference: Line No. 7 of
Table 9-6). ARMT BUS is not energized from TRU BUS.
STEP 1. Check for voltage at terminal X1 of TRU ARMT RLY (2K12).
If voltage is present, replace relay (2K12) (paragraph 9-16).
If voltage is not present, check for voltage at load side of TRU BUS circuit breaker (2CB9).
If voltage is present, check and repair wiring between circuit breaker (2CB9), through contacts of
BAT CONT RLY (2K8), normally closed contacts 13 and 14 of ARMT CONT RLY (2K17) to
terminal X1 of TRU ARMT RLY (2K12).
If voltage is not present, check for voltage on power side of circuit breaker (2CB9).
If voltage is present, replace circuit breaker (2CB9) (paragraph 9-23).
If voltage is not present, check and repair wiring between circuit breaker (2CB9) and TRU BUS.
7. External power is applied to helicopter. BATTERY switch is in RUN position, MASTER ARM switch is set to
STBY. Generator and TRU are both off. (Reference: Line No. 12 of Table 9-6). ESS BUS and NON ESS BUS are
energized, but the ARMT BUS is not energized.
STEP 1. Check for voltage at terminal X1 of ARMT RLY (2K13).
If voltage is present, replace relay (2K13) (paragraph 9-16).
If voltage is not present, check for voltage at terminal B1 of ARMT CONT RLY (2K17).
If voltage is present at terminal F1 of relay (2K17) continue with step 2.
9-53
TM 55-1520-236-23
Table 9-7. ~~ Troubleshooting DC Power Distribution and Interconnect Logic (Cont)
CONDTION
TEST OR INSPECTION
CORRECTIVE ACTION
If voltage is not present at terminal F1 of relay (2K17), continue with step 3.
STEP 2. Check for voltage at terminal X1 of ARMT CONT RLY (2K17).
If voltage is present at terminal X1 of relay (2K17), replace relay (2K17) (paragraph 9-16).
If voltage is not present at terminal X1 of relay (2K17), check and repair wiring to terminal X1 of
relay 2K17 from turret armament system.
STEP 3. Check for voltage at terminal F1 of EXT PWR CONT RLY (2K16).
If voltage is present, check and repair wiring between terminal F1 of relay (2K16) through
normally closed contacts of TRU CONT RLY (2K15) to terminal B1 of ARMT CONT RLY (2K17).
If voltage is not present, check for voltage at terminal X1 of EXT PWR CONT RLY (2K16).
If voltage is present, replace relay (2K16) (paragraph 9-16).
If voltage is not present, check for voltage at terminal 12 of EXT PWR RLY (2K1).
If voltage is present on terminal 12 of relay (2K1) replace circuit breaker (2CB7) and/or repair
wiring between terminal 12 of relay (2K1) and terminal X1 of relay (2K16).
If voltage is not present, replace EXT PWR RLY (2K1) (paragraph 9-16).
8. External power is applied to helicopter. Generator and TRU are both off, BATTERY switch is in RUN position,
MASTER ARM switch is in STBY position. ESS BUS and ARMTBUS are energized. (Reference: Line No. 20 of
Table 9-6.) NON ESS BUS is not energized.
STEP 1. Check for voltage at terminal X1 of NON ESS BUS RLY (2K4).
If voltage is present, replace relay (2K4) (paragraph 9-16).
If voltage is not present, continue with step 2.
STEP 2. Check for voltage at terminal X1 of EXT PWR CONT RLY (2K16).
If voltage is present, continue with step 3.
If voltage is not present, check for voltage at terminal 12 of EXT PWR RLY (2K1).
If voltage is present on terminal 12 of relay (2K1) replace circuit breaker (2CB7) (paragraph 9-23),
or repair wiring between relay 2K1, terminal 12 and relay 2K16, terminal X1.
If voltage is not present, replace EXT PWR RLY (2K1) (paragraph 9-16).
9-54
TM 55-1520-236-23
Table 9-7. q ~ Troubleshooting DC Power Distribution and Interconnect Logic (Cont)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
STEP 3. Check for voltage at load side of ESS BUS circuit breaker (2CB8).
If voltage is present, check and repair wiring from circuit breaker (2CB8) through normally closed
contacts of TRU CONT RLY (2K15), actuated contacts of EXT PWR CONT RLY (2K16) to
terminal X1 of NON ESS BUS RLY (2k4).
If voltage is not present, check for voltage on power side of ESS BUS CIRCUIT BREAKER
(2CB8).
If voltage is present, replace circuit breaker (2CB8) (paragraph 9-23).
If voltage is not present, repair wiring between circuit breaker (2CB8) and 28 Vdc ESS BUS in
electrical compartment.
9. External power is applied to helicopter. Generator and TRU are both off. BATTERY switch is in either RUN or
OFF position. MASTER ARM switch is in STBY position. (Reference: Lines No. 19 and 20 of Table 9-6.) Only
the ESS BUS becomes energized.
STEP 1. Check for voltage on PWR XFR BUS in electrical compartment.
If PWR XFR BUS is energized, refer to conditions 6 and 7 and perform applicable troubleshooting
procedures.
If PWR XFR BUS is not energized, check for voltage on terminal X1 of ESS RLY (2K9).
If voltage is present, replace relay (2K9) (paragraph 9-16).
If voltage is not present, check for voltage at terminal Xl of EXT PWR CONT RLY (2K16).
If voltage is present, replace relay (2K16) (paragraph 9-16).
If voltage is not present, check for voltage at terminal 12 of EXT PWR RLY (2K1).
If voltage is present on terminal 12 of relay (2K1), replace circuit breaker (2CB7) (paragraph 9-
23), and/or repair wiring between EXT PWR RLY, terminal 12 and EXT PWR CONT RLY (2K16),
terminal X1.
If voltage is not present, replace EXT PWR RLY (2K1) (paragraph 9-16).
STEP 2. Check for voltage on load side of ESS BUS circuit breaker (2CB8).
If voltage is present, check and repair wiring from circuit breaker (2CB8) through diode (2CR2),
through normally closed contacts of RVS CUR CONT RLY (2K14)and THRU CONT RLY (2K15),
actuated contacts of EXT PWR CONT RLY (2K16) to terminal X1 of ESS RLY (2K9).
9-55
TM 55-1520-236-23
Table 9-7. q m Troubleshooting DC Power Distribution and Interconnect Logic (Cont)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
If voltage is not present, check for voltage on power side of circuit breaker (2CB8).
If voltage is present, replace circuit breaker (2CB8) (paragraph 9-23).
If voltage is not present, repair wiring between circuit breaker (2CB8) and ESS BUS in electrical
compartment.
SECTION Ill. ALTERNATING CURRENT POWER DISTRIBUTION SYSTEM
9-119. q ALTERNATING CURRENT on pilot electrical power panel (2S2), ac systems
POWER DISTRIBUTION SYSTEM. terminal board (3TB1), and MAIN INVTR and STBY
INVTR segments (18 and 19) of pilot caution panel.
The main-inverter is powered from the main 28 Vdc
9-120. q D E S C R I P T I O N -
bus and protected by MAIN inverter overload sensor
ALTERNATING CURRENT POWER
(3S2). The standby inverter is powered from the 28
DISTRIBUTION SYSTEM.
Vdc non-essential bus and protected by the STBY
inverter overload sensor (3S3). The reference
The alternating current power distribution system
transformer (3T1) is powered from the main inverter
provides all primary power (115 volt alternating
and protected by the REF XMFR circuit breaker
current) to the ac bus, which supplies ac power to the
(20CB4). The 11 5/28 Vac transformer is powered
instruments, avionics systems, and armament
from the 115 Vac bus, protected by the 28 Vac XMFR
subsystems.
circuit breaker (3CB3), and provides power for the 28
Vac bus. The main inverter, main inverter power
9-121. ~ I N V E R T E R S Y S T E M .
relay, main inverter overload sensor switch, standby
inverter, standby inverter power relay, standby
9-122. ~ DESCRIPTION - INVERTER
inverter overload sensor switch, ac power control
SYSTEM. relay, three-phase to single-phase relay, main ac fail
relay, inverter select relay, standby ac fail relay, ac fail
a. The inverter system is a dual system consisting
light relay, and main inverter fail relay are located in
of a 750 Va solid state, three phase, static main
inverter, and a 250 Va motor driven standby inverter. the aft electrical compartment. The reference
transformer, power factor correction capacitors, and
Both units produce 115 Vac 400 Hz power. The
11 5/28 Vac Transformer are located in the pilot
inverter system is comprised of the main inverter
section left well, The inverter switch is located in pilot
(3PS1), main inverter power relay (3K1), main
electrical power panel and the circuit breakers are
inverter overload sensor switch (3S2), standby
located in the applicable circuit breaker panel.
inverter (3MG1), standby inverter power relay (3K2),
standby inverter overload sensor switch (3S3), ac
power control relay (3K3), three-phase to single- b. The main invertersupplies single-phase power
phase inverter relay (3K4), main ac fail relay (3K5), to the ac bus system until TOW is selected, then
inverter select relay (3K6), standby ac fail relay (3K7), switches to three-phase power wired delta to feed the
ac fail light relay (3K8), reference transformer (3T1, TOW missile subsystem and the reference
power factor correction capacitors 3C1 and 3C2), transformer to supply the necessary power for the
11 5/28 Vac transformer (3T2), inverter switch (3S1) M65 TOW missile subsystem and M136 helmet sight
9-56
TM 55-1520-236-23
subsystem. The standby inverter provides normal Check that under preceding conditions, ac bus
single-phase power for the 115 Vac bus and is a voltage is 115 + 2.5 OR -7.5 Vac and that frequency
backup unit for the main inverter. The standby is 400 7 Hz.
inverter will not power the TOW missile subsystem.
With the inverter switch positioned to MAIN, dc e. Open INV MAIN circuit breaker. Check that
power from the 28 Vdc essential bus is routed main inverter is de-energized, standby inverter is
through the main inverter power relay and main automatically energized, and STBY INVTR caution
inverter overload sensor switch to the main inverter. light is extinguished. MAIN INV caution light will be
The ac output of the main inverter is routed through illuminated.
the inverter select relay, three-phase to single-phase
relay, and ac power control relay to the 115 Vac f. Place the INV selector switch to STBY, check
feeder bus. In the event of a main inverterfailure, the that standby inverter is energized, that all ac
standby inverter is automatically energized to supply instruments are energized, STBY INVTR caution light
power to the 115 Vac bus. With the inverter switch is extinguished and MAIN INVTR caution light is
positioned to STBY, dc power from the 28 Vdc non- extinguished.
essential bus is routed through the standby inverter
power relay and standby inverter overload sensor
g. Connect multimeter (T77) and frequency meter
switch to the standby inverter. The ac output of the
(T7.1) to the 115 Vac bus at engine vibration meter
standby inverter is routed through the inverter select
receptacle orotherconvenient monitoring point. With
relay and ac power control relay to the 115 Vac bus.
essential dc bus voltage at 28 0.5 Vdc, check that
The 11 5/28 Vac transformer reduces 115 Vac to 28
the ac bus voltage is 113.5 0.5 Vac, and that
Vac for 28 Vac equipment operation. The main and
frequency is 400 18 Hz.
standby inverter overload sensor switches are
thermal actuated and provide overload protection for
h. Open the INV STBY circuit breaker. Check that
the main and standby inserters. The main ac fail relay,
standby inverter is de-energized, that all ac
ac fail light relay and/or standby ac fail relay, when
instruments are de-energized, and that MAIN INVTR
de-energized, completes an electrical circuit to
caution light and STBY INVTR caution lights are
illuminate the MAIN INVTR or STBY INVTR segment
illuminated.
of the pilot caution panel.
i. Place INV selector switch to OFF and close INV
9-123. @ FUNCTIONAL TEST - INVERTER MAIN and INV STBY circuit breakers. Check that
SYSTEM. MAIN INVTR and STBY INVTR caution lights remain
a. Open all circuit breakers and place all switches illuminated. Check that main and standby inverters
to their OFF or normal positions. Connect 28 Vdc and all ac instruments are de-energized.
power source to external power receptacle (2J1).
Energize power source. j. Place INV selector switch to MAIN, Check that
no voltage is present on terminals (A-1 and B1) of the
b. Place NON-ESNTL BUS switch (2S2) to three-phase to single-phase relay (3K4), and that
MANUAL. Close INV MAIN, INV STBY, GEN BUS MAIN INVTR and STBY INVTR caution lights are
RESET, CAUT LT, and all ac circuit breakers. Check extinguished.
that MAIN INVTR and STBY INVTR caution lights are
illuminated. k. Place the MODE SELECT switch on the
gunners TOW control panel on GUN position. check
c. Place INV selector switch (3S1), located on that 115 + 2.5, or -7.5 Vac at a frequency of 400 7
pilot electrical power panel to MAIN position. Check Hz is present on terminals (A1 and B1) of the three-
that main inverter and all ac instruments are phase to single-phase relay (3K4) with respect to
energized. Check that both MAIN INVTR and STBY helicopter structure (grounded). Check that MAIN
INVTR caution lights are extinguished. INVT and STBY INVTR caution lights are
extinguished.
d. Connect multimeter (T77) or equivalent and
frequency meter (T7.1) or equivalent to the 115 Vac 1. Place the MODE SELECT switch to the STBY
bus at engine vibration meter receptacle or other TOW, ARMED MAN, and then ARMED AUTO
convenient monitoring point. Close all ac circuit position. Check that the ac voltage and frequency are
breakers. Set essential bus voltage to 28 0.5 Vdc. 113.5 0.5 Vac, and 400 18 Hz, respectively, at
9-57
TM 55-1520-236-23
terminals (A1 and B1) of the three-phase to single- 9-124. ~ T R O U B L E S H O O T I N G -
phase relay (3K4) for each of these switch positions. INVERTER SYSTEM.
Check that MAIN INVT and STBY INVTR caution lights
remain extinguished. Refer to paragraph F-9 in Appendix F for wiring
diagram. Use table 9-8 and perform checks as
necessary to isolate trouble. In the following table,
m. Place INV selector switch to STBY position. tripped circuit breakers are omitted from indications
Check that there is no voltage at terminals (A1 and of trouble. Such trouble is usually easily detected and
B1) of the three-phase to single-phase relay (3K4) and corrected. Broken wiring is always a probable cause
that STBY INVTR and MAIN INVTR caution lights are of circuit malfunction or failure and has not been
extinguished. Place INV selector switch to OFF. included.
NOTE
Before you use this table, be sure you
have performed all normal operational
checks. If you have a malfunction which
is not listed in this table, notify the next
higher level of maintenance.
Table 9-8. q Troubleshooting Inverter System
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. Main inverter (3PS1) fails to operate.
STEP 1. Ensure that voltage is present on 28 Vdc essential bus and check for bus voltage on switch side of
MAIN INVT circuit breaker (3CB1).
Replace circuit breaker if defective (paragraph 9-23).
STEP 2. With inverterswitch (3S1) in MAIN position, check for bus voltage on terminals 2 and 3 of switch.
Replace switch if defective (paragraph 9-16).
STEP 3. Check for bus voltage at terminals S1, S2, L1 and L2 of main inverteroverload sensor switch (3S2).
Replace main inverter overload sensor switch if defective (paragraph 9-16).
NOTE
If main inverter overload sensor switch is tripped due to overload condition, terminal S1 will
be grounded causing INV MAIN circuit breaker (3CB1) to trip.
STEP 4. Ensure that actuating voltage is present at terminal X1 and ground potential is present at terminal
X2 of main inverter power relay (3K1). Determine if relay is actuated.
Replace relay if defective (paragraph 9-16)
9-58
TM 55-1520-236-23
Table 9-8. q Troubleshooting Inverter System (Cont)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
STEP 5. Determine if main inverter (3PS1) is defective.
Replace inverter if defective (paragraph 9-133, 9-142)
2. Standby inverter (3MG1) fails to operate.
STEP 1. Ensure that voltage is present on 28 Vdc non-essential bus and check for bus voltage on switch
side of INV STBY circuit breaker (3CB2).
Replace circuit breaker if defective (paragraph 9-23).
STEP 2. With inverter switch (3S1) in MAIN position, check for bus voltage on terminals 5 and 6, with
switch in STBY position, check for bus voltage on terminals 4 and 5.
Replace switch if defective (paragraph 9-16).
STEP 3. Check for bus voltage at terminals S1, S2, L1, and L2 of standby inverter overload sensor switch
(3S3).
Replace standby inverter overload sensor switch if defective (paragraph 9-16).
NOTE
If standby inverter overload sensor switch is tripped due to overload condition, terminal S1
will be grounded causing INV STBY circuit breaker (3CB2) to trip.
STEP 4. Ensure that bus voltage is present at terminal X1 and ground potential is present at terminal X2 of
standby inverter power relay (3K2). Determine if relay is actuated.
Replace relay if defective.
STEP 5. Determine if standby inverter is defective
Replace inverter if defective.
3. Inverter (either 3PS1 or 3MG1) operates, but no ac output to instruments.
STEP 1. With inverter operating, check for 115 Vac output.
Replace inverter if defective. (Refer to paragraph 9-133 or paragraph 9-150 as applicable.)
STEP 2. With main inverter operating, check that main ac fail relay (3K5), inverterselect relay (3K6), and ac
power control relay (3K3) are actuated.
Replace relay if defective (paragraph 9-16).
9-59
TM 55-1520-236-23
Table 9-8. ~ Troubleshooting Inverter System (Cont)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
STEP 3. With standby inverter operating, check that inverter select relay (3K6) and ac power control relay
(3K3) are de-energized.
Replace relay if defective (paragraph 9-16)
4. Improper inverter output voltage or frequency (either main inverter or standby inverter).
STEP 1. Check for low input voltage to inverter.
Correct the cause of low primary voltage condition.
9-125. ~ q A L T E R N A T I N G the generator control unit when positioned to OFF
CURRENT POWER DISTRIBUTION RESET.
SYSTEM.
9-126. q ~ D E S C R I P T I O N 9 - 1 2 7 . q q ALTERNATOR SYSTEM
ALTERNATING CURRENT POWER
DISTRIBUTION SYSTEM. 9-128. ~ DESCRIPTION -
ALTERNATOR SYSTEM.
The ac electrical system consists of a three phase,
115 Vac, 400 Hz power distribution bus system. The The alternator system is comprised of ALTNR switch
115 Vac bus system is powered by either the inverter (3S1), ELEC PWR switch (2S4), ac source relay (3K1),
or the alternator depending on crew control switch alternator control unit (3VR1), alternator (3G1) and
settings and aircraft power plant operation. The current transformer (3T3). With engine running,
primary ac electrical power system is a three phase ALTNR switch (3S1) positioned to ON position and
wye connected arrangement that is supplied by a ELEC PWR switch (2S4) positioned to ELEC PWR
120/208 Vat, 400 Hz, 10 kva alternator. Three phase position, ac source relay (3K1) is energized allowing
primary ac power is supplied by the alternator to the alternator (3G1) to furnish power to the ac
essential ac buses, which power the transformer distribution system. Alternator control unit (3VR1)
rectifier unit (TRU). The TRU supplies power only and current transformer (3T3) are also activated by
when the alternator is in operation since TRU input the switching procedure and monitor phase
power is dependent on the alternator. Secondary ac relationship and frequency at the alternator assuring
power is supplied by a solid state, three phase, wye that proper voltages and frequencies are furnished to
connected 115 Vat, 400 Hz, 750 Va inverter. Inverter the ac distribution system.
power is utilized when engine speed is insufficient to
bring the alternator on-line or an alternator failure NOTE
occurs. The BATTERY switch activates the inverter in
RUN position. The inverter is inhibited when the ELEC PWR switch (2S4), when
alternator is in operation. The ALTNR switch positioned to the EMER OFF position,
energizes the alternator to supply its power to the 115 removes all electrical power from the
Vac buses and TRU when in the ON position. It resets helicopter systems.
9-60
TM 55-1520-236-23
9-129. q q I N V E R T E R SYSTEM. MASTER and ALTER caution lights are not
illuminated.
9-130. ~ ~ DESCRIPTION -
INVERTER SYSTEM. g. Position ELEC PWR switch to EMER OFF.
Verify that no voltage is present at ENG VIB METER
The inverter system is comprised of BATTERY switch receptacle.
(2S1), ac source relay (3K1), ac control relay (3K2),
inverter remote control circuit breaker (3CB7) and NOTE
inverter (3PS1). With ALTNR switch (3S1) positioned The reference transformer (3T1) is
to OFF RESET, ELEC PWR switch (2S4) positioned to functionally tested when turret and TOW
ELEC PWR, and BATTERY switch (2S1) positioned to missile systms are operated, The
RUN, ac source relay (3K1) and ac control relay (3K2) 115/28 Vac transformer (3T4) is
are de-energized. A ground circuit for inverter f u n c t i o n a l l y t e s t e d when the
remote control circuit breaker (3CB7) is furnished gyromagnetic compass and adf
when the BATTERY switch (2S1) is positioned to navigation systems are operated.
RUN and INVTR circuit breaker (3CB1) is closed.
With inverter remote control circuit breaker closed, h. Connect dc voltmeter to transformer-rectifier
28 vdc is applied from essential relay (2K9) to the unit (3PS2) positive and negative terminals. With the
inverter. With power applied to the inverter, an helicopter engine running, position ELEC PWR switch
output of 115 vac from the inverter is routed to the to ELEC PWR. Verify approximately 28 Vdc power is
at/armament circuit breaker panel (3A1). present between positive and negative terminals of
transformer- rectifier unit.
9-131. ~~ FUNCTIONAL TEST - AC
POWER SYSTEM. i. Open TRU circuit breaker (3CB2) on the de
circuit breaker panel. Verify that no voltage is present
a. Connect ac voltmeter to ENG VIB METER at transformer-rectifier unit positive and negative
receptacle (3J1). terminals.
b. Start helicopter engine in accordance with j. Close TRU and INV circuit breakers. Verify 115
TM 55-1520-236-10. Vac is present at ENG VIB METER receptacle and 28
Vdc is present at transformer-rectifier unit positive
NOTE and negative terminals.
With helicopter engine operating at 100
percent (6600 rpm) the alternator k. Position ALTNR switch to OFF and BATTERY
electrical output frequency should be switch to RUN. Verify that no voltage is present at
399 1 Hz. transformer-rectifier unit positive and negative
terminals.
c. Open INV circuit breaker (3CB1) on the dc
circuit breaker panel. Verify that no voltage is present l. Verify 115 + 2.5, or -7.5 Vac, 400 7 Hz is
at ENG VIB METER receptacle, and MASTER and present at ENG VIB METER receptacle.
ALTER caution lights are illuminated.
m. Perform helicopter engine shutdown in
d. Position ALTNR switch (3S1) on pilot electrical accordance with TM 55-1520-236-10.
control to ON. Reset MASTER caution light. Verify
that 115 +2.5, -7.5 Vac is present at ENG VIB METER
9-132. q q TROUBLESHOOTING - AC
receptacle, and MASTER and ALTER caution lights
POWER SYSTEM.
are not illuminated.
e. Position ALTNR switch to OFF. Verify that no Refer to paragraph F-9 in Appendix F for wiring
voltage is present at ENG VIB METER receptacle, and diagram. Use Table 9-9 and perform checks as
MASTER and ALTER caution lights are illuminated. necessary to isolate trouble. In the following table,
tripped circuit breakers are omitted from indications
f. Position ALTNR switch to ON and ELEC PWR of trouble. Such trouble is usually easily detected and
switch (2S4) on gunner miscellaneous control panel corrected. Broken wiring is always a probable cause
to ELEC PWR. Reset MASTER caution light. Verify of circuit malfunction or failure and has not been
115 Vac is present at ENG VIB METER receptacle, and included.
Change 2 9-61
TM 55-1520-236-23
NOTE
Before you use this table, be sure you
have performed all normal operational
checks. If you have a malfunction which
is not listed in this table, notify the next
higher level of maintenance.
Table 9-9. _ roubleshooting AC Power System
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. Alternator fails to supply ac power to ac system.
STEP 1. Check AC source relay (3K1) coil for open circuit.
Replace relay if coil is open (paragraph 9-16).
STEP 2. Check for defective ALTNR switch (3S1).
Replace switch if defective (paragraph 9-16).
STEP 3. Check for defective ELEC PWR switch (2S4).
Replace switch if defective (paragraph 9-16).
STEP 4. Check for defective alternator control unit (3VR1).
Replace unit if defective (paragraph 9-206).
STEP 5. Check for defective current transformer (3T3)
Replace transformer if defective (paragraph 9-221).
STEP 6. Check for defective alternator (3G1).
Replace alternator if defective (paragraph 9-158).
2. Inverter fails to supply ac power to ac system when ALTNR switch is in OFF RESET position.
STEP 1. Determine if the inverter is operating. If inverter is operating, check for 115 Vac output at the
inverter connector (3PS1P2) pins A, B, and C.
Replace inverter if 115 Vac is not present (paragraph 9-142).
STEP 2. If inverter is not operating, check for 28 Vdc at the inverterconnector (3PS1P1) pin C, and ground at
pin A.
Replace inverter if 28 Vdc was present at 3PS1P1 pin C and ground was present at 3PS1P1 pin A
(paragraph 9-142).
9-62 Change 16
TM 55-1520-236-23
Table 9-9. q ~ Troubleshooting AC Power System (Cont)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
STEP 3. Check for ground circuit at inverter circuit breaker (3CB7) terminal 3.
Replace circuit breaker if ground circuit is present (paragraph 9-16).
STEP 4. Deleted.
STEP 5. Check INV circuit breaker (3CB1) for continuity.
Replace circuit breaker if continuity was not present (paragraph 9-16).
STEP 6. Check BATTERY switch (2S1) for continuity from terminals 2 to 3 with switch in RUN position.
Replace switch if continuity is not present (paragraph 9-16).
9-133. ~ MAIN INVERTER. prolonged breathing of solvent vapors
and contact with skin or eyes.
9-134. @ DESCRIPTION - MAIN b. Remove grease, fungus, and ground-in dirt
INVERTER. with a clean, lint-free cloth dampened with dry
The main inverter is a 750 VA solid state, single- cleaning solvent (C112).
phase or three-phase delta-connected with an output
of 115 + 2.5, or -7.5 Vac, 400 7 Hz, 0.75 lagging to c. Remove dirt from electrical connectors with a
0.95 leading power factor, 65 percent efficiency. The bristle brush.
main inverter supplies single-phase power to the ac
bus system until TOW is selected, then switches to 9-136. q INSPECTION - MAIN
three-phase power wired delta to power the ac bus INVERTER.
system, TOW missile system, and reference
transformer which supplies necessary power for the a. Inspect case for cracks or damage.
M65 TOW missile subsystem and M136 helmet sight
subsystem. b. Inspect electrical connectors for broken pins or
cracked connector inserts.
9-135. ~ CLEANING - MAIN INVERTER.
c. Check for bonding and security of mounting.
a. Remove moisture and loose dirt with a clean,
soft cloth. d. Check for faulty operation.
9-137. q OPERATIONAL CHECK - MAIN
INVERTER.
Cleaning solvent is flammable and toxic. Refer to paragraph 9-123 for operational check of
Provide adequate ventilation. Avoid main inverter.
Change 2 9-63
TM 55-1520-236-23
9-138. W ADJUSTMENT - MAIN 9-142. m ~ INVERTER.
INVERTER.
9-143. ~ DESCRIPTION - INVERTER.
No adjustment can be made. (Refer to TM 11-6130-
385-34.) The inverter is a 750 Va, 3-phase, wye connected
inverter. it receives power from the essential dc bus
through the inverter remote control circuit breaker.
Carefully support inverter during 9-144. n q CLEANING - INVERTER.
removal and installation to preclude
a. Remove moisture and loose dirt with a clean,
damage to equipment.
soft cloth.
9-139. ~ REMOVAL - MAIN INVERTER.
a. Ensure all electrical power is OFF.
b. Disconnect electrical connectors from inverter. Cleaning solvent is flammable and toxic.
Protect receptacles and plugs with caps or electrical Provide adaquate ventilation. Avoid
tape (C121). prolonged breathing of solvent vapors
and contact with skin or eyes.
c. Remove mounting bolts, washers, and nuts.
Carefully lower inverter from compartment ceiling. b. Remove grease, fungus, and ground-in dirt
with a clean, lint-free cloth dampened with dry
9-140. q REPAIR - MAIN iNVERTER. cleaning solvent (C112).
Repair connectors, and replace missing mounting c. Remove dirt from electrical connectors with a
bolts. For further repair refer toTM 11-6130-385-34. bristle brush.
9-145. W~ INSPECTION - INVETER.
Carefully support inverter during a. Inspect case for cracks or damage.
removal and installation to preclude
damage to equipment. b. Inspect electrical connectors for broken pins or
cracked connector inserts.
9-141. q INSTALLATION - MAIN
INVERTER. c. Check for bonding and security of mounting.
a. Ensure all electrical power is OFF. d. Check for faulty operation.
NOTE 9-146. q q ADJUSTMENT INVERTER.
Some inverters have a thinner mounting No adjustment can be made (Refer to TM 11-6130-
flange than others, In these cases, use 385-34).
washers AN960PD516 between bolt
head and mounting flange.
b. Carefully position and secure inverter in
compartment with mounting bolts, washers, and Carefully support the inverter during
nuts. removal and installation to preclude
damage to equipment.
c. Remove caps or electrical tape from plugs and
receptacles.
9-147. ~ q REMOVAL - INVERTER.
d. Connect electrical connectors to the inverter. a. Ensure all electrical power is OFF.
9-64
TM 55-1520-236-23
b. Disconnect electrical connectors from inverter.
Protect receptacles and plugs with caps or electrical
tape (C121).
c. Remove mounting bolts, washers, and nuts.
Cleaning solent is flammable and toxic.
Carefully lower inverter from compartment ceiling.
Provide adequate ventilation. Avoid
prolonged breathing of solvent vapors
9-148. ~ q REPAIR - INVERTER. and contact with skin or eyes.
Repair connectors, and replace mounting bolts. For b. Remove grease, fungus, and ground-in dirt
further repair refer to TM 11-6130-385-34. with a clean, lint-free cloth dampened with dry
cleaning solvent (C112).
9-149. ~R I N S T A L L A T I O N -
INVERTER. c. Remove dirt from electrical connectors with a
bristle brush.
a. Ensure all electrical power is OFF.
9-153. ~ INSPECTION - STANDBY
INVERTER.
Carefully support the inverter during a. Inspect case for cracks or damage.
removal and installation to preclude
damage to equipment. b. Inspect electrical connectors for broken pins or
NOTE cracked connector inserts.
Inverter mounting pads may vary in c. Check for bonding and security of mounting.
thickness. Add washers as necessary for
secure installation of inverter. d. Check for faulty operation.
b. Carefully position and secure inverter in 9-154. m A D J U S T M E N T - S T A N D B Y
compartment with mounting bolts, washers, and INVERTER.
nuts.
a. Open aft compartment access door to gain
c. Remove caps or electrical tape from plugs and access to the inverter.
receptacles.
NOTE
d. Connect electrical connectors to the inverter.
To properly conduct the inverter check,
9-150. ~ STANDBY INVERTER. apply a regulated 28 Vdc external power
source or ground run the helicopter to
9-151. ~ D E S C R I P T I O N - S T A N D B Y assure an adequate source of dc power
INVERTER. for inverter operation. Do not use
helicopter battery power.
The standby inverter is a 250 VA motor-driven,
single-phase inverter with an output of 115 3 Vac, b. Turn on inverter. Close all ac circuit breakers
400 7 Hz, 0.80 lagging to 0.95 leading power factor. and actuate ac circuits.
The standby inverter provides normal single-phase
power for the 115 Vac bus and is a backup unit for the c. Using multimeter (T77) and frequency meter
main inverter. (T7.1), check output voltage and frequency at the 115
Vac bus (engine vibration receptacle or other
9-152. ~ CLEANING - STANDBY convenient monitoring point).
INVERTER.
d. If the output voltage is 115 2.5 vac, and the
a. Remove moisture and loose dirt with a clean, frequency is between 380 and 520 Hz, no ajustment
soft cloth. is necessary.
9-65
TM 55-1520-236-23
e. If the output voltage isaboveorbelowthe limits b. Carefully position and secure inverter in
prescribed in the preceding step, proceed as follows: compartment with mounting bolts, washers, and
Turn off de power to inverter. Remove cover from end nuts.
of inverter. (It may be necessary to remove the
inverter from mounting.) Loosen hex-head jam nut c. Remove cap or electrical tape from plug and
securing adjustment screw. receptacle.
f. Close all ac circuit breakers. Actuate all ac d. Connect electrical connector to the inverter.
circuits. Turn on inverter power. Connect multi meter
and frequency meter at one of the test points
described in step c. and note reading. Turn inverter 9-158. ~ ALTERNATOR.
output adjustment screw counterclockwise to
increase or clockwise to decrease inverter output. 9 - 1 5 9 . #m D E S C R I P T I O N -
Nominal setting of 111 volts at full output load should ALTERNOR.
produce an output frequency within limits of 380 TO The alternator is mounted on and driven by the
420 Hz. See figure 9-12 for directional references. transmission. It is rated at 10 kva, 3-phase, wye-
connected, 120/208 v, 400 Hz. In normal operation,
9-155. ~ REMOVAL - STANDBY the alternator is energized and is driven at a speed
INVERTER. corresponding to 100 percent or 324 rpm rotor speed.
Under these operating conditions the frequency is
a. Ensure all electrical power is OFF. 399 1 Hz. It is energized by placing ALTNR switch
(3S1) to the ON position, and de-energized by placing
b. Disconnect electrical connector from inverter. this switch to OFF position. Alternator is
Protect receptacle and plug with cap or electrical tape automatically connected to the 3-phase AC buses
(C 121). when it is energized and the frequency is 360 5 Hz
(corresponding to 90 percent or 292.5 RPM rotor
c. Remove mounting bolts, washers, and nuts. speed) or higher. Alternator is automatically
Carefully lift inverter from compartment. disconnected from the buses when de-energized, or
when frequency falls below 360 5 Hz (below 90
9-156. ~ REPAIR - STANDBY INSERTER. percent rotor RPM).
Repair connectors, replace missing mounting bolts Refer to paragraphs 9-126, 9-128, 9-131, and 9-132
and replace unit if other inspection requirements are for further information.
not met. (Refer to TM 11-6125-220-12 and -35.)
9 - 1 6 0 . ~ C L E A N I N G
9-157. q INSTALLATION - STANDBY ALTERNATOR.
INVERTER.
a. Remove moisture and loose dirt with a clean,
a. Ensure all electrical power is OFF. soft cloth.
Figure 9-12. ~ Standby Inverter Adjustment
9-66
TM 55-1520-236-23
9-164. q w REPAIR - ALTERNATOR.
Repair connectors, and tighten loose terminals.
Cleaning solvent is flammable and toxic. 9-165. ~ INSTALLATION
Provide adequate ventilation. Avoid ALTERNATOR.
prolonged breathing of solvent vapors a. Ensure all electrical power is OFF.
and contact with skin or eyes.
b. Install packing on shaft.
c. Apply light coat of grease (C85) on driveshaft and
b. Remove grease, fungus, and ground-in dirt with with wire bundles at 12 oclock, carefully position alter-
a clean, lint-free cloth dampened with dry cleaning nator into drive quill splines.
solvent (C112).
c. Remove dirt from electrical connectors with a Carefully support alternator during
bristle brush. removal and installation to preclude
damage to equipment.
9-161. g INSPECTION -
ALTERNATOR. Alignment pin on quill flange must
align with corresponding hole in alter-
a. Inspect case for cracks or damage. nator flange.
NOTE
b. Inspect electrical connectors for broken pins or Clean mating splines before installa-
cracked connector inserts. tion of alternator with plastilube.
d. Reinstall V-band clamp. Tap around V-band
c. Check for bonding and security of mounting. clamp with plastic mallet to assure clamp is seated
while torquing retaining nut 50 TO 70 inch-pounds.
d. Check for faulty operation.
e. Remove caps or electrical tape from plugs and
9-162. q R ADJUSTMENT - receptacles.
ALTERNATOR.
f. Connect electrical connectors to the alternator.
No adjustment can be made.
g. Close cowl.
9-163. ~ REMOVAL - ALTERNATOR.
9-166. ~ MAIN INVERTER POWER RELAY.
9-167. q DESCRIPTION - MAIN INVERTER
a. Ensure all electrical power is OFF.
POWER RELAY.
The main inverter power relay (3K1) is used as a
b. Open left transmission cowl.
remote controlled switch. When energized, 28 Vdc is
routed from the essential bus through the main inverter
c. Disconnect electrical connectors from alternator.
overload sensor (3S2) to the main inverter (3PS1).
Protect receptacles and plugs with caps or electrical
(Refer to paragraph 9-18 through 9-22 for maintenance
tape (C121).
procedures.)
9-168. q STANDBY INVERTER POWER
RELAY.
9-169. q D E S C R I P T I O N - S T A N D B Y
Carefully support alternator during INVERTER POWER RELAY.
removal and installation to preclude
damage to equipment.
The standby inverter power relay (3K2) is used as
a remote controlled switch. When energized, 28 Vdc
d. Remove Iockwire, if installed, and loosen V-band is routed from the Non-essential bus through the
attaching bolt. Remove V-band and remove alternator. standby inverter overload sensor (3S3) to the standby
Change 16 9-67
TM 55-1520-236-23
inverter (3MG1). (Refer to paragraphs 9-18 through 9-178. ~ THREE-PHASE TO SINGLE-
9-22 for maintenance procedures.) PHASE INVERTER RELAY.
9-170. q M A I N INVERTER 9-179. ~ DESCRIPTION - THREE-PHASE
OVERLOAD SENSOR. TO SINGLE-PHASE INVERTER RELAY.
9-171. ~ DESCRIPTlON - MAIN The three-phase to single-phase inverter relay (3K4)
INVERTER OVERLOAD SENSOR. is used as a six-pole, double-throw remote controlled
switch. When armament TOW mode is selected, the
The main inverter overload sensor (3S2) is used to three-phase to single-phase inverter relay is
automatically de-energize the main inverter power energized to supply three-phase 115 Vac from the
relay (3K1) when an overload exists between the main inverter (3PS1) to the REF XFMR and TOW PWR
main inverter (3PS1) and the 28 Vdc essential bus. circuit breakers. Also, a portion of the TOW blower
(Refer to paragraphs 9-18 through 9-22 for circuit is completed when relay is energized. When
maintenance procedures.) relay is de-energized, 115 Vac (A phase) is routed to
REF XFMR circuit breaker. (Refer to paragraphs 9-18
9-172. q STANDBY INVERTER through 9-22 for maintenance procedures.)
OVERLOAD SENSOR.
9-180. ,# MAIN AC FAIL RELAY.
9-173. ~ D E S C R I P T I O N - S T A N D B Y
INVERTER OVERLOAD SENSOR. 9-181. ~ DESCRIPTION - MAIN AC FAIL
RELAY.
The standby inverter overload sensor (3S3) is used to
automaticIly de-energize the standby inverter power The main ac fail relay (3K5) monitors 115 Vac output
relay (3K2) when an overload of current exists from the main inverter (3PS1). When energized by
between the standby inverter (3MG1) and the 28 Vdc main inverter output, the relay completes the circuit
Non-essential bus, (Refer to paragraphs 9-18 through from INV MAIN circuit breaker to actuate the inverter
9-22 for maintenance procedures.) select relay (3K6). When de-energized, the relay
completes the INV MAIN caution light circuit. (Refer
9-174. ~ AC POWER CONTROL to paragraphs 9-18 through 9-22 for maintenance
RELAY. procedures.)
9-175. q DESCRIPTION - AC POWER 9-182. q STANDBY AC FAIL RELAY.
CONTROL RELAY.
9-183. q DESCRIPTION - STANDBY AC
The ac power control relay (3K3) is used as a double- FAIL RELAY.
pole, double-throw remote controlled switch. When
energized, the relay separates and balances the ac The standby ac fail relay (3K7) monitors 115 Vac
loads on main inverter (3PS1). When de-energized, output from the standby inverter (3MG1). When
the relay connects the ac loads to the standby inverter energized by standby inverter output, the relay opens
(3MG1). (Refer to paragraphs 9-18 through 9-22 for the INV STBY caution light circuit. When de-
maintenance procedures.) energized, the relay, in conjunction with de-
energized inverter select relay (3K6), completes the
9-176. m lNVERTER SELECT RELAY. INV STBY caution light circuit. (Refer to paragraphs 9-
18 through 9-22 for maintenance procedures. )
9-177. q DESCRIPTION - INVERTER
SELECT RELAY.
9-184. ~ MAIN INVERTER FAIL LIGHT
The inverter select relay (3K6) is used as a six-pole, RELAY
double-throw remote controlled switch. The relay
provides automatic switch-over to the standby 9-185. q DESCRIPTION - MAIN
inverter (3MG1) in the event of a main inverterfailure INVERTER FAIL LIGHT RELAY.
and, also, provides control of the ac power control
relay (3K6). (Refer to paragraphs 9-18 through 9-22 The main inverter fail light relay (3K8) interrupts the
for maintenance procedures.) MAIN INVTR caution light circuit when INV selector
9-68
TM 55-1520-236-23
switch is in the STBY INVTR position. When de- 9-191. REMOVAL - 115/28 VAC
energized, this relay completes the MAIN INVTR TRANSFORMER.
caution light circuit. (Refer to paragraphs 9-18
through 9-22 for maintenance procedures.) a. Ensure all electrical power is OFF.
9-186. 115/28 VAC TRANSFORMER. b. Disconnect wiring from transformer and cover
wire ends. Tag wires for proper identification.
9-187. DESCRIPTION - 115/28 VAC
TRANSFORMER. c. Remove mounting screws and lift transformer
from compartment.
The 115/28 Vac transformer (3T4) is an
autotransformer that reduces 115 Vac to 26 Vac, to 9-192. R E P A I R - 115/28 VAC
power the 26 Vac bus, for operation of navigation TRANSFORMER.
instruments.
Repair is limited to tightening or properly installing
9-188. CLEANING - 115/28 VAC any loose or improperly installed mounting hardware.
TRANSFORMER. Replace transformer if damaged.
a. Remove moisture and loose dirt with a clean, 9-193. INSTALLATION - 115/28 VAC
soft cloth. TRANSFORMER.
a. Ensure all electrical power is OFF.
b. Position transformer in compartment and
secure with mounting screws.
Cleaning solvent is flammable and toxic.
Provide adequate ventilation. Avoid c. Remove cover from wire ends and connect
prolonged breathing of solvent vapors tagged wires to transformer.
and contact with skin or eyes.
9-194. REFERENCE TRANSFORMER.
b. Remove grease, fungus, and ground-in dirt
with a clean, lint-free cloth dampened with dry
9-195. DESCRIPTION - REFERENCE
TRANSFORMER.
cleaning solvent (C112).
The reference transformer (3T1) furnishes various
9-189. INSPECTION - 11 5/28 VAC reference voltages (0.5, 5, 10, 26, and 115 Vac)
TRANSFORMER. required by the armament subsystems. The 115 Vac
input and output power is routed through a receptacle
a . Inspect transformer for broken contact pins. mounted on the transformer. q m The reference
transformer transforms 115 Vac, 400 Hz, 3 phase
b. Inspect transformer case for damage. wye to 115 Vac, 400 Hz 3 phase delta.
c. Inspect for damaged insulation between 9-196. CLEANING - REFERENCE
terminals. TRANSFORMER.
d. Check for discoloration that would indicate a. Remove moisture and loose dirt with a clean,
internal shorting or excessive overload. soft cloth.
e. Check for security of mounting.
9-190. ADJUSTMENT - 115/28 VAC Cleaning solvent is flammable and toxic.
TRANSFORMER. Provide adequate ventilation. Avoid
prolonged breathing of solvent vapors
No adjustment can be made. and contact with skin or eyes.
9-69
TM 55-1520-236-23
b. Remove grease, fungus, and ground-in dirt 9-202. POWER FACTOR
with a clean, lint-free cloth dampened with dry CORRECTION CAPACITOR.
cleaning solvent (C112).
9-203. DESCRIPTION - POWER FACTOR
9-197. INSPECTION - REFERENCE CORRECTION CAPACITOR.
TRANSFORMER.
The power factor correction capacitor (3C1) and (3C2)
a. Inspect transformer for broken contact pins. balances voltage and current for correct and efficient
operation of the instruments. (Refer to paragraph 9-
b. Inspect transformer case for damage. 16.)
c. Inspect for damaged insulation between 9-204. ENGINE VIBRATION METER
contact pins. RECEPTACLE.
d. Check for discoloration that would indicate 9-205. DESCRIPTION - ENGINE
internal shorting or excessive overload. VIBRATION METER RECEPTACLE.
e. Check for security of mounting. The engine vibration meter receptacle (3J1) is
powered from the 115 Vac bus, and used as a source
9-198. ADJUSTMENT - REFERENCE of 115 Vac power for the vibration meter during
TRANSFORMER. engine vibration tests. It is also used as a convenient
point to monitor ac voltage from the 115 Vac essential
No adjustment can be made. bus during functional tests or troubleshooting.
9-206. ~~ ALTERNATOR CONTROL
9-199. REMOVAL - REFERENCE UNIT
TRANSFORMER.
9 - 2 0 7 . ~g D E S C R I P T I O N --
a. Ensure all electrical power is OFF. ALTERNATOR CONTROL UNIT.
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 The alternator control unit (3VR1) regulates the ac
transformer. Protect receptacle and plug with cap or terminal voltage of the alternator by varying dc
electrical tape (C121). excitation voltage and controls the alternator.
c. Remove mounting screws and lift transformer 9-208. 9 ~ C L E A N I N G -
from compartment. ALTERNATOR CONTROL UNIT.
a. Remove moisture and loose dirt with a clean,
9-200. REPAIR - REFERENCE soft cloth.
TRANSFORMER.
Repair is limited to tightening or properly installing
any loose or improperly installed mounting hardware.
Replace transformer if damaged.
Cleaning solvent is flammable and toxic.
9-201. INSTALLATION - REFERENCE Provide adequate ventilation. Avoid
TRANSFORMER prolonged breathing of solvent vapors
and contact with skin or eyes.
a. Ensure all electrical power is OFF.
b. Remove grease, fungus, and ground-in dirt
b. Position transformer in compartment and with a clean, lint-free cloth, dampened with dry
secure with mounting screws. cleaning solvent (C112).
c. Remove protective cap or electrical tape from c. Remove dirt from electrical connectors with a
electrical connector and connect to transformer. bristle brush.
9-70
TM 55-1520-236-23
9-209. RE INSPECTION - The inverter remote control circuit breaker (3CB7) is
ALTERNATOR CONTROL UNIT. used as a remote controlled switch. When energized,
28 Vdc is routed from the power transfer bus through
a. Inspect case for cracks or damage. essential relay (2K9) to the inverter (3PS1). (Refer to
paragraph 9-14).
b. Inspect electrical connectors for broken pins or
cracked connector inserts. 9-216. ~ AC CONTROL RELAY.
c. Check for bonding and security of mounting. 9-217. ~ DESCRIPTION - AC
CONTROL RELAY.
d. Check for faulty operation.
9 - 2 1 0 . q A D J U S T M E N T - The ac control relay (3K2) is used as a double-pole,
ALTERNATOR CONTROL UNIT. double throw remote controlled switch. When
deenergized, the relay opens the ground for the TRU
No adjustment can be made. remote control circuit breaker (3CB6). When
energized, the relay connects transformer rectifier
9-211. m REMOVAL - ALTERNATOR unit (3PS2), through the TRU remote control circuit
CONTROL UNIT. breaker (3CB6), ac source relay (3K1), and current
transformer (3T3) to the alternator (3G1), when
a. Ensure all electrical power is OFF. alternator switch (3S1) is ON. (Refer to paragraph
9-1 6).
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
alternator control unit. Protect receptacle and PIug
with caps or electrical tape (C121). 9-218. ~ AC SOURCE RELAY.
c. Remove mounting screws, washers, and nuts. 9-219 .m~ DESCRIPTION - AC
Remove alternator control unit from helicopter. SOURCE RELAY.
9-212. m REPAIR - ALTERNATOR The ac source relay (3K1) is a four-pole, double throw
CONTROL UNIT. remote controlled switch. When de-energized, the
relay connects the ac loads to inverter (3PS1). When
Repair connectors, and replace any missing energized, the relay connects ac loads to alternator
mounting screws. (3G1). (Refer to paragraphs 9-16).
9-213. ~ g INSTALLATION -
ALTERNATOR CONTROL UNIT. 9-220. q C U R R E N T
TRANSFORMER.
a. Ensure all electrical power is OFF.
b. Position alternator control unit in helicopter
9-221 .~~ DESCRIPTION - CURRENT
TRANSFORMER.
and install mounting screws, washers, and nuts.
The current transformer (3T3) monitors phase
c. Remove caps or electrical tape from plugs and
relationship and frequencies at the alternator, and
receptacles.
assures that proper voltages and frequencies are
furnished to the ac distribution system.
d. Connect electrical connector to the alternator
control unit.
9-214. mm I N V E R T E R REMOTE 9-222. ~ C L E A N I N G - C U R R E N T
CONTROL CIRCUIT BREAKER. TRANSFORMER.
9-215. q q DESCRIPTION - INVERTER a. Remove moisture and loose dirt with a clean,
REMOTE CONTROL CIRCUIT BREAKER. aoft cloth.
Change 2 9-71
TM 55-1520-236-23
b. Position transformer in compartment and
secure with mounting screws.
c. Remove protective cap or electrical tape from
Cleaning solvent is flammable and toxic. plug and receptacle.
Provide adequate ventilation. Avoid
prolonged breathing of solvent vapors d. 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 t o t h e
and contact with skin or eyes. transformer.
b. Remove grease, fungus, and ground-in dirt 9-228. n m TRANSFORMER-
with a clean, lint-free cloth dampened with dry RECTIFIER UNIT.
cleaning solvent (C112).
9 - 2 2 9 . w~ DESCRIPTION -
9-223. q R INSPECTION - CURRENT TRANSFORMER-RECTIFIER UNIT.
TRANSFORMER.
The transformer-rectifier unit (3PS2) receives 115
a. Inspect transformer for broken contact pins. Vat, three phase from the alternator (3G1) and
changes it to 28 Vdc for TRU bus power.
b. Inspect transformer case for damage.
9 - 2 3 0 . mm CLEANING -
c. inspect for damaged insulation between pins. TRANSFORMER-RECTIFIER UNIT.
d. Check for discoloration that would indicate a. Remove moisture and loose dirt with a clean,
internal shorting or excessive overload. soft cloth.
e. Check for security of mounting.
9-224. m g ADJUSTMENT -
CURRENT TRANSFORMER.
Cleaning solvent is flammable and toxic.
No adjustment can be made. Provide adequate ventilation. Avoid
prolonged breathing of solvent vapors
9-225. ~~ R E M O V A L - C U R R E N T and contact with skin or eyes.
TRANSFORMER.
b. Remove grease, fungus, and ground-in dirt
a. Ensure all electrical power is OFF. with a clean, lint-free cloth dampened with dry
cleaning solvent (C112).
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
transformer. Protect receptacle and plug with cap or
electrical tape (C121).
9-231. m~ lNSPECTlON -
c. Remove mounting screws and lift transformer TRANSFORMER-RECTIFIER UNIT.
from compartment.
a. Inspect transformer-rectifier for broken
9 - 2 2 6 . ~ R E P A I R - C U R R E N T contact pins.
TRANSFORMER.
b. Inspect transformer-rectifier case for damage.
Repair is limited to tightening or properly installing
any loose or improperly installed mounting hardware. c. Inspect for damaged insulation between
Replace transformer if damaged. contact pins.
9-227. mm INSTALLATION - CURRENT d. Check for discoloration that would indicate
TRANSFORMER. internal shorting or excessive overload.
a. Ensure all electrical power is OFF. e. Check for security of mounting.
9-72
TM 55-1520-236-23
9-232. q m ADJUSTMENT - 9-235. Deleted.
TRANSFORMER-RECTIFIER UNIT.
9-236. TRU REMOTE CONTROL CIRCUIT
No adjustment can be made. BREAKER.
9 - 2 3 3 . ~~ R E M O V A L - 9-237. ~ DESCRIPTION - TRU
TRANSFORMER-RECTIFIER UNIT. (Refer to REMOTE CONTROL CIRCUIT BREAKER.
paragraph 9-112).
The TRU (transformer-rectifier unit) remote control
circuit breaker (3CB6) is used as a remote controlled
a. Deleted. switch. By placing alternator switch (3S1) to ON, TRU
remote control circuit breaker (3CB6) is energized,
b. Deleted. supplying power to transformer-rectifier unit (3PS2).
(Refer to paragraph 9-8.)
c. Deleted.
9-234. Deleted.
SECTION IV. STARTING SYSTEM
9-238. STARTING SYSTEM. (1K3) closes, and that voltage is present at the ends of
the disconnected wires.
9-239. DESCRIPTION - STARTING
SYSTEM . b Open STARTER RELAY circuit breaker (1CB7).
The starting system requires 24 Vdc power to activate c. Reconnect wires K4B4 and K4D4 after check.
the starter portion of the starter-generator during the
starting cycle. The 24 Vdc power source maybe either
from the external power source or battery. The 9-241. TROUBLESHOOTING - STARTING
starting system consists of the starter (1MG1), starter SYSTEM.
relay (1K3), and starter switch (1S36).
Refer to paragraph F-9 in Appendix F for wiring
9-240. FUNCTIONAL TEST - STARTING diagram. Use table 9-10 and perform checks as
SYSTEM. necessary to isolate trouble. In the following table,
tripped circuit breakers are omitted from indications
a. Disconnect wires K4B4 and K4D4 from of trouble. Such trouble is usually easily detected and
terminal C of the starter-generator. Close STARTER corrected. Broken wiring is always a probable cause
RELAY circuit breaker. Actuate starter switch (1S36) of circuit malfunction or failure and has not been
on pilot collective stick and check that starter relay included
Change 16 9-73
TM 55-1520-236-23
NOTE
Before you use this table, be sure you
have performed all normal operational
checks. If You have a malfunction which
is not listed in this table, notify the next
higher level of maintenance.
Table 9-10. Troubleshooting Starting System
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. Starter fails to operate when start switch is depressed.
STEP 1. Determine if START REL circuit breaker (1CB7) is defective.
Replace circuit breaker if defective (paragraph 9-23).
STEP 2. Determine if starter switch (1S36) is defective.
Replace starter switch if defective (paragraph 9-16).
STEP 3. With starter switch depressed, ensure that actuating voltage is present on terminal X1 and ground
potential is present on terminal X2 of starter relay (1K3). Determine if relay actuates.
Replace starter relay if defective (paragraph 9-16).
STEP 4. Determine if starter-generator brushes are excessively worn.
Replace brushes if worn excessively (paragraph 9-79).
STEP 5. Determine if starter-generator armature is burned out.
Replace starter-generator if defective (paragraph 9-79).
2. Starter fails to produce sufficient rpm during start cycle.
STEP 1. Determine if power source is producing sufficient current.
Use fully charged battery or connect an external power source.
STEP 2. Determine if starter-generator armature bearings are excessively worn.
Replace starter-generator if defective (paragraph 9-79).
STEP 3. Determine if malfunction is caused by excessive friction or hang up in engine or drive train.
Shutdown and correct mechanical malfunction.
9-74
TM 55-1520-236-23
9-242. STARTER. 9-244. STARTER RELAY.
9-245. DESCRIPTION - STARTER
RELAY.
9-243. DESCRIPTION - STARTER.
The starter-relay (1K3) is an electrically operated
The starter-generator (1MG1) is located on the switch between the main bus bar and the starter-
underside of the engine. This unit is used to start the generator. It is energized when the starter switch
engine, charge the battery, and supply power for (1S36) on the pilot collective stick is pressed. (Refer to
operation of dc equipment. (Refer to paragraphs 9-79 paragraphs 9-18 through 9-22 for maintenance
through 9-85 for maintenance procedures.) procedures).
SECTION V. IGNITION SYSTEM
9-246. IGNITION SYSTEM. switch (1S36) on pilot collective stick and check that
ignition unit and primer solenoid valve both operate.
9-247. DESCRIPTION - IGNITION
SYSTEM. c. Position FUEL switch (1S33) to OFF. Actuate
pilot STARTER switch (1S36) and check that neither
The ignition system is energized during the starting the ignition nor the solenoid valve operates.
cycle and controls fuel flow into the power plant and
initiates ignition in the combustion chamber. A key d. Reconnect starter wires K4B4 and K4D4.
lock ignition switch (1S39) is installed on left side of
pilot instrument panel. The ignition system consists
of the igniter pack and the engine primer solenoid 9-249. TROUBLESHOOTING - IGNITION
valve. SYSTEM.
9-248. FUNCTIONAL TEST - IGNITION Refer to paragraph F-9 in Appendix F for wiring
SYSTEM. diagram. Use Table 9-11 and perform checks as
necessary to isolate trouble. In the following table,
a. Disconnect starter wires K4B4 and K4D4. tripped circuit breakers are omitted from indications
of trouble. Such trouble is usually easily detected and
b. Close IGN SOL circuit breaker. Position FUEL corrected. Broken wiring is always a probable cause
switch (1S33) on pilot engine control panel and key of circuit malfunction or failure and has not been
lock ignition switch (1S39) to ON. Actuate pilot starter included.
NOTE
Before you use this table, be sure you
have performed all normal operational
checks. If you have a malfunction which
is not listed in this table, notify the next
higher level of maintenance.
Table 9-11. Troubleshooting Ignition System
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. Igniter or primer valve fails to operate when starter switch (1S36) is depressed.
9-75
TM 55-1520-236-23
Table 9-11. Troubleshooting Ignition System (Cont)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
STEP 1. Determine that starter switch (1S36) contacts are not corroded or burned.
If starter switch (1S36) contacts are corroded or burned, replace switch (paragraph 9-16).
STEP 2. Determine that key lock ignition switch (1S36) is functional.
If key lock ignition switch is not functioning properly, replace switch (paragraph 9-16).
STEP 3. Determine that fuel switch (1S33) is functional.
If fuel switch is not functioning properly, replace switch (paragraph 9-16).
STEP 4. Ensure igniter is functioning properly.
Replace igniter if required in accordance with TM 55-2840-229-23.
STEP 5. Determine that primer valve is functioning properly,
If primer valve is not functioning properly, replace valve in accordance with TM 55-2840-229-23.
9-250. IGNITER PACK. 9-252. ENGINE PRIMER SOLENOID
VALVE.
9-2510 DESCRIPTION - IGNITER PACK. 9-253. DESCRIPTION - ENGINE PRIMER
SOLENOID VALVE.
Ignition to the power plant is provided by the igniter
pack furnished with and attached to the engine. This The engine primer solenoid valve directs fuel to the
unit provides a continuous ignition arc during engine starting fuel nozzle during engine start. (Refer to TM
start cycle (Refer to TM 55-2840-229-23) 55-2840-229-23).
SECTION VI. LIGHTING PROVISIONS
9-254. LIGHTING PROVISIONS. 9-256. COCKPIT LIGHTS.
9-255, DESCRIPTION - LIGHTING 9-257. DESCRIPTION - COCKPIT
PROVISIONS. LIGHTS.
The lighting provisions, include cockpit lights, The cockpit lights (8DS13, 8DS14, and 8DS15)
console, engine, flight, and tactical lights, caution and are multi-purpose utility lights designed to selec-
warning lights systems, position lights, anti-collision tively provide either red or white (blue- green on-
light, searchlight, and transmission oil level light ly after NVG compatibility modification) il-
systems. lamination, utilizing a narrow spotlight beam or
a wide floodlight beam and protected by a 5
ampere CKPT LT circuit breaker.
9-76 Change 10
TM 55-1520-236-23
Controls necessary to obtain operational modes of b. Close CKPT LT circuit breaker. Check that pilot
ON-OFF, dim-bright, spot-flood, and red or white and gunner utility lights are operational in each mode
illumination are incorporated into the lamp body. (ON-OFF, dim-bright and spot-flood on both red and
white).
9-258. CLEANING - COCKPIT LIGHTS.
c Open CKPT LT circuit breaker
Clean cockpit lights in accordance with paragraph 9-
18. 9-261. TROUBLESHOOTING - COCKPIT
LIGHTS.
9-259. INSPECTION - COCKPIT LIGHTS.
Refer to paragraph F-9 in Appendix F for wiring
Inspect cockpit lights in accordance with paragraph diagrams. Use Table 9-12 and perform checks as
9-19. necessary to isolate trouble. In the following table,
tripped circuit breakers and burned out bulbs are
9-260. FUNCTIONAL TEST - COCKPIT omitted from indications of trouble. Such trouble is
LIGHTS. usually easily detected and corrected. Broken wiring
is always a probable cause of circuit malfunction or
a. Open all circuit breakers. failure and has not been included.
NOTE
Before you use this table, be sure you
have performed all normal operational
checks. If you have a malfunction which
is not listed in this table, notify the next
higher level of maintenance.
Table 9-12. Troubleshooting Cockpit Lights
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. Switch fails to operate lights.
STEP 1. Determine that lighting switch/rheostat is functioning properly.
If lighting switch/rheostat is not functioning properly, replace light (paragraph 9-16).
2. One light dim or out intermittent.
STEP 1. Check that light is properly grounded.
If light is not properly grounded, remove light and clean ground.
STEP 2. Check for corrosion in light socket.
Clean light socket terminals or replace light if required (paragraph 9-16).
9-77
TM 55-1520-236-23
9-262. REMOVAL - COCKPIT LIGHTS. Clean lights in accordance with paragraphs 9-18 and
9-32.
a Disengage COCKPIT LT circuit breaker (8CB8).
9-268. INSPECTION - CONSOLE, ENGINE,
b. Remove mounting hardware, lift out light FLIGHT, AND TACTICAL INSTRUMENT
assembly and disconnect light wire. LIGHTS.
Inspect lights in accordance with paragraphs 9-19 and
9-263. REPAIR-COCKPIT LIGHTS. 9-33.
Light assembly may be repaired by replacing damaged
or defective component parts. If light case is damaged 9-269. FUNCTIONAL TEST - CONSOLE,
beyond repair, complete unit must be replaced ENGINE, FLIGHT, AND TACTICAL INSTRU-
MENT LIGHTS.
9-264. INSTALLATION - COCKPIT LIGHTS. a. Open all circuit breakers.
a. Connect light wire and install light assembly with b. Close PLT INSTR LT circuit breaker (8CB6).
mounting hardware. Rotate FLIGHT instrument lights rheostat (8R11)
slightly in a clockwise direction and note that attached
b. Engage CKPT LT circuit breaker (8CB8) and switch closes. Continue clockwise rotation. Check that
check light for proper operation. all flight instruments on the pilot instrument panel
become illuminated and increase in brightness with
clockwise rotation of the rheostat.
9-265. CONSOLE, ENGINE, FLIGHT, AND
TACTICAL INSTRUMENT LIGHTS. c. Rotate CONSOLE lights rheostat (8R13) clock-
wise. Check that all control panels in the pilot left and
9-266. DESCRIPTION right consoles become illuminated and increase in
ENGINE, FLIGHT, AND TACTICAL INSTRU- brightness with rotation of the rheostat. Doppler indica-
MENT LIGHTS. tor light dims to fixed in tensity as rheostat is turned
from OFF.
The console, engine, flight, and tactical instrument
lights are energized by the 28 Vdc Essential Bus and d. Rotate TACTICAL lights rheostat (8R10) in the
protected by PLT INSTR LT and GNR INSTR LT 5 amp clockwise direction. Check that all tactical instrument
Circuit breakers. Four rheostats (8R10, 8R11, 8R12, lights on the pilot instrument panel become illuminated
and 8R13) mounted on the pilot lighting control panel and increase in brightness with clockwise rotation of
provide light dimming of the pilot console, engine, the rheostat.
flight, and tactical instrument lights. ARC-201 Singars
radio internal lighting is controlled by CONSOLE e. Rotate ENGINE lights rheostat (8R12) clock-
LIGHT rheostat (8R13) and a dimmer control assem- wise. Check that all engine instruments become illumi-
bly. ~ Two rheostats (8R3 and 8R4) mounted on the nated and increase in brightness with clockwise rota-
gunner miscellaneous control panel provide light dim- tion of the rheostat.
ming of gunner instrument and console lights. Rheostat
(8R5) on gunner instrument panel provides dimming of f. Deleted.
gunner tactical instrument lights. ~ ~ All three
rheostats (8R3, 8R4, and 8R5) are mounted on the
gunner instrument panel.
g. Open PLT INSTR LT circuit breaker.
9-267. CLEANING - CONSOLE, ENGINE,
FLIGHT, AND TACTICAL INSTRUMENT h. Close GNR INSTR LT circuit breaker. Rotate
LIGHTS. gunner INSTR LTS Rheostat (8R3) slightly in a
clockwise direction and note that attached switch
9-78 Change 19
TM 55-1520-236-23
closes. Continue clockwise rotation. Check that gun- cuit breakers.
ner caution panel, edge-lit panel and all instrument
lights on gunner instrument panel become illuminated b. Adjust cockpit instrument lights to maximum
and increase in brightness with clockwise rotation of brightness.
the rheostat.
c. Measure input voltage (Vdc) by connecting
i. Rotate gunner CSL LT Rheostat (8R4) in a positve test lead of multimeter (T2 or equivalent) to
clockwise direction. Check that all lights on the gunner termmal 1 of DIM TB1 and negative lead to terminal 3
console panel become illuminated and increase in of DIM TB1. Record voltage and determine corre-
brightness with clockwise rotation of the rheostat. sponding output voltage (Table 9-12.1).
j. D e l e t e d . d. Set multimeter to record Vac and connect leads
to terminals 3 and 4 of DIM TB1. Loosen dimmer net-
k. Open all circuit breakers. work locking nut and using a screwdriver, adjust dim-
mer network until multimeter indicates output voltage
9-269.1. ADJUSTMENT -- DIMMER CONTROL determined in paragraph 9-269.1.c. Retighten dimmer
network locking nut.
a. Energize AN/ARC-201 and cockpit lighting cur-
TABLE 9-21.1. DIMMER CONTROL lNPUT/OUTPUT VOLTAGES
INPUT OUTPUT
(VDC) (VAC)
20 45.5
21 47.5
22 50.0
23 52.5
24 55.0
25 57.5
26 60.0
27 62.5
28 65.0
29 67.5
30 70.0
NOTE
Desired voltage is 28VDC input for 65.0 VAC output.
9-270. TROUBLESHOOTING - CONSOLE, cuit breakers and burned out bulbs are omitted from
ENGINE, FLIGHT, AND TACTICAL INSTRU- indications of trouble. Such trouble is usually easily
MENT LIGHTS. detected and corrected. Broken wiring is always a
probable cause of circuit malfunction or failure and has
Refer to paragraph F-9 in Appendix F for wiring dia- not been included.
grams. Use Table 9-13 and perform checks as neces-
sary to isolate trouble. In the following table tripped cir-
9-78.1(9-78.2 blank)
TM 55-1520-236-23
NOTE
Before you use this table, be sure you have
performed all normal operational checks. If
you have a malfunction which is not listed in
this table, notify the next higher level of main-
tenance.
Table 9-13. Troubleshooting Console, Engine, Flight, and Tactical Instrument Lights
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. Rheostat fails to operate lights (on position or dimming).
STEP 1. Determine if rheostat is functioning properly.
If rheostat is not functioning properly, replace rheostat (paragraph 9-16).
2. ~ Doppler indicator lights fail to dim or go off when console lights rheostat is turned from OFF.
STEP 1. Determine if relay RP7633G152 is functioning properly.
If relay RP7633G152 is not functioning propely, replace relay.
STEP 2. Determine if resistor between 8TB5-B9 and 8TB5-D9 is functional.
If resistor is faulty, replace resistor.
9-271. REMOVAL - CONSOLE. ENGINE, 9-272. REPAIR - CONSOLE, ENGINE,
FLIGHT, AND TACTICAL INSTRUMENT FLIGHT, AND TACTICAL INSTRUMENT
LIGHTS. LIGHTS.
Remove lights in accordance with paragraph 9-20. Repair lights in accordance with paragraph 9-21.
Change 19 9-79
TM 55-1520-236-23
9-273. INSTALLATION - CONSOLE, CAUTION lights momentarily illuminate brightly and
ENGINE, FLIGHT, AND TACTICAL then extinguish and that all caution light segments
momentarily illuminate brightly and return to their
INSTRUMENT LIGHTS. previous condition.
Install lights in accordance with paragraph 9-22. d. Push BRIGHT/DIM switch to DIM and release.
Check that caution lights do not dim.
9-274. CAUTION LIGHT SYSTEM.
e. Rotate pilot CONSOLE lights rheostat clock-
9-275. DESCRIPTION - CAUTION LIGHT wise from OFF. Place the DIM/BRIGHT switch to DIM
SYSTEM. and release. Check that the lights dim and hold.
The caution light system includes the pilots and f. Rotate CONSOLE lights rheostat counterclock-
gunners caution panels. The purpose of these units is wise to OFF and check that the lights return to
to provide a visual warning in the event of system bright.
malfunctions in the helicopter. The pilots and gunners
caution panels (see figures 9-13 through 9-17.1) 9-276. FUNCTIONAL TEST - CAUTION LIGHT
contain independent lights and internal lamp driver SYSTEM.
circuits. The lights are arranged in four columns in the
pilots caution panel, and three in the gunners panel. a. During the following checks, the MASTER
Each light has its own unique nomenclature filter and CAUTION lights should illuminate each time a cau-
two individual lamps. These illuminate when tion panel segment illuminates and shall be reset
associated sensor/switches, located in the helicopter each time in readiness for another fault indication. All
to monitor various systems, actuate to complete checks shall apply to both pilots and gunners caution
circuits, indicating malfunctions. The panels are panels, as applicable.
energized from a 28 Vdc essential bus and protected
by a 5 ampere CAUT LT circuit breaker located in the b. Accomplish the following caution light cir-
pilot dc circuit breaker panel (2A1). cuitry functional test steps in sequence:
9-275.1. FUNCTIONAL TEST - CAUTION LIGHT (1) Engine Oil Pressure Lights.
PANEL.
(a) Connect a variable pressure tester (Tl2),
During the following checks, MASTER CAUTION or equivalent, to engine oil pressure switch (1S13)
light on pilots and gunners instrument panels should and apply pressure. Check that ENG(INE) OIL PRESS
illuminate each time a caution panel segment caution lights extinguish at 27 1 psig increasing.
illuminates, except for pilot q EMER HYDR PUMP
ON 9 q EMERG HYD PUMP ON segment, and (b) Relieve pressure on engine oil pressure
switch. Check that ENG(INE) OIL PRESS caution
shall be reset each time in readiness for another fault
lights illuminate at 25 psig decreasing.
indication. All checks shall apply to both pilots and
gunners caution panels as applicable.
(2) Transmission Oil Pressure Lights.
a. Close CAUT LT and q GOV CONT g (a) Disconnect connector (1S9P1) from
GOV CONTR circuit breakers. Check that MASTER transmission oil pressure switch (1S9). Check that
CAUTION lights illuminate and that each caution
~ XMSN OIL PRESS q TRANS OIL PRESS cau-
light segment operates as indicated below.
tion lights extinguish.
b. Reset MASTER CAUTION light by placing the (b) Apply temporary jumper between pins A
RESET/TEST switch to RESET and releasing. Check and B of connector (1S9P1). Check that q XMSN
that MASTER CAUTION lights extinguish and the OIL PRESS q q TRANS OIL PRESS lights illumi-
caution light segments remain as indicated in Tables nate.
9-14 and 9-15.
(c) Remove jumper and reconnect connec-
c. Test caution lights by placing the RESET/TEST tor. Check that q XMSN OIL PRESS q q TRANS
switch to TEST and releasing. Check that MASTER OIL PRESS lights are illuminated.
9-80
Change 16
TM 55-1520-236-23
Figure 9-13. ~ Pilot Caution Panel
Figure 9-14. ~ Pilot Caution Panel
Page 9-81, including Figure 9-14.1, has been deleted
Change 19 9-80.1/(9-80.2 blank)
TM 55-1520-236-23
Figure 9-15. ~ Piiot Caution Panel
Figure 9-15.1 - deleted.
(9-81 blank)/9-82 Change 19
TM 55-1520-236-23
Figure 9-14.1. q Pilot Caution Panel (After Incorporation of MWO 55-1520-236-50-12)
Change 16 9-81
TM 55-1520-236-23
Figure 9-15. * Pilot Caution Panel (Prior to Incorporation of MWO 55-1520-236-50-12)
Figure 9-15.1. q Pilot Caution Panel
(After Incorporation of MWO 55-1520-236-50-12)
9-82 Change 16
TM 55-1520-236-23
Figure 9-16. ~ Gunners Caution Panel
Figure 9-17. m m Gunner Caution Panel
Figure 9-17.1- deleted
Change 19 9-82.1/(9-82.2 blank)
TM 55-1520-236-23
Table 9-14. Pilots Caution Panel Lights Table 9-14. Pilots Caution Panel Lights-Continued
Table 9-15
Change 20 9-83
TM 55-1520-236-23
NOTE gunner XMSN OIL TEMP ~ ~ TRANS OIL HOT
caution lights illuminate.
Operate engine in accordance with
TM 55-1520-236-10. (b) Remove ground from transmission oil
temperature switch (1S8) and check that both caution
(d) Perform run-up to check transmission oil lights extinguish.
pressure switch (1S9) pressure actuation.
(6) Engine Fuel Pump Lights.
(3) Engine Oil Bypass Light.
Do not allow electrical wires to
make contact with each other or
with helicopter structure (ground).
(a) Disconnect wires W71D18 and W71E18
from forward fuel pressure switch (1S12) terminal on
left hand side of the engine. Check that both pilots and
gunners ENG FUEL PUMP caution lights are
extinguished.
(b) Temporarily connect wires W71D18 and
W71E18 to each other, but do not permit electrical
contact with forward fuel pressure switch terminal or
ground. Check that both pilot and gunner ENG FUEL
PUMP caution lights are illuminated.
(c) Reconnect wire W71D18 to forward fuel
pressure switch (1S12) terminal, but leave wire
W71E1 8 disconnected. Check that both pilot and
gunner ENG FUEL PUMP caution lights are illuminated.
(d) Reconnect wire W71E18 to forward fuel
pressure switch (1S12) terminal, thus returning the
wiring to its normally installed position. Check that both
ENG FUEL PUMP caution lights are illuminated.
(7) Engine Chip Light.
(a) Short engine chip detector (1E4) output
wire (W10C18) to ground. Check that ENG CHIP light
on pilot caution panel (8A2) illuminates.
(b) Check that CHIP DETECTOR light on
gunner caution panel (8A3) illuminates.
(8) 42 Chip Light.
(a) Short 42 chip detector (1E1) output wire
(W8C20) to ground. On helicopters with MWO 1-
1520-236-50-30 (ODDS), short pin 1 of chip detector
cable plug to ground. Check that 42 CHIP light on
pilot caution panel illuminates.
9-84 Change 20
TM 55-1520-236-23
(b) Check that CHIP DETECTOR light on
gunner caution panel illuminates.
(9) 90 Chip Light.
(a) Short 90 chip detector (1E2) output wire
(W9C20) to ground. On helicopters with MWO 1-
1520-236-50-30, short pin 1 of chip detector cable
plug to ground.
(b) Check that CHIP DETECTOR light on
gunners caution panel illuminates.
9-84.1/(9-84.2 blank)
TM 55-1520-236-23
(10) Transmission Chip Light.
(a) Short transmission chip detector (1E3)
output wire (W7C20) to ground. On helicopters with is low fuel in tanks, approximately
MWO 1-1520-236-50-30, short pin 1 of debris monitor 33 gallons, with nose down at 7
degrees, gage indication will read
225 pounds (actual fuel 209
illuminates. pounds) or less. Low level
switches (1S18 and 1S19) will be
(b) Check that CHIP DETECTOR light on closed and both pilots and
gunners caution panel illuminates. gunners FUEL LOW caution lights
will be illuminated.
(11) Forward Fuel Boost Light.
1 Disconnect plug (1S4P1) from forward
fuel boosst pressure switch (1S4) and plug (IS5P1)
from aft fuel boost pressure switch (1S5). Check that
Fuel boost caution lights tests may both FUEL LOW caution lights remain illuminated.
be performed simultaneously with
low fuel level tests. 2 Disconnect wire W34A22 from terminal
4 of terminal board (1TB6). Check that both FUEL
(a) Disconnect plug (1S4P1) on fuel manifold LOW caution lights extinguish.
valve. Check that FWD FUEL BOOST caution Iight
extinguishes. 3 Reconnect plug (IS4P1) to forward fuel
boost pressure switch (1S4). Check that both FUEL
(b) Reconnect plug. Check that FWD FUEL LOW caution lights illuminate.
BOOST caution light is illuminated.
4 Disconnect plug (IS4P1) from forward
(12) Fuel Filter Lights. fuel boost pressure switch (1S4). Check that both
FUEL LOW caution lights are extinguished.
(a) Disconnect plug (1S14P1) from fuel filter
bypass switch (1S14). Short pin A to pin B and check 5 Connect plug (1S5P1) to aft fuel boost
that both FUEL FILTER caution lights illuminate. pressure switch (1S5). Check that both FUEL LOW
caution lights are illuminated.
(b) Remove short from between pins A and
B of plug (1S14P1) and check that FUEL FILTER 6 Disconnect plug (1S5P1). Check that
caution lights extinguish. Reconnect plug. both FUEL LOW caution lights are extinguished.
(13) Fuel Low Light. 7 Reconnect wire W34A22 to terminal 4
on terminal (1TB6). Check that both FUEL
(a) Accomplish the following for low fuel level LOW caution lights are illuminated.
condition, 215 pounds or less: change second
paragraph of note to: If there is low fuel in tanks, tow 8 Disconnect wire W36A22 from terminal
level switches (1S18 and 1S19) will be closed and both 3 of terminal board (1TB7). Check that both FUEL
pilots and gunners fuel low caution tights will illuminate LOW caution lights are extinguished.
when aircraft is nose down at 7 degrees, gauge
indication will read 216-234 pounds (actual fuel 209 9 Connect plug (1S4P1) to forward fuel
pounds). boost pressure switch (1S4). Check that both FUEL
LOW caution lights are illuminated.
NOTE
10 Disconnect plug (1S4P1). Check that
This test and fuel boost caution both FUEL LOW caution lights are extinguished.
lights tests may be performed
simultaneously if desired. If there 11 Reconnect wire W36A22 to terminal 3
of terminal board (1TB7). Check that both FUEL LOW
caution lights are illuminated.
Change 20 9-85
TM 55-1520-236-23
1 2 Disconnect wire W37C22 from (a) Disconnect plug (1S5P1) on fuel
terminal 4 of terminal board (1TB7). Check that both manifold valve. Check that AFT FUEL BOOST caution
FUEL LOW caution Iights are extinguished Iight extinguishes.
13 Connect plugs (1S4P1 and 1S5P1). (b) Reconnect plug. Check that AFT FUEL
Check that FUEL LOW caution Iights do not illuminate. BOOST caution Iight is illuminated.
14 Reconnect wire W37C22 to terminal (15) DC Generator Lights. The DC GEN
4 of terminal board (1TB7). Check that both FUEL caution Iights are checked as apart of the dc generator
LOW caution lights are illuminated. system. (Refer to paragraphs 9-73 or 9-77.)
1 5 visually check that plugs (1S4P1
and 1S5P1) and wires W37C22, W36A22, and caution Iight is checked as a part of the main inverter
W34A22 are properly reinstalled on their proper recep- system. (Refer to paragraph 9-133.)
tacles and terminals. Cheek that each connection is
tight and secure.
caution Iight is checkd as a part of the main inverter
(b) Accomplish the following procedure for and standby inverter system. (Refer to paragraph
fuel in tanks, 235 pounds or greater. 9-150.)
NOTE
If the tanks have more than 236 pounds (a) Disconnect wire P17K20N from
of fuel, when aircraft is nose down at 7 2JB1 -B7. Check that both RECT Iights extinguish.
degrees low level switches (1S18 and
1S19) Will be open and both pilots (b) Reamed wire P17K20N to 2JB1-B7.
gunners fuel low caution lights wiII be Check that both RECT Iights illuminate.
extinguished.
1 Disconnect wire W37C22 from
terminal 4 of terminal board (1TB7) and temporarily (a) Disconnect wire X61A22N from air-
connect the wire to ground. Cheek that both FUEL frame structure. Check that both ALTER caution lights
LOW caution Iights illuminate. extinguish.
2 Remove wire W37C22 from ground (b) Reconnect wire X61A22N. Check that
and reconnect to terminal 4 of terminal board (1TB7). both ALTER caution lights illuminate.
Check that FUEL LOW caution Iights are extinguished.
(20) Governor Emergency Lights.
3 Remove wire W34A22 from terminal
4 of terminal board (1TB6) and temporarily connect to
ground. Check that FUEL LOW caution lights are GOV CONTR circuit breaker (1CB5) is dosed. Posi-
illuminated tion GOV switch (1S32) on pilot ENGINE control panel
and GOV switch (1S28) on gunner miscellaneous
4 Remove wire W34A22 from ground
and reconnect to terminal 4 of terminal board (1TB6).
Check that FUEL LOW caution Iights are extinguished.
(b) Place GOV switch on pilot control
(14) Aft Fuel Boost Light.
NOTE
Fuel boost caution lights test rnay be (c) Return GOV switch on pilot control
performed simultaneously with low fuel
level tests.
9-86 Change 22
TM 55-1520-236-23
(26) IFF CAUTION Light. IFF caution light is
functionally tested as part of the IFF system. (Refer to
TM 11-1520-236 series maintenance manuals.)
(a) Close FCC and HUD PWR circuit
breakers. Turn HUD power on. Check that HUD INOP (27) External Power Light.
caution light is not illuminated.
(a)
(b) Open HUD PWR circuit breaker, check
that HUD INOP caution Iight illuminates. power access door and check that EXT PWR caution
light on pilots caution panel illuminates.
(b) Close external power access door and
check that EXT PWR caution light is extinguished.
(a) Place battery switch to run. Close REF
XFER circuit breaker on AC/ARMT circuit breaker (28) No. 1 Hydraulic Pressure Lights.
panel.
(a) Apply external hydaulic pressure to
(b) Close FCC circuit breaker. Check that
FCC INOP caution light is not illuminated.
PRESS caution lights extinguish at 800 100 psig
(c) Remove wire A1112A22N from increasing pressure.
airframe ground. Check that FCC INOP caution light
illuminates. (b) Relieve pressure applied to hydraulic
NOTE
PRESS caution lights illuminate at 500 100 psig
Wire is located in local grounds behind decreasing pressure.
front cross tube on right hand side of
aircraft. (29) Emergency Hydraulic Pump Lights.
(d) Connect wire A1112A22N to airframe (a) Remove plug (1S20P1) from emer-
ground. Check that FCC INOP caution Iight does not gency hydraulic pressure switch (1S20). Connect
illuminate. jumper wire from pin C to pin B of plug (1S20P1)
nate.
ARMED caution Iight is functionally tested as a part of
the M65 TOW missile subsystem. (Refer to paragraph
(b) Remove jumper cable. Check that both
9-524.)
PUMP ON Iights extinguish.
caution Iight is functionally tested as part of the IR (30) No. 2 Hydraulic Pressure Lights.
counter measure function test. (Refer to TM
11-1520-236-series manuals.) (a) Apply external hydraulic pressure to
(25) IFF CODE HOLD Light. The IFF CODE
HOLD caution light is functionally tested as part of the
IFF system. (Refer to TM 11-1520-236 series mainte- caution lights illuminate at 500* 100 psig decreasing
nance manuals.) pressure.
Change 22 9-86.1
TM 55-1520-236-23
(a) Move turret from stowed position.
Check that GUN ELEV STOWED Iight on pilots
caution panel extinguishes.
NOTE
(b) Move turret to stowed position. Check
Refer to TM 55-1520-236-10 for turret that GUN ELEV STOWED light on pilots caution panel
operation Information. illuminates.
9-86.2 Change 22
TM 55-1520-236-23
(32) R ~ Engine Inlet Air Light.
(a) Disconnect plug (1S101P1) from
differential pressure switch (1S101). Short pin A to pin
B and check that both pilot and gunner ENGINE AIR
INLET caution lights illuminate.
(b) Remove short between pins A and B of
plug (1S101P1) and check that ENGINE AIR INLET
caution lights extinguish. Reconnect plug.
(33) q q Inlet Bypass Light.
(a) Disconnect plug (1A50P1) from bypass
door actuator (1A50). Short pin D to pin C and check
that both pilot and gunner INLET BYPASS caution lights
illuminate.
(b) Remove short between pins D and C of
plug (1A50P1) and check that INLET BYPASS caution
lights extinguish. Reconnect plug.
9-87
TM 55-1520-236-23
9-276.1. PILOTS CAUTION PANEL. from SW1-3 through pin 8 of the circuit board edge
connector. This acts the same as the negative fault
described earlier which lights the indicator lamps.
9-277. DESCRIPTION - PILOTS CAUTION PANEL.
b. The three negative, one positive fault apply cir-
There are eight lamp driver circuit boards in the pilot cuit board (P/N 81-1886-3) processes its negative
caution panel. Each circuit board drives four circuits fault apply signals in the same manner as described
for a total of 32 light positions. Five of the circuit for circuit board (P/N 81-1886-1). The one positive
boards (P/N 81-1886-1) contain all negative (ground) fault apply circuit receives +28 Vdc through con-
fault apply input circuits. Another board (P/N nector J1-1. It is routed through wiring to edge con-
81-1886-7) also contains all negative (ground) fault nector pin 1 on the circuit board. CR10 and R12
apply inputs, while circuit board (P/N 81-1886-3) provide the route to the + input of op amp U1. This
contains three negative (ground) fault apply input positive signal overcomes the voltage reference level
circuits and one positive (+28 Vdc) circuit. Circuit set by semiconductor zener diode VR 1. This causes
board (P/N 81-1 886-5) has two negative (ground) U1 to output a positive voltage to the base of NPN
and two positive (+28 Vdc) fault apply circuits. The transistor Q2, which forward biases Q2. This, in
BRT/DIM, RESET/TEST and master caution circuitry turn, provides a path to ground through CR4 and
are contained on circuit board (P/N 81-1888-1). CR7, brightly lighting the indicator lamps through Q1
Circuit board (P/N 81-1884-1) is an interconnection if the BRT/DIM switch SW2 is in the BRT position. If
printed circuit board between the lamp driver boards SW2 is in the DIM position, ground is provided
and the indicator lamp circuits. There are no active through resistor R5 causing the lamps to light dimly.
components on the board. Refer to paragraph 9-274 The BRT/DIM signal from edge connector pin 17 of
for system description and system functional circuit board (P/N 81-1888-1) passes through inter-
testing. nal wiring to edge connector pin 5 of circuit board (P/
N 81-1886-3). The signal continues across CR1 and
a. Refer to schematic figure FO-23.1. The all neg- R1 to the base of NPN transistor Q1. When the posi-
ative fault apply circuit boards (P/N 81-1886-1 & -7) tive apply fault is also present, Q1 is forward biased.
receive their fault signals through connector J1 at Its conduction provides a path to ground for the indi-
the back of the unit. This signal (for each typical cir- cator lamps causing them to light. When the BRT/
cuit) is routed through internal wiring to the circuit DIM switch is in the DIM position, the indicator
board edge connector. It passes through diodes CR3, lamps find their ground across current limiting resis-
CR4 and resistor R2 to the base of NPN transistor tor R5 which causes the lamps to light dimly. The
Q1. In the bright mode of operation, a positive signal presence of the positive apply fault is also felt at the
voltage is also received across CR 1 and R 1 to Q1s junction of CR7 and R3 as a low voltage. CR6 con-
base. Q1 conducts and provides a path through CR4 ducts this out edge connector pin 15, through inter-
and CR3 for the negative (ground) fault apply to light nal wiring to pin 6 of circuit board (P/N 81-1888-1)
the indicator lamps. The lamps receive +28 Vdc edge connector. The master caution and the RESET
through pin J1-r. In the dim mode of operation, the functions for the negative apply fault circuits operate
fault signal (ground) is shunted around Q1 through the same as described previously for circuit boards
resistor R5. This extra resistance causes the indica- (P/N 81-1886-1 & -7). When the TEST/RESET
tor lamps to light dimly. The negative fault is also felt switch SW1 is placed in the TEST position, ground
across R3 and CR6 in each circuit. (CR6 is absent in from SW1-2 is routed through internal wiring to pin 8
one circuit board P/N 81-1886-7. This allows an ad- of circuit board (P/N 81-1886-3) edge connector.
visory indicator to light without lighting the master CR12 and R11 pass the signal to the base of PNP
caution indicator.) This master caution signal is fed transistor Q3. Q3 conducts and provides a path for
out edge connector pin 15 to edge connector pin 6 the +28 Vdc at its collector to pass on through
on circuit card P/N 81-1888-1. When the RESET/ CR11 and R12 to the + input of op amp U1. The op-
TEST switch SW1 is placed to RESET, +28 Vdc from eration of the circuit from this point on is the same as
pin 6 of SW1 is applied through pin 3 of the circuit that for the positive apply fault.
board edge connector. This signal passes through
CR5 and R6 to SCR1. When SCR1 fires, a positive c. The two negative and two positive fault apply
voltage is felt across CR6 of the master caution cir- circuits on circuit board (P/N 81-1886-5) operate in
cuit instead of a negative voltage. When RESET/ the same manner as those described earlier, with the
TEST SW1 is placed to TEST, a ground is supplied following exception: Positions 26 and 30 will not
9-88 Change 16
TM 55-1520-236-23
activate the master caution circuitry when a fault is b. Disconnect electrical connector from the rear
applied. Diode CR6 has been removed from that cir- of unit.
cuit on the board. This allows an aviation green lens
to be illuminated in an advisory manner to inform the 9-278. BENCH TESTING - PILOTS CAUTION
aircrew of a non-critical situation. PANEL.
d. The circuit board (P/N 81-1888-1) contains cir- Bench testing procedures consist of connecting the
cuitry for BRT/DIM, master caution and TEST func- external electrical connections to connector J1 as
tions. When the BRT/DIM switch SW2 is in the BRT shown in figure FO-23.1, and then supplying the
position, relays K2 and K1 are de-energized. When fault inputs as specified and checking for the correct
the relays are de-energized, +28 Vdc is applied results. To do this, proceed as follows:
through pin 18 of the edge connector, across the
contacts of the relay, and out pin 17 of the edge con- a. Make ground connections to connector J1-p, -
nector. This voltage enters pin 5 of each circuit card k, and -m.
edge connector and lights the indicator lamps in the
bright mode as described previously. Relay K1 pro- b. Connect +28 Vdc to connector J1-r, -n, and -j.
vides ground to an external function. When the BRT/
DIM switch is in the DIM position, relays K2 and K1 c. Check that the edge lit panel is lit by all three
are energized. The bright function is removed from lamps.
the circuit boards, and the external dimming is re-
moved also. Ground is provided to relays K1 and K2 d. Momentarily place the TEST/RESET switch to
through contact 4 of SW2, and +28 Vdc is applied the TEST position. All 32 positions shall illuminate to
through contact 1 and edge connector pin 16. The full brightness.
+28 Vdc through pin 8 latches the relays in the ener-
gized position. When RESET/TEST switch SW1 is e. Check BRIGHT/DIM operation:
placed in the TEST position, ground is provided from
J1-m through SW1 and on through pins 8 of each cir- (1) Hold the TEST/RESET switch in the TEST
cuit board edge connector, The ground is also routed position, and close the external ground switch. All
through edge connector pin 1 of circuit board (P/N 32 positions shall remain brightly illuminated.
81-1888-1), and on through CR3 and R1 to the base
of PNP transistor Q1. Q1, which had been reversed (2) Momentarily place the BRIGHT/DIM switch
biased by pull- up resistor R2, now conducts, which to DIM. All 32 positions shall reduce in illumination
in turn drives PNP transistor Q2 into conduction. This and remain dim after the switch is released.
provides a path for the +28 Vdc at the collector of
Q2 to pass through diodes CR1 and CR2 out through (3) Momentarily place the BRIGHT/DIM switch
edge connector pins 4 and 5, and on out through J1- to BRIGHT. All 32 positions brightly illuminate.
s and t (TEST OUTPUTS). The RESET function does
not pass through this circuit board. When the indica- (4) Repeat step (2), then open the external
tor positions (except position 26) illuminate, the ground switch. All 32 positions shall brightly illumi-
master caution signals from the circuit boards are re- nate.
ceived through edge connector pin 6, and are passed
through R6 to the base of PNP transistor Q4 forcing f. One at a time, check lamp driver circuits by
it into conduction. This lowers the voltage at pull-up connecting a simulated fault input. Refer to figure
resistor R4 which, in turn, forward biases Q3 into FO-23.1 for type and pin number. Only the corres-
conduction. The +28 Vdc is conducted through Q3 ponding position shall illuminate in each case.
and CR4 out pin 9 of the edge connector and J1-q as
master caution light output. The zener diode VR1 NOTE
regulates the voltage in the unit.
The external master caution light shall illumi-
nate (multimeter reads +28 Vdc) ehen one
9-277.1. REMOVAL - PILOTS CAUTION PANEL.
or more of the individual panel lights (except
positions 26 and 30) are illuminated.
a. Loosen fasteners and lift caution panel from in-
strument panel.
Change 13 9-88.1
TM 55-1520-236-23
g. Monitor J1-q with a voltmeter. Supply a simu- 9-278.1. TROUBLESHOOTING - PILOTS
lated fault input on any one fault circuit pin. Measure CAUTION PANEL.
+28 Vdc on the multimeter (the master caution light
shall illuminate). Momentarily place the TEST/RESET NOTE
switch to the RESET position, then release. Measure
Before you use this table, be sure you have
0 Vdc on the multimeter (the master caution light performed all operational checks.
shall extinguish), but the individual position light
shall remain illuminated.
Table 9-15.1. Troubleshooting - Pilots Caution Panel
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. Edge lit panel fails to illuminate.
STEP 1. Substitute known good lamps.
If lamps are defective, install serviceable lamps. (Refer to paragraph 9-279 and 9-281.)
STEP 2. Check for corrosion in lamp socket.
If required, clean lamp socket terminals or replace lamp. (Refer to paragraph 9-18.)
2. All 32 positions fail to illuminate during lamp TEST.
STEP 1. Test operation of circuits with multimeter.
If TEST switch or wiring is damaged or defective, replace as required.
3. During lamp TEST, one position is dim only.
STEP 1. Substitute two known good lamps.
If one of two lamps is defective, replace with serviceable lamp.
STEP 2. Check for corrosion in lamp socket.
If required, clean lamp socket terminals or replace lamp. (Refer to paragraph 9-18.)
STEP 3. Substitute a known good printed circuit board in circuit. (Refer to paragraph 9-279 and 9-281.)
If problem is solved, replace defective printed circuit board with a serviceable one.
4. During lamp TEST, one position does not illuminate.
STEP 1. Using multimeter, ensure lamp is properly grounded.
If lamp is not properly grounded, remove lamp and clean ground. (Refer to paragraph 9-18.)
9-88.2 Change 13
TM 55-1520-236-23
Table 9-15.1. Troubleshooting - Pilot Caution Panel (Cont)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
STEP 2. Check for corrosion in lamp socket.
If required, clean lamp socket terminals or replace lamp. (Refer to paragraph 9-18.)
5. On lamp TEST, external master caution light does not illuminate.
STEP 1. Check BRIGHT/DIM control on printed circuit board (P/N 81-1888-1) for proper transistor
switching.
If transistor switching is incorrect, replace defective components on printed circuit board. (Refer to
paragraph 9-12.)
6. Master caution lamp fails to illuminate with one individual position illuminated.
STEP 1. Substitute a known good printed circuit board for printed circuit board that drives that lamp
position.
If known good printed circuit board corrects problem, install a serviceable printed circuit board for
that position. (Refer to paragraph 9-279 and 9-281.)
7. With one individual position illuminated, master caution lamp fails to extinguish when TEST/RESET switch is
placed to RESET.
STEP 1. Substitute a known good printed circuit board for printed circuit board that drives that lamp
position.
If known good printed circuit board corrects problem, install a serviceable printed circuit board for
that position. (Refer to paragraph 9-279 and 9-281.)
8. One side, or adjacent positions fail to illuminate.
STEP 1. Check for defective wiring with multimeter.
If wiring is defective, repair or replace. (Refer to paragraph 9-11.)
STEP 2. Substitute a known good interconnection printed circuit board (paragraph 9-279) in unit.
If that corrects problem, install a serviceable interconnection printed circuit board in unit. (Refer to
paragraph 9-279.)
9. All lamps fail to dim or return to bright.
STEP 1. Check for defective wiring with multimeter.
If wiring is defective, repair or replace. (Refer to paragraph 9-11.)
Change 13 9-88.3
TM 55-1520-236-23
Table 9-15.1. Troubleshooting - Pilots Caution Panel (Cont)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
STEP 2. Check test setup connection and position of external ground input switches.
Refer to figure FO-23.1 for proper connections and position of switch.
STEP 3. Check for proper operation of BRIGHT/DIM switch with a multimeter.
If switch is defective, replace with a serviceable switch. (Refer to paragraph 9-12.)
STEP 4. Substitute a known good BRIGHT/DIM printed circuit board in unit.
If that corrects problem, install a serviceable BRIGHT/DIM printed circuit board in unit. (Refer to para-
graph 9-279 and 9-281.)
10. Printed circuit board (34, figure 9-17.2) fails to operate.
STEP 1. Check printed circuit board for cracks, distortion, or burnt circuit tracks.
If any damage is found, replace printed circuit board.
STEP 2. Check components for cracks, broken leads, signs of overheating, or other physical damage.
If any components are damaged, replace them. (Refer to paragraph 9-280.1.)
STEP 3. Check for loose, broken, or cold solder joints using a multimeter.
If any defective solder joints are found, repair them. (Refer to paragraph 9-280.1.)
STEP 4. Use a multimeter to check components for electrical shorts or open circuits.
If defective components are found, replace them. (Refer to paragraph 9-280.1.)
11. Printed circuit board (35, figure 9-17.2) fails to operate.
STEP 1. Check printed circuit board for cracks, distortion, or burnt circuit tracks.
If any damage is found, replace printed circuit board.
STEP 2. Check components for cracks, broken leads, signs of overheating, or other physical damage.
If any components are damaged, replace them. (Refer to paragraph 9-280.1.)
STEP 3. Check for loose, broken, or cold solder joints using a multimeter.
If any defective solder joints are found, repair them. (Refer to paragraph 9-280.1.)
9-88.4 Change 13
TM 55-1520-236-23
Table 9-15.1. Troubleshooting - Pilots Caution Panel (Cont)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
STEP 4. Use a multimeter to check components for electrical shorts or open circuits.
If defective components are found, replace them. (Refer to paragraph 9-280.1.)
12. Printed circuit board (36, figure 9-17.2) fails to operate.
STEP 1. Check printed circuit board for cracks, distortion, or burnt circuit tracks.
If any damage is found, replace printed circuit board.
STEP 2. Check components for cracks, broken leads, signs of overheating, or other physical damage.
If any components are damaged, replace them. (Refer to paragraph 9-280.1.)
STEP 3. Check for loose, broken, or cold solder joints using a multimeter.
If any defective solder joints are found, repair them. (Refer to paragraph 9-280.1.)
STEP 4. Use a multimeter to check components for electrical shorts or open circuits.
If defective components are found, replace them. (Refer to paragraph 9-280.1.)
13. Printed circuit board (37, figure 9-17.2) fails to operate.
STEP 1. Check printed circuit board for cracks, distortion, or burnt circuit tracks.
If any damage is found, replace printed circuit board.
STEP 2. Check components for cracks, broken leads, signs of overheating, or other physical damage.
If any components are damaged, replace them. (Refer to paragraph 9-280.1.)
STEP 3. Check for loose, broken, or cold solder joints using a multimeter.
If any defective solder joints are found, repair them. (Refer to paragraph 9-280.1.)
STEP 4. Use a multimeter to check components for electrical shorts or open circuits.
If defective components are found, replace them. (Refer to paragraph 9-280.1.)
14. Printed circuit board (20, figure 9-1 7.2) fails to operate.
STEP 1. Check printed circuit board for cracks, distortion, or burnt circuit tracks.
If any damage is found, replace printed circuit board.
Change 13 9-88.5
TM 55-1520-236-23
Table 9-15.1. Troubleshooting - Pilots Caution Panel (Cont)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
STEP 2. Check components for cracks, broken leads, signs of overheating, or other physical damage.
If any components are damaged, replace them. (Refer to paragraph 9-280.1.)
STEP 3. Check for loose, broken, or cold solder joints using a multimeter.
If any defective solder joints are found, repair them. (Refer to paragraph 9-280.1.)
STEP 4. Use a multimeter to check components for electrical shorts or open circuits.
If defective components are found, replace them. (Refer to paragraph 9-280.1.)
9-279. DISASSEMBLY - PILOTS CAUTION PANEL. and white filters (6 or 12) may be removed by push-
ing from rear through lamp sockets.
NOTE
Perform steps a, b, and c only when these d. Remove identification plate (15) from panel
parts must be replaced. These steps are not subassembly (16) only if damaged or illegible.
required for other disassembly steps, for
example, removing a printed circuit board. e. Remove screws (2, figure 9-17.2) and pull tog-
gle switch assembly (1) free from contact assembly
Perform disassembly procedures only as (38). Remove screw (3) and lockwasher (4) which
required to accomplish repair. attach wire to connector (8).
a. Remove light indicating panel (13, figure 9-17.1) f. Disassemble toggle switch assembly (1) as fol-
by removing two screws (14). lows:
b. To remove cap assemblies (1), lift up slightly (1) Remove knurled nuts (6), Iockwashers (7),
while pulling outward on lever (45, figure 9-17.2). To and toggle switches (5) from switch plate (12).
remove cap assemblies (7, figure 9-17.1), pull down
slightly while pulling outward. (2) Remove ferrule nut (9), Iockwasher (10),
lug terminal (11), and connector (8) from switch
c. Disassemble cap assemblies (1 and 7) as fol- plate (12). Do not remove lug terminal (11) from wire
lows: unless replacement is required.
(1) With cap assembly (1 or 7) lying face
(3) Identify, tag, and unsolder wires from each
down, lamps (2 or 8) may be removed using a thin,
toggle switch (5).
sharp edged instrument or fingernail by prying up-
ward on base ring of each lamp (2 or 8).
g. To gain access to inside of unit, remove six
(2) Remove lens retainers (3 or 9) to provide screws (13) from sides and top at rear of housing as-
access for gray filters (4 or 10), legends (5 or 11), or sembly (59). This will allow cover assembly (65) to
white filters (6 or 12) replacement. Legends (5 or 11) swing down as far as wiring will permit.
9-88.6 Change 13
TM 55-1520-236-23
1. Cap assembly 7. Cap assembly 13. Light indicating panel
2. Lamp 8. Lamp 14. Screw
3. Lens retainer 9. Lens retainer 15. Identification plate
4. Gray filter 10. Gray filter 16. Panel subassembly
5. Legend 11. Legend
6. White filter 12. White filter
Figure 9-17.2 Pilots Caution Panel Assembly
Change 16 9-88.7
TM 55-1520-236-23
Figure 9-17.3 Pilots Caution Panel Subassembly (Sheet 1 of 2)
9-88.8 Change 16
TM 55-1520-236-23
Figure 9-17.3 Pilots Caution Panel Subassembly (Sheet 2 of 2)
Change 16 9-88.9
TM 55-1520-236-23
NOTE n. Using circuit board puller (T90), unplug and tag
eight printed circuit boards (34 thru 37).
Refer to figures 9-17.3, 9-17.4, FO-23.1 and
Table 9-15.1 for wiring information.
o. Remove 14 screws (39, figure 9-17.2) and
h. Remove four self-locking nuts (15) and screws contact assembly (38) from housing assembly (59).
(16), lug terminal (17), and connector (14). Do not
remove lug terminal (17) from wire unless replace- Disassemble contact assembly (38) as follows:
p.
ment is required.
NOTE
i. Identify and tag wires. Remove pins from con-
nector (14). When latch base assemblies (40 and 41) are
removed, loose springs (42) and contacts
(43 and 44) will fall free. Ensure none are
j. Identify, tag, and unsolder wires from radio filter
lost.
(18). Remove screw (19) and radio filter 18).
(1) Remove 12 screws (46) from housing (55)
and six screws (47) from latch base assemblies (40
and 41).
Use care when unplugging printed circuit
board (20) to prevent damage to compo- (2) Lift out latch base assemblies (40) and lev-
nents. ers (45) from housing (55). Remove 12 springs (42)
and contacts (43).
k. Remove two screws (21) and lockwashers
(3) Lift out latch base assemblies (41) and lev-
(22). Unplug printed circuit board (20) from recepta-
ers (45) from housing (55). Remove 64 springs (42)
cle connector (31).
and contacts (44).
l. Remove receptacle connector (31) from cover (4) Identify, tag, and unsolder wires from
assembly (65) as follows: printed circuit board (48). Refer to figure 9-17.6 for
tagging.
(1) Remove two self-locking nuts (32), screws
(33), and receptacle connector (31). (5) Remove screws (49 and 50, figure 9-17.2)
and printed circuit board (48) from housing (55).
(2) Cut and remove wire ties if required.
q. Remove pins (53) from housing (55).
(3) Identify, tag, and remove wires from recep-
tacle connector (31). r. Remove turnlock stud assemblies (54) from
housing (55).
m. Lower cover assembly (65) far enough to re-
move printed circuit boards (34 thru 37). s. Identify, tag, and unsolder wires from recepta-
cle connectors (56). Remove screws (57) and recep-
tacle connectors (56) from bracket assemblies (71).
t. Remove polarizing keys (58) from receptacle
Use care when unplugging printed circuit connectors (56). Refer to figure 9-17.7 for location
boards (34 thru 37) to prevent damage to of polarizing keys (58).
components.
9-88.10 Change 13
TM 55-1520-236-23
Figure 9-17.4 Housing Subassembly
Figure 9-17.5 Cover Assembly
Change 16 9-88.11
TM 55-1520-236-23
Figure 9-17.6 indicating Light Circuit Card (Sheet 1 of 4)
9-88.12 Change 16
TM 55-1520-236-23
Figure 9-17.6 Indicating Light Circuit Card (Sheet 2 of 4)
Change 16 9-88.13
TM 55-1520-236-23
Figure 9-17.6 Indicating Light Circuit Card (Sheet 3 of 4)
9-88.14 Change 16
TM 55-1520-236-23
1. Resistor 30. Resistor 59. Resistor
2. Resistor 31. Diode 60. Operational amplifier
3. Diode 32. Resistor 61. Diode
4. Resistor 33. Resistor 62. Transistor
5. Resistor 34. Operational amplifier 63. Transistor
6. Capacitor 35. Mounting pad 64. Diode
7. Diode 36. Capacitor 65. Diode
8. Mounting pad 37. Diode 66. Capacitor
9. Transistor 38. Resistor 67. Mounting pad
10. Resistor 39. Transistor 68. Mounting pad
11. Resistor 40. Resistor 69. Resistor
12. Resistor 41. Resistor 70. Resistor
13. Resistor 42. Diode 71. Resistor
14. Resistor 43. Resistor 72. Resistor
15. Resistor 44. Resistor 73. Resistor
16. Diode 45. Transistor 74. Resistor
17. Transistor 46. Mounting pad 75. Resistor
18. Mounting Pad 47. Resistor 76. Resistor
19. Operational amplifier 48. Diode 77. Operational amplifier
20. Capacitor 49. Resistor 78. Diode
21. Mounting pad 50. Resistor 79. Transistor
22. Diode 51. Capacitor 80. Transistor
23. Diode 52. Diode 81. Diode
24. Resistor 53. Resistor 82. Diode
25. Transistor 54. Resistor 83. Capacitor
26. Resistor 55. Resistor 84. Mounting pad
27. Resistor 56. Resistor 85. Mounting pad
28. Transistor 57. Resistor 86. Resistor
29. Mounting pad 58. Resistor
Figure 9-17.6 Indicating Light Circuit Card (Sheet 4 of 4)
Change 16 9-88.15
TM 55-1520-236-23
Figure 9-17.7 Contact Assembly (A10)
9-88.16 Change 16
TM 55-1520-236-23
Figure 9-17.8 Polarizing Keys Location
Change 16 9-88.17
TM 55-1520-236-23
9-279.1. CLEANING - PILOTS CAUTION PANEL. f. Check printed circuit boards for delamination of
metal foil wiring pattern.
9-280.1. REPAIR - PILOTS CAUTION PANEL.
Solvent is highly flammable and toxic. Use NOTE
only in wall ventilated areas away from flame Perform steps b thru d only as required for
and hot surfaces. Avoid skin contact. repair.
Breathing fumes, or directing comprassad air
at solvent in contact with skin could result in Repair procedures for caution panel consist of
personal injury. replacement of damaged or defective parts with
serviceable ones. Removal and installation, by
riveting or soldering, of any part or parts are covered
in this paragraph.
Do not use solvent for cleaning nonmetallic a. Replace parts that do not meet inspection re-
parts, electrical wiring, or electronic parts. quirements, Chase damaged threads.
Solvent could damage parts.
b. When replacing any part or subassembly se-
a. Clean metal parts with dry cleaning solvent cured by rivets, proceed as follows:
(C112).
(1) Drill out rivets with proper size drill.
b. Clean electrical parts with a clean, soft, lint-
free cloth moistened with isopropyl alcohol (C64). (2) Deburr and assemble new parts.
Allow to air dry.
(3) Secure parts with new rivets of size and
c. Gently wipe printed circuit boards with a clean, type indicated in Repair Parts and Special Tools List
soft, lint-free cloth moistened with isopropyl alcohol (RPSTL).
(C64). Allow to air dry. Use care to prevent damage
to printed circuits. c. When replacing components on printed circuit
boards use the following precautions:
9-280. INSPECTION - PILOTS CAUTION PANEL.
(1) Use a low wattage (25 watts or less) sol-
a. Check all parts for general condition and for
dering iron.
structural damage that impairs proper system opera-
tion.
(2) Ground circuit track adjacent to compo-
nents.
b. Check internal and external threads for evi-
dence of wear, stripping, and crossthreading.
(3) Use heat sinks to avoid overheating adja-
cent components.
c. Visually inspect wiring for damaged insulation.
(4) Coat printed circuit boards with insulating
d. Visually inspect all soldered connections for
compound (C63.1).
looseness and corrosion. Do not stress joint during
inspection.
d. Finish all visible exterior surfaces, except hard-
ware, with black anodic (C18.1). Refer to figure
e. Visually inspect printed circuit boards for
9-17.8 for areas not to be finished.
burned, broken, or damaged circuits.
9-88.18 Change 13
TM 55-1520-236-23
Figure 9-17.9 Removal of Finish for Electrical Bonding
Change 16 9-88.19
TM 55-1520-236-23
9-281. ASSEMBLY - PILOTS CAUTION PANEL. d. install contact assembly (38) in housing as-
sembly (59) and secure with screws (39).
a. Install polarizing keys (58, figure 9-17.2) in re-
ceptacle connectors (56). Refer to figure 9-17.7 for
locations.
b. Install receptacle connectors (56, figure 9-17.2)
Use care when installing printed circuit
in housing assembly (59) as follows:
boards (34 thru 37) to prevent damage to
components.
(1) Solder wires to pins on receptacle connectors
(56).
e. Refer to paragraph 9-279. Hold lower cover as-
(2) Install receptacle connectors (56) on brackets sembly (65) out of way and install printed circuit
(71) and secure with screws (57). boards (34 thru 37) in correct receptacle connectors
(56), component side downward.
c. Assemble contact assembly (38) as follows:
f. Install receptacle connector (31) in cover assem-
(1) Install turnlock stud assemblies (54) in
bly (65) as follows:
housing (55).
(1) Solder wires to pins on receptacle connector
(2) Install pins (53) in housing (55).
(31).
(3) Install printed circuit board (48) on housing
(2) Install receptacle connector (31) and secure
(55) and secure with screws (49 and 50).
with two screws (33) and self-locking nuts (32).
(4) Solder wires to printed circuit board (48).
Refer to figure 9-17.6 and table 9-15.2 for wiring in-
formation.
(5) Install contacts (43 and 44, figure 9-17.2)
Use care whan installing printed circuit board
in latch base assemblies (40 and 41). Refer to figure
(20) to prevant damage to components.
9-17.9 for proper location.
(6) Install springs (42, figure 9-17.2) on top of g. Install printed circuit board (20) in receptacle
contacts (43 and 44). connector (31) and secure with two screws (21) and
lockwashers (22).
(7) Engage hole in levers (45) with tabs in latch
base assemblies (40 and 41). Install latch base as- h. Solder wires to pins on radio filter (18). Install
semblies (40 and 41) in housing (55) using levers radio filter (18) and secure with screw (19).
(45).
i. Install pins and wires in connector (14). Install
(8) Secure latch base assemblies (40 and 41)
connector (14) and lug terminal (17). Secure with
in housing (55) using screws (46 and 47).
four screws (16) and self-locking nuts (15).
(9) Lightly push in on contacts (43 and 44) to
ensure springs (42) are properly installed.
9-88.20 Change 13
TM 55-1520-236-23
Table 9-15.2. Pilots Caution Panel Wiring Chart
Change 13 9-88.21
TM 55-1520-236-23
Table 9-15.2. Pilots Caution Panel Wiring Chart (Cont)
9-88.22 Change 13
TM 55-1520-236-23
Figure 9-17.10 Position of Contacts in Latch Base
Change 16 9-88.23
TM 55-1520-236-23
j. Carefully close cover assembly (65), ensuring p. Insert cap assemblies (1 and 7) in correct posi
wiring is clear. Secure with six screws (13) in two tion and firmly push until it snaps into place.
sides and top of housing assembly (59).
k. Assemble toggle switch assembly (1) as fol-
lows:
Do not overtighten screws (14) or light indi-
(1) Insert connector (8) through switch plate cating panel (13) may crack.
(12). Install lug terminal (11) and Iockwasher ( 10) on
connector (8). Secure with ferrule nut (9). q. Install light indicating panel (13) by pushing in
until connector mates, secure using two screws
(2) Install one lockwasher (7) on each toggle (14).
switch (5).
9-281.1. INSTALLATION - PILOTS CAUTION
(3) Insert toggle switches (5) through switch PANEL.
plate (12) and secure with knurled nuts (6).
a. Connect electrical connector to back of caution
l. Attach wire to connector (8) using screw (3) panel.
and lockwasher (4).
b. Position panel in helicopter instrument pane
m. Install toggle switch assembly (1) on contact and tighten fasteners.
assembly (38) and secure with two screws (2).
9-282. GUNNERS CAUTION PANEL (BHT
n. If identification plate (15, figure 9-17.1) was P/N 204-075-705-77, and -83).
removed from panel subassembly (16), install a new
one. 9-282.1. DESCRIPTION - GUNNERS CAUTION
PANEL.
o. Refer to figures 9-13 thru 9-15 and assemble
cap assemblies (1 and 7, figure 9-17.1) as follows: There are three lamp driver circuit boards in the
gunners caution panel. Each circuit board drives six
circuits for a total of 18 light positions. The three
boards (P/N 76-1127-1 & -3) are identical, except
that one of the boards (P/N 76-1127-3) contains a
Ensure correct legends are installed in cor- larger resistor in one circuit. The BRT/DIM circuitry is
rect indicator light positions. If legends are contained on circuit card assembly (P/N 76-1129-1).
installed in wrong positions, aircrew will re- The BRT/DIM switch is located on the face of the
ceive false information during inflight mal- unit along with a TEST switch. An edge lit panel (P/N
functions. 76-1131-1) provides illumination for the unit. Refer
to paragraph 9-275 for system description and
(1) Install white filters (6 or 12), legends (5 or 9-276 for system functional testing.
11), and gray filters (4 or 10) in bases. Install gray fil-
ters (4 or 10) with dull side facing out. a. Refer to schematic figure 9-17.10. The three
lamp driver boards (P/N 76-1127) receive their fault
(2) Secure with lens retainers (3 or 9). signals (one +28 Vdc apply fault and six ground ap-
ply faults on each board) through connector J1 at the
(3) Place cap assemblies (1 and 7) face down back of the unit. The signal (for each typical circuit)
and install two lamps (2 or 8) in each indicator lamp is routed through wiring to the circuit board edge
position. connector. A typical ground apply fault will pass
through diode CR3 and out the circuit card edge con-
NOTE nector to the indicator lamps. The lamps will light
since +28 Vdc is constantly available as CAUTION
The cap assemblies are color coded and
SEGMENT POWER through J1-z and circuit card
keyed for correct positioning in contact as-
edge connector pin 1. This is routed across resistor
sembly.
R1 and through pins (2, 4, 6, 7, 8, 9 and R) of the
9-88.24 Change 13
TM 55-1520-236-23
Figure 9-17.11 Gunners Caution Panel Schematic Diagram
Change 16 9-88.25
TM 55-1520-236-23
edge connector to the indicator lamps. When the d. The four lamps of the edge lit panel (P/N 76-
BRT/DIM switch (SW2) is placed in the BRT position, 1131) receive +28 Vdc through J1-Y, and ground
+28 Vdc is applied through pin 3 of the edge con- through J1-W.
nector, across diode CR2 and out the previously
mentioned pins to the lamps. The lamps will light 9-283. REMOVAL - GUNNERS CAUTION PANEL.
brightly since resistor RI is bypassed in each circuit.
When the TEST pushbutton (SW1) is pushed, ground a. Loosen fasteners and lift caution panel from in-
from J1-W is applied through edge connector 5 and strument panel.
diode CR4 to each lamp circuit. All the lamps will
light. In the case of the +28 Vdc apply circuit, the b. Disconnect electrical connector from the rear
fault signal is applied through J1-H and edge connec- of unit.
tor pin P across diode CR6 and out edge connector
pin R to the indicator lamps. Ground for this circuit 9-283.1. BENCH TESTING - GUNNERS CAUTION
comes through J1-a and edge connector pin 13 PANEL.
across resistor R2 in the dim mode. In the bright
mode, ground is provided through edge connector a. Refer to schematic figure 9-17.10. Apply +28
pin 14, across diode CR5 (bypassing resistor R2) and Vdc to J1-X, Y and Z. Apply ground to pins J1-W and
out edge connector pin 15 to light the lamps of posi- J1-a. The edge lit panel lamps shall light.
tion 8. During test, +28 Vdc arrives through edge
connector pin 5 and passes through diode CR7 to b. Press the TEST pushbutton and hold it. Place
light the lamps as described earlier. the BRT/DIM switch to the BRT position. All the indi-
cator positions shall light brightly.
b. Circuit card assembly (P/N 76-1129-1) con-
tains two relays (K1 & K2) and diode CR1. The board c. Check BRT/DIM operation:
constantly receives +28 Vdc through terminals 5
and 6, and ground through terminal 3. When the (1) Apply ground to pin J1-V. Press and hold
BRT/DIM switch (SW2) is placed to the BRT position, the TEST pushbutton. All 18 positions shall remain
ground is absent from terminal 2. This de-energizes brightly illuminated.
relays K1 & K2. In this state, BRT mode +28 Vdc at
terminal 6 is applied, through terminal 7, to edge (2) Momentarily place the BRT/DIM switch to
connector pin 3 on circuit cards (P/N 76-1127). At DIM. All 18 positions shall reduce in illumination and
the same time, ground at terminal 3 is felt out remain dim after the BRT/DIM switch is released.
through terminal 4 to edge connector pin 14. This
provides ground for the positive apply lamps. When (3) Place the BRT/DIM switch to BRT while still
the BRT/DIM switch is placed in the DIM position, holding the TEST pushbutton. All 18 positions
ground for relays (K1 & K2) is applied to terminal 2 brightly illuminate.
from J1-V. The +28 Vdc through J1-X and contacts
of SW2, energizes the relays through terminal 1, and (4) While still pressing the TEST pushbutton,
latches the relays through terminal 5. The +28 Vdc remove ground from pin J1-V. All 18 positions shall
at terminal 7 (BRT mode for negative apply fault cir- remain brightly illuminated.
cuits) is removed. Also, the ground at terminal 3 is
removed from terminal 4 (BRT mode ground for posi- d. Refer to table 9-15.3. One at a time, momen-
tive apply circuit). tarily apply ground to each pin of connector J1 that
receives a negative input. Only the position being
c. The TEST switch (SW1) receives ground tested should light brightly.
through J1-W and applies it, through its switching
contacts, to pin 5 of the edge connectors. This e. Repeat step c. above applying +28 Vdc only
ground lights all the negative apply circuits during to pin J1-H. Position 8 should light brightly.
TEST.
9-88.26 Change 13
TM 55-1520-235-23
Table 9-15.3. Gunners Caution Panel Fault Inputs
75-0326-1 m
PIN FILTER COLOR FAULT
NOMENCLATURE NO. INPUT
1 ENGINE OIL PRESS A AVN YELLOW NEG
2 SPARE B AVN YELLOW NEG
3 ENG FUEL PUMP c AVN YELLOW NEG
4 SPARE D AVN YELLOW NEG
5 SPARE E AVN YELLOW NEG
6 HYDR PRESS #1 F AVN YELLOW NEG
7 DC GEN G AVN YELLOW NEG
8 GOV EMER H AVN YELLOW POS
9 FUEL LOW J AVN YELLOW NEG
10 SPARE K AVN YELLOW NEG
11 CHIP DECTOR L AVN YELLOW NEG
12 EMER HYDR PUMP ON M AVN GREEN NEG
13 XMSN OIL PRESS N AVN YELLOW NEG
14 XMSN OIL TEMP P AVN YELLOW NEG
15 FUEL FILTER R AVN YELLOW NEG
16 SPARE s AVN YELLOW NEG
17 SPARE T AVN YELLOW NEG
18 HYDR PRESS #2 u AVN YELLOW NEG
75-0326-3 ~ ~
PIN FILTER COLOR FAULT
NOMENCLATURE NO. INPUT
1 ENGINE OIL PRESS A AVN YELLOW NEG
2 SPARE B AVN YELLOW NEG
3 ENG FUEL PUMP C AVN YELLOW NEG
4 ALTER D AVN YELLOW NEG
5 SPARE E AVN YELLOW NEG
6 #1 HYD PRESS F AVN YELLOW NEG
7 SPARE G AVN YELLOW NEG
8 GOV EMERG H AVN YELLOW POS
9 FUEL LOW J AVN YELLOW NEG
10 RECT K AVN YELLOW NEG
11 CHIP DETECTOR L AVN YELLOW NEG
12 EMERG HYD PUMP ON M AVN GREEN NEG
13 TRANS OIL PRESS N AVN YELLOW NEG
14 TRANS OIL HOT P AVN YELLOW NEG
15 FUEL FILTER R AVN YELLOW NEG
16 DC GEN S AVN YELLOW NEG
17 SPARE T AVN YELLOW NEG
18 #2 HYD PRESS U AVN YELLOW NEG
Change 19 9-88.27
TM 55-1520-236-23
9-284. TROUBLESHOOTING - GUNNERS CAUTION PANEL.
NOTE
Before you use this table, be sure you have performed all operational checks.
Table 9-15.4. Troubleshooting - Gunners Caution Panel
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. Edge lit panel fails to illuminate.
STEP 1. Substitute known good lamps.
If lamps are defective, install serviceable lamps. (Refer to paragraph 9-284.1.)
STEP 2. Check for corrosion in lamp socket.
If required, clean lamp socket terminals or replace lamp. (Refer to paragraph 9-18.)
2. All 18 positions fail to illuminate during lamp TEST.
STEP 1. Test operation of circuits with multimeter.
If TEST switch or wiring is damaged or defective, replace as required. (Refer to paragraph 9-16.)
3. During lamp TEST, one position is dim only.
STEP 1. Substitute two known good lamps.
If one of two lamps is defective, replace with serviceable lamp.
STEP 2. Check for corrosion in lamp socket.
If required, clean lamp socket terminals or replace lamp. (Refer to paragraph 9-18.)
STEP 3. Replace diode CR2 for negative apply circuits, or CR5 for positive apply circuit (position 8).
If diode is defective, remove and install a serviceable one. (Refer to paragraph 9-286.)
STEP 4. Substitute a known good printed circuit board into string of circuits. (Refer to figures 9-16 and 9-
17.)
If problem is solved, replace dafective printed circuit board with a serviceable one. (Refer to para-
graph 9-284.1 and 9-286.1.)
9-88.28 Change 13
TM 55-1520-236-23
Table 9-15.4. Troubleshooting - Gunners Caution Panel (Cont)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
4. During lamp TEST, one position does not illuminate.
STEP 1. Using multimeter, ensure lamp is properly grounded.
If lamp is not properly grounded, remove lamp and clean ground. (Refer to paragraph 9-18.)
STEP 2. Check for corrosion in lamp socket.
If required, clean lamp socket terminals or replace lamp. (Refer to paragraph 9-18.)
5. With BRT/DIM switch to BRT, and TEST button pushed, all 18 positions do not remain brightly illuminated
when ground is applied to pin J1-V.
STEP 1. Use multimeter to check operation of switch SW1.
If switch does not operate correctly, remove and install a serviceable one. (Refer to paragraph 9-12.)
6. With the BRT/DIM switch in DIM position, all 18 positions do not light dimly.
STEP 1. Use multimeter to check resistor R1 (R2 in positive apply circuit) in affected circuit.
If resistor is defective, remove and replace with a serviceable one. (Refer to schematic figure 9-
17.10.)
STEP 2. Use multimeter to check operation of switch SW2.
If switch is defective, remove and install a serviceable one. (Refer to paragraphs 9-284.1 and 9-286.1.)
STEP 3. Use multimeter to check operation of relays K1 and K2 and diode CR1.
If a relay or diode is defective, remove and install a serviceable one. (Refer to paragraph 9-284.1.)
7. All 18 positions do not remain brightly illuminated with BRT/DIM switch in BRT, and TEST pushbutton
pressed.
STEP 1. Using a multimeter, check operation of switches SW1 and SW2.
If either switch is defective, remove and install a serviceable one. (Refer to paragraphs 9-284.1 and
9-286.1.)
Change 13 9-88.29
TM 55-1520-236-23
Table 9-15.4. Troubleshooting - Gunners Caution Panel (Cont)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
8. An individual position does not light when the proper fault is input at connector J1. Refer to table 9-15.3 for
the proper fault input.
STEP 1. Substitute known good lamps.
If lamps are found to be defective, install serviceable lamps. (Refer to paragraph 9-284.1.)
STEP 2. Using a multimeter, check operation of diode CR3.
If diode is defective, remove and install a serviceable one. (Refer to paragraph 9-286.)
STEP 3. Check for corrosion in lamp socket.
If required, clean lamp socket terminals or replace lamp. (Refer to paragraph 9-18.)
STEP 4. Check for defective wiring with multimeter.
If wiring is defective, repair or replace. (Refer to paragraph 9-11.)
9. Position 8 does not light brightly when +28 Vdc is applied to pin J1-H.
STEP 1. Using multimeter, check operation of resistor R2 and diode CR5.
If components are defective, remove and install serviceable ones. (Refer to paragraph 9-286.)
STEP 2. Check for corrosion in lamp socket.
If required, clean lamp socket terminals or replace lamp. (Refer to paragraph 9-18.)
STEP 3. Check for defective wiring with multimeter.
If wiring is defective, repair or replace. (Refer to paragraph 9-11.)
10. Printed circuit board (17, figure 9-17.11) fails to operate.
STEP 1. Check printed circuit board for cracks, distortion, or burnt circuit tracks.
If any damage is found, replace printed circuit board.
STEP 2. Check components for cracks, broken leads, signs of overheating, or other physical damage.
If any components are damaged, replace them. (Refer to paragraph 9-286.)
STEP 3. Check for loose, broken, or cold solder joints using a multimeter.
If any defective solder joints are found, repair them. (Refer to paragraph 9-286.)
9-88.30 Change 13
TM 55-1520-236-23
Table 9-15.4. Troubleshooting - Gunners Caution Panel (Cont)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
STEP 4. Use a multimeter to check components for electrical shorts or open circuits.
If defective components are found, replace them. (Refer to paragraph 9-286.)
11. Printed circuit board (18, figure 9-17.11) fails to operate.
STEP 1. Check printed circuit board for cracks, distortion, or burnt circuit tracks.
If any damage is found, replace printed circuit board.
STEP 2. Check components for cracks, broken leads, signs of overheating, or other physical damage.
If any components are damaged, replace them (Refer to paragraph 9-286.)
STEP 3. Check for loose, broken, or cold solder joints using a multimeter.
If any defective solder joints are found, repair them. (Refer to paragraph 9-286.)
STEP 4. Use a multimeter to check components for electrical shorts or open circuits.
If defective components are found, replace them. (Refer to paragraph 9-286.)
Change 13 9-88.31
TM 55-1520-236-23
Figure 9-17.12 Gunners Caution Panel (Sheet 1 of 2)
9-88.32 Change 16
TM 55-1520-236-23
1. Indicator module 17. Printed circuit board 32. Connector assembly 48.
2. Lamp (A1 & A3) 33. Lug terminal 49. Screw
3. Lens retainer 18. Printed circuit board (A2) 34. Screw 50. Spacer
4. Gray filter (light) 19. Resistor 35. Lockwasher 51. Housing assembly
5. Legend 20. Resistor 36. Connector 52. Electrical post
6. Gray filter (dark) 21. Diode 37. Ferrule nut 53. Contact assembly
7. Light indicating panel 22. Printed circuit board 38. Lockwasher 54. Turnlock stud assembly
8. Screw 23. Diode 39. Lug terminal 55. Board guide
9. Identification plate 24. Relay 40. Toggle switch 56. Rivet
10. Panel subassembly 25. Terminal stud 41. Pushbutton switch 57. Connector bracket
11. Cover plate 26. Screw 42. Knurled plain nut 58. Rivet
12. Screw 27. Lock-spring washer 43. Receptacle connector 59. Self-locking nut
13. Access cover plate 28. Sleeve spacer 44. Screw 60. Self-locking nut
14. Screw 29. Connector 45. Annunciator light assembly 61. Annunciator housing
15. Screw 30. Self-locking nut 46. Screw
16. Self-locking nut 31. Screw 47. Bracket
Figure 9-17.12 Gunners Caution Panel (Sheet 2 of 2)
Change 16 9-88.33
TM 55-1520-236-23
9-284.1. DISASSEMBLY - GUNNERS CAUTION NOTE
PANEL.
Refer to figure 9-17.12 and table 9-15.5 for
NOTE wiring information.
Perform steps a. (1) thru a. (3) only when
these parts must be replaced. These steps g. Using circuit board puller (T93), unplug and tag
are not required for other disassembly steps, printed circuit boards (17 and 18).
for example, removing a printed circuit
board. h. Remove four screws (26), lock-spring washers
(27), and sleeve spacers (28) and printed circuit
a. Change lamps (2, figure 9-17.11) as follows: board (22).
(1) Press indicator module (1) to unlatch, then
i. Identify, tag, and unsolder wires from printed
pull forward and rotate face downward.
circuit board (22).
(2) Pry lamps (2) out with a thin, flat-bladed in-
strument. Replace lamps (2) with serviceable parts. j. Remove four self-locking nuts (30) and screws
(31), and connector (29).
(3) Rotate indicator module (1) to horizontal
position and push into housing assembly (51) until k. Identify and tag wires. Remove pins from con-
detent is reached. nector (29).
b. Remove lens retainers (3). Push gray filters (4 l. Remove connector assembly (32 from annun-
and 6) and legends (5) out of lens retainers (3). ciator housing (61) as follows:
c. Remove screws (8). Remove light indicating
(1) Remove screw (34), lockwasher (35), and
panel (7) from panel subassembly (10) by gently pry- lug terminal (33) from connector (36).
ing out to disconnect from connector assembly (32).
d. Remove six screws (12) and cover plate (11) (2) Remove ferrule nut (37), lockwasher (38),
from annunciator housing (61). and lug terminal (39) from connector (36).
e. Remove identification plate (9) from access (3) Remove connector (36) from annunciator
cover plate (13) only if damaged or illegible. housing (61).
f. Remove four screws (14), two screws (15), m. Remove two knurled plain nuts (42), toggle
Bnd access cover plate (13) from annunciator hous- switch (40), and pushbutton switch (41) from annunci-
ing (61). ator housing (61). Identify, tag, and unsolder wires
from switches (40 and 41).
n. Remove screws (44) and receptacle connec-
Use care when unplugging printed circuit tors (43) from annunciator housing (61). Identify,
boards (17 and 18) to prevent damage to tag, and unsolder wires from receptacle connectors
components. (43).
9-88.34 Change 13
TM 55-1520-236-23
Figure 9-17.13 Gunners Caution Panel Wiring Connections
Change 16 9-88.35
TM 55-1520-236-23
Table 9-15.5. Gunners Caution Panel Wiring Chart
9-88.36 Change 13
TM 55-1520-236-23
Table 9-15.5. Gunners Caution Panel Wiring Chart (Cont)
Change 13 9-88.37
TM 55-1520-236-23
o. Remove eight screws (46) from sides of panel 9-285.1. INSPECTION - GUNNERS CAUTION
subassembly (10). Separate annunciator light assem- PANEL.
bly (45) as far as wiring permits, identify, tag, and
resolder wires from annunciator light assembly (45). a. Check all parts for general condition and for
structural damage that impairs proper system opera-
p. Disassemble annunciator light assembly (45) tion.
as follows:
b. Check internal and external threads for evi-
(1) Remove 12 screws (49), bracket (47), and dence of wear, stripping, and crossthreading.
bracket assembly (48) from annunciator light assem-
bly (45).
c. Visually inspect wiring for damaged jacketing
and insulation.
(2) Slide housing assemblies (51) and spacers
(50) off electrical posts (52).
d. Visually inspect ail soldered connections for
(3) Remove contact assemblies (53) from looseness and corrosion. Do not stress joint during
housing assemblies (51). inspection.
e. Visually inspect printed circuit boards for
burned, broken, or damaged circuits.
9-285. CLEANING - GUNNERS CAUTION PANEL. f. Check printed circuit boards for delamination of
metal foil wiring pattern.
9-286. REPAIR - GUNNERS CAUTION PANEL.
Solvent is highly flammable and toxic. Use NOTE
only in well ventilated areas away from flame
Perform the following steps only as required.
and hot surfaces. Avoid skin contact.
Breathing fumes, or directing compressed air
at solvent in contact with skin could result in Repair procedures for caution panel consist of
personal injury. replacement of damaged or defective parts with
serviceable ones. Removal and installation, by
riveting or soldering, of any part or parts are covered
in this paragraph.
Do not use solvent for cleaning nonmetallic a. Replace parts that do not meet inspection re-
parts, electrical wiring, or electronic parts. quirements. Chase damaged threads.
Solvent could damage parts.
b. When replacing any part or subassembly se-
a. Clean metal parts with dry cleaning solvent cured by rivets, proceed as follows:
(C112).
(1) Drill out rivets with proper size drill.
b. Clean electrical parts with a clean, soft, lint-
free cloth moistened with isopropyl alcohol (C64).
Allow to air dry. (2) Deburr and assemble new parts.
c. Gently wipe printed circuit boards with a clean, (3) Secure parts with new rivets of size and
soft, lint-free cloth moistened with isopropyl alcohol type indicated in Repair Parts and Special Tools List
(C64). Allow to air dry. Use care to prevent damage (RPSTL).
to printed circuits.
9-88.38 Change 13
TM 55-1520-236-23
c. When replacing components on printed circuit e. Install connector assembly (32) in annunciator
boards use the following precautions: housing (61) as follows:
(1) Use a low wattage (25 watts or less) sol- (1) Insert connector (36) through hole in an-
dering iron. nunciator housing (61).
(2) Ground circuit track adjacent to compo- (2) Install lug terminal (39) and lockwasher
nents. (38) on connector (36). Secure with ferrule nut (37).
(3) Use heat sinks to avoid overheating adja- (3) Attach lug terminal (33) on connector (36).
cent components. Secure with screw (34) and Iockwasher (35).
(4) Coat printed circuit boards with insulating f. Install pins and wires in connector (29).
compound (C63.1).
g. Install connector (29). Secure with four screws
(31) and self-locking nuts (30).
d. Finish all visible exterior surfaces, except hard-
ware, with black anodic (C18.1). Refer to figure 9-
h. Solder wires to terminals on printed circuit
17.8 for areas not to be finished.
board (22).
3-286.1. ASSEMBLY - GUNNERS CAUTION
PANEL.
a. Assemble annunciator light assembly (45, figure Do not overtighten screws (26) or printed cir-
1-17.11) as follows: cuit board (22) may crack.
(1) Assemble contact assemblies (53) by plac- i. Install sleeve spacers (28) on back of printed
ing grooved side of swivel arm on latch and install circuit board (22). Secure with four screws (26) and
each in housing assemblies (51). lock-spring washers (27). Install printed circuit board
(22). Secure with four screws (26) and lock-spring
(2) Slide spacers (50) and housing assemblies washers (27).
(51) onto electrical posts (52).
(3) Install bracket (47) and bracket assembly
(48) on annunciator light assembly (45) and secure
with 12 screws (49). Use care when installing printed circuit
boards (17 and 18) to prevent damage to
(4) Solder wires to back of annunciator light components.
assembly (45).
j. Install printed circuit boards (17 and 18) in cor
rect receptacle connector (43), component side for
b. Install annunciator light assembly (45) in an-
nunciator housing (61) and secure with eight screws ward.
(46).
k. If identification plate (9) was removed from ac
cess cover plate (13) install a new one.
c. Solder wires to switches (40 and 41). Insert
switches (40 and 41) through holes and secure with
knurled plain nuts (42). l. Install access cover plate (13). Secure with fou
screws (14) and two screws (15).
d. Solder wires to pins on receptacle connectors
m. Install cover plate (11) and secure with six
(43). Install receptacle connectors (43) in annuncia-
screws (12).
tor housing (61) and secure with six screws (44).
Change 13 9-88.39
TM 55-1520-236-23
b. Tighten four turnlock stud assemblies to install
caution panel in instrument panel of helicopter.
9-287. RPM LIMIT WARNING SYSTEM.
Do not overtighten screws (8) or light indica-
ting panal (7) may crack. 9-288. DESCRIPTION - RPM LIMIT WARNING
SYSTEM.
n. Install light indicating panel (7) on panel subas-
sembly (10) with screws (8). The rpm limit warning system includes a 5 ampere
RPM WARN circuit breaker (8CB10) located in dc
o. Assemble indicator module (1) as follows: circuit breaker panel (2A1), a dectector unit (1Z3) in
left forward side of pilot section, a warning light (P/O
8DS7) on pilot instrument panel, an RPM WARNING
switch (1S1) in pilot engine control panel (1A1),
electrical wiring, and connectors. Power is supplied
Ensure correct legends are installed in cor- by a 28-volt dc essential bus. Also included in the
rect indicator light positions. If legends are rpm limit warning system are gunner headset
installed in wrong positions, aircrew will re- terminal board (2301TB2) and pilot headset terminal
ceive false information during inflight mal- board (2301TB1). The rpm limit detector, operating
functions. on dc power, senses and interprets rotor and engine
rpm through connection to tachometer circuits. If the
(1) Install gray filters (4 and 6) and legend (5) rotor rpm exceeds normal limit, warning light will
in lens retainer (3). Install gray filters (6) with dull illuminate. When both rotor or engine rpm reaches low
side facing out. limit, an audio signal is produced in pilot and gunner
headsets and warning light is illuminated. For starting
(2) Install lens retainers (3) on contact assem- and ground operation, audio tone can be turned off by
bly (53). the RPM WARNING switch. Before installation, the rpm
warning system detector is adjusted. Readjustment may
(3) Rotate indicator module (1) to horizontal be required whenever a tachometer generator is
replaced, due to tolerances on tachometer components.
position and push into housing assembly (51) until
Replacement of an engine tachometer generator will not
detent is reached. require a check of rotor high rpm setting.
9-286.2. INSTALLATION - GUNNERS CAUTION
PANEL.
a. Connect electrical connector to back of caution
panel.
9-86.40 Change 16
TM 55-1520-236-23
9-289. FUNCTIONAL TEST - RPM LIMIT b. Accomplish test for high rpm warning as follows:
WARNING SYSTEM.
(1) Position the RPM WARNING audio switch
(1S1) to the RPM WARNING position.
NOTE
The rpm limit warning system shall be
tested upon replacement of the rpm limit
Do not exceed 27 percent (15 psi) torque
warning detector, rotor tachometer
pressure or 103 percent engine speed.
generator, or power turbine tachometer
generator. Tests shall be conducted with
helicopter engine running and prior to
alignment. The rpm limit warning detec- (2) With the rotor in flat pitch and the GOV
tor is aligned during overhaul. If after in- AUTO/EMER governor switch set to EMER, slowly
stallation, the detector does not match increase throttle until the RPM warning light
the dual tachometer readings, perform illuminates. The warning light should illuminate at a
functional test of the dual tachometer rotor speed of 103 1 percent (between 329 and 334
system before changing alignment of de- rpm, corresponds to engine speed between 6700 and
tector. 6800 rpm). The audio warning signal should not be
audible in the pilot and gunner headsets.
a. Accomplish test for low rpm warning as follows: 9-290. ALIGNMENT - RPM LIMIT WARNING
SYSTEM.
(1) Position the RPM WARNING audio switch
(1S1) on the pilot engine control panel to RPM
WARNING.
NOTE
(2) Adjust for an engine speed of approximately
98 percent (6468 rpm, corresponds to 318 rotor rpm) Perform alignment of low or high rpm
and check that the red RPM limit warning light on the limit warning, whichever is applicable, if
instrument panel is off and that the audio warning system does not meet test requirements
signal is not audible in the pilot or gunner headsets. of paragraphs 9-289.
(3) Decrease engine speed very slowly to the
point where the RPM limit warning light illuminates and a. Perform alignment of low rpm limit warning as
a swept-frequency audio warning signal (series or follows:
audio bursts) is audible in the pilot and gunner
headsets. This point should beat engine and/or rotor
speed of 94 1 percent (engine: 6200 100 rpm,
rotor: 305 5 rpm).
Use caution in making adjustment as
(4) Position the RPM WARNING audio switch
excessive turning of slotted adjustment
(1S1) to OFF. The audio signal in the headsets should
can damage box.
cease.
(5) Adjust for engine and/or rotor speed below 91
percent (engine: 6000 rpm, rotor: 295 rpm). The RPM
limit warning light should be illuminated, but the audio NOTE
warning signal should not be audible in the pilot and
gunner headsets. To increase the percent rpm at which the
warning light will illuminate, turn
(6) Increase the engine speed and verify that the clockwise ROTOR LOWER LIMIT (R1),
RPM limit warning light extinguishes within the limits ROTOR HIGH LIMIT (R2), or ENGINE
of 94 1 percent for both engine and rotor (engine: LOW LIMIT (T3) slotted adjustments.
6200 100 rpm, rotor 305 5 rpm). The RPM WARN- One half turn of the potentiometer shaft
ING audio switch should automatically return to RPM will cause a change of approximately 1.5
WARNING position. percent rotor or engine rpm.
Change 8 9-89
TM 55-1520-236-23
(1) Position ROTOR NORMAL/DISABLE switch b. Perform alignment of rotor high rpm limit warning
to DISABLE to deactivate the rotor low rpm signal. as follows:
(2) Start helicopter and increase engine speed to
approximately 98 percent (6468 rpm, corresponds to
318 rotor rpm).
Use caution in making adjustments as
(3) Slowly decrease engine speed to 92 percent excessive turning of slotted adjustment
(6072 rpm). can damage box.
Do not exceed 15 psi engine torque.
(4) If, following step (3), the RPM limit warning
light is illuminated, turn ENGINE LOWER LIMIT
adjustment slowly counterclockwise until the warning (1) With the rotor in flat pitch and GOV
light extinguishes and then very slowly clockwise until AUTO/EMER switch set to EMER, slowly increase
the warning light again illuminates. If, following step (3), throttle until rotor speed is 102.3 percent (331.4 rotor
the RPM limit warning light is extinguished, turn the rpm, corresponds to engine speed of 6750 rpm).
ENGINE LOWER LIMIT adjustment slowly clockwise
until the warning light just illuminates.
(2) If, following step (1), the warning light is
(5) Vary the engine speed slowly above and illuminated, turn ROTOR HIGH LIMIT adjustment
below 92 percent (6072 rpm) while observing the clockwise until the light just extinguishes, then very
warning light. Verify that the warning occurs at an slowly counterclockwise until the light just illuminates.
engine speed of 94 1 percent (6200 100 rpm); if If, following step (1), the warning light is extinguished,
not, repeat steps (3), (4), and (5). turn ROTOR HIGH LIMIT adjustment very slowly
counterclockwise until the warning light just
illuminates,
(6) Position the ROTOR NORMAL/DISABLE
switch to NORMAL and the ENGINE
NORMAL/DISABLE switch to DISABLE to deactivate (3) Vary the engine speed to verify that the
the engine low rpm signal. warning light illuminates and that audio warning does
not occur at a rotor speed of 103 1 percent (329 to 334
rotor rpm, corresponds to engine speed between 6700
(7) Adjust for a rotor speed of 92 percent (298 and 6800 rpm). If warning light does not illuminate,
rpm). repeat steps (1), (2), and (3).
(4) Repeat low and high rpm warning functional
(8) If, following step (7), the warning light is
illuminated, turn ROTOR LOWER LIMIT adjustment tests as specified in paragraph 9-289.
slowly counterclockwise until the warning light just
extinguishes, then very slowly clockwise until the light
again illuminates. If, following step (7), the warning light (5) Close detector cover.
is extinguished, turn ROTOR LOWER LIMIT
adjustment very slowly clockwise until the light just
illuminates. 9-291. TROUBLESHOOTING - RPM LIMIT
WARNING SYSTEM.
(9) Vary rotor speed above and below 92 percent Refer to paragraph F-9 in Appendix F for wiring
(298 rpm) while observing the warning light. Verify that diagrams. Use table 9-16 and perform checks as
warning occurs at 94 1 percent (305 5 rpm). If necessary to isolate trouble. In the following table,
light does not illuminate, repeat steps (7), (8), and (9). tripped circuit breakers are omitted from indications of
trouble. Such trouble is usually easily detected and
corrected. Broken wiring is always a probable cause
(10) Return the ENGINE NORMAL/DISABLE of circuit malfunction of failure and has not been
switch to NORMAL. included.
9-90 Change 8
TM 55-1520-236-23
NOTE
Before you use this table, be sure you
have performed all normal operational
checks. If you have a malfunction which
is not listed in this table, notify the next
higher level of maintenance.
Table 9-16. 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 warning light is illuminated.
STEP 1. Check for defective RPM WARNING switch (1S1).
Replace switch if defective (paragraph 9-16).
STEP 2. Check for defective rpm limit warning detector (1Z3).
Replace rpm limit warning detector if defective (paragraph 9-292).
2. Placing RPM WARNING switch (1S1) to OFF does not eliminate audio tone in headsets.
STEP 1. Check for defective RPM WARNING switch (1S1).
Replace switch if defective (paragraph 9-16)
3. Rpm warning light (8DS7) does not illuminate when engine is not running. Audio tone present in headsets.
STEP 1. Check for defective rpm limit warning detector (1Z3).
Replace rpm limit warning detector if defective (paragraph 9-292).
4. Rpm warning light (8DS7) does not illuminate, no audio tone present in headsets when engine iS not
running.
STEP 1. Check for defective RPM WARN circuit breaker (8CB10).
Replace circuit breaker if defective (paragraph 9-23).
STEP 2. Check for defective rpm limit warning detector (1Z3).
Replace rpm limit warning detector if dafective (paragraph 9-292).
9-91
TM 55-1520-236-23
9-292. RPM LIMIT WARNING DETECTOR The pilot and copilot (gunner) audio
outputs are loaded within the test set so
9-293. DESCRIPTION - RPM LIMIT WARNING that an oscilloscope may be used to
DETECTOR. monitor audio signals. The scope input
cable is connected to a scope input
The rpm limit warning detector (1Z3), operating on dc switch that allows selection of pilot or
power from the essential bus senses and interprets copilot (gunner) audio output.
rotor and engine rpm through connection to tachometer
circuits. If rotor exceeds normal limit, power is furnished b. Use equipment shown in figure 9-18 and test
through the detector to illuminate the rpm warning light each rpm limit warning detector as follows:
(8DS7). When either rotor or engine rpm reaches low
limit, the detector produces an audio signal in the pilot NOTE
and copilot headsets and illuminates the rpm warning
light. For Saturn detectors, step (15) checks the
engine channel tachometer circuits. For
9-294. CLEANING RPM LIMIT WARNING other models go to step (16).
DETECTOR.
(1) Remove jumper or loosen detector cover
a. Remove moisture and loose dirt with a clean, soft strip screws and move cover strips to expose
cloth. adjustment potentiometers.
NOTE
Cleaning solvent is flammable and toxic. For Saturn detectors, step (20) checks the
Provide adequate ventilation. Avoid engine channel tachometer circuits. For
prolonged breathing of solvent vapors other models go to step (21).
and contact with skin or eyes.
(2) Remove jumper or connect detector to the
b. Remove grease, fungus, and ground-in dirt with bench test equipment as shown in figure 9-18. Set initial
a clean, lint-free cloth dampened with dry cleaning control positions on the test set as follows:
solvent (C112).
CONTROL POSITION
c. Remove dirt from electrical connectors with a
bristle brush. PWR ON/OFF OFF
ENGINE SPEED FULLY COUNTERCLOCKWISE
9-295. INSPECTiON - RPM LIMIT WARNING ROTOR SPEED FULLY COUNTERCLOCKWISE
DETECTOR. AUDIO ON/OFF ON
SCOPE INPUT PILOT
a. inspect rpm limit warning detector for cracked or
distorted case. (3) Energize the test equipment and allow a
sufficient warmup period.
b. Check for bent or broken connector pins.
(4) Apply 27.5 Vdc power to the DC power packs
c. Check for proper operation. on the front of the test set. Observe that the warning light
on the test set is illuminated and that a sweeping audio
9-296. BENCH TEST AND ADJUSTMENT - RPM signal is displayed on the oscilloscope for both the
LIMIT WARNiNG DETECTOR. (AVIM). PILOT and COPILOT (GUNNER) positions of the scope
input switch.
a. Setup bench test equipment as shown in figure
9-18. (5) Connect a headset to the COPILOT
(GUNNER) phone jack and determine that the aural
NOTE signal is of good quality, Disconnect headset.
The rpm test set may be locally (6) Repeat step (5) with headset plugged into the
fabricated. Refer to paragraph F-9 for PILOT phone jack.
index to wiring diagrams.
9-92 Change 18
TM 55-1520-236-23-2
Figure 9-18. BHC Model RPM Warning Control
Figure 9-18.1. Saturn Model RPM Limit Warning Detector
9-18.1
TM 55-1520-236-23
Figure 9-18.2. Cables for Alignment of Rpm Limit Warning Detector
9-92.2
TM 55-1520-236-23
Figure 9-18.3. Bench Test Set Up for BHT 205-074-033-101 Rpm
Limit Warning Detector
Change 18 9-93
TM 55-1520-236-23
(7) Disable engine circuit to align R11-ROTOR warning light is illuminated, observe that audio signal is
LOWER LIMIT. displayed on the oscilloscope for both the PILOT and
COPILOT (GUNNER) positions of the scope input
(8) Adjust test set for a simulated rotor speed switch.
of 300 rpm and an engine speed of 6100 rpm. If the
warning light is illuminated, adjust R1-ROTOR LOWER (19) Adjust for a simulated engine speed of 6400
LIMIT counterclockwise until the light just extinguishes. rpm. Observe that the warning light is extinguished and
that the audio signal is not displayed on the oscilloscope
(9) Adjust R1-ROTOR LOWER LIMIT for either the PILOT or COPILOT (GUNNER) positions
clockwise very slowly until the light just illuminates. With of the scope input switch.
the light illuminated, an audio signal must be displayed
on the oscilloscope for both the PILOT and COPILOT NOTE
(GUNNER) position of the scope input switch. Step (19) checks proper function only.
The engine high limit potentiometer R4 is
(10) Position audio ON/OFF switch to OFF. The factory adjusted fully clockwise and is
sweeping audio signal must cease. not to be adjusted.
(11) Slowly increase simulated rotor speed (20) Repeat step (18) at a simulated engine
through 300 rpm. Observe that the audio switch speed of 7000 rpm.
automatically returns to the ON position when the
warning light extinguishes. (21) Position switch used to disable rotor circuit
in step (15). Adjust rotor and engine speed controls on
(12) Increase simulated rotor speed to 334 rpm. test set fully counterclockwise.
If the warning light is illuminated, adjusted R2-ROTOR
HIGH LIMIT clockwise until the light just extinguishes. (22) Position scope input switch to PILOT and
adjust R5-AUDIO for a waveform of 0.5 volts
(13) Adjust R2-ROTOR HIGH LIMIT very slowly peak-to-peak across an 8 ohm load. Position scope
counterclockwise until the light just illuminates. input switch to COPILOT (GUNNER) and observe that
Observe that an audio signal is not displayed on the the indicated waveform is not less than 0.25 volts
oscilloscope for either PILOT or COPILOT (GUNNER) peak-to-peak and not more than 0.75 volts peak-to-peak
positions of the scope input switch. across an 8 ohm load.
(14) Adjust for a simulated rotor speed of 324 (23) Disconnect detector from test set and
rpm. Observe that the warning light is extinguished and reassemble unit.
that audio signal is not displayed on the oscilloscope for
either the PILOT or COPILOT positions of the scope 9 - 2 9 7 . R E M O V A L - RPM LIMIT WARNING
input switch. DETECTOR.
(15) Momentarily adjust for a simulated engine a. Disconnect electrical connector.
speed of 0 rpm. Observe that the warning light
illuminates and that audio signal is displayed on the b. Remove attaching hardware and remove
oscilloscope for both PILOT and COPILOT positions of detector.
the scope input switch.
9-298. REPAIR - RPM LIMIT WARNING
(16) Reposition switch used to disable engine DETECTOR.
circuits in step (7) and disable rotor circuit to align R3-
ENGINE LOWER LIMIT. Repair is limited to replacement of defective unit. Return
defective unit to depot for repair.
(17) With the simulated rotor speed still at 324
rpm, adjust for a simulated engine speed of 6200 rpm. 9-299. INSTALLATION - RPM LIMIT WARNING
If the warning light is illuminated adjust R3-ENGINE DETECTOR.
LOWER LIMIT counterclockwise until the light just
extinguishes. a. Position detector into place and install mounting
hardware.
(18) Adjust R3-ENGINE LOWER LIMIT
clockwise until the light just illuminates, While the b. Connect connector.
9-94 Change 18
TM 55-1520-236-23
9-299.1. SKID LANDING LIGHT SYSTEM. the SKID LDG LT switch in the ON position. Check that
the skid landing light is energized. Return switch to
9-299.2. DESCRIPTION - SKID LANDING OFF and open circuit breaker.
LIGHT SYSTEM.
9-299.4. TROUBLESHOOTING - SKID
The skid landing light circuit consists of a 20 ampere LANDING LIGHT SYSTEM.
SKID LDG LT circuit breaker located in the dc circuit
breaker panel, an on/off switch located on the left side Refer to paragraph F-9 for wiring diagram. Use table 9-
of the pilots cockpit aft of the ashtray, and a landing 16.1 and perform checks as necessary to isolate
light mounted on the left side of the forward crosstube trouble. In table 9-16.1, tripped circuit breakers are
assembly. omitted from indications of trouble. Such trouble is
usually easily detected and corrected. Broken wiring is
9-299.3. FUNCTIONAL TEST - SKID always a probable cause of a circuit malfunction or
failure and has not been included.
LANDING LIGHT SYSTEM.
Close the SKID LDG LT circuit breaker. Plact
NOTE
Before using table 9-16.1, be sure you
have performed the functional test.
Table 9-16.1. Troubleshooting Skid Landing Light System
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. Skid landing light fails to illuminate.
STEP 1. Check if bulb is burned out and heck lamp connections for corrosion.
Clean lamp connections and/or replace bulb.
STEP 2. With the SKID LDG LT circuit breaker closed and the SKID LDG LT switch in the ON position, check
for 28 Vdc essential bus voltage on both sides of switch.
Replace switch if voltage is preseent on wire SLB12 terminal of switch but not on wire SLC12
terminal.
2. Skid landing light does not turn off.
Replace switch.
9-94.1
TM 55-1520-236-23
9-299.5. SKID LANDING LIGHT. 9.299.11. OIL DEBRIS DETECTION SYSTEM (ODDS)
(HELICOPTERS WITH MWO 1-1520-236-50-30)
9-299.6. CLEANING - SKID LANDING LIGHT.
9.299.12. DESCRIPTION. The oil debris detection
a. Remove moisture and loose dirt with a clean soft system (ODDS) provides for prediction/detection of
cloth. impending failures of oil-wetted components: engine,
transmission, and 42 and 90 tailrotor gearboxes. The
system also improves oil filtration, reduces wear on
seals, reduces unscheduled removal of oil-wetted
components, and reduces nuisance chip indications
Cleaning solvent is flammable and caused by normal-wear particles on detector gaps.
toxic. Provide adequate ventilation. Twenty-eight volt dc for system operation is obtained
Avoid prolonged breathing of from the essential bus through 5-ampere ODDS circuit
solvent vapors and contact with breaker.
skin or eyes.
a. Powerplant oil system components:
b. Remove grease, fungus, and ground-in dirt with
a clean, lint-free cloth dampened with dry cleaning (1) Oil separator (Lubriclone) in engine compart-
solvent (C112). ment (paragraph 4-61 .2).
c. Remove dirt from electrical connections with a (2) Oil filter, with 3-micron element, in engine
bristle brush. compartment (paragraph 4-61. 14).
9-299.7. INSPECTION - SKID LANDING LIGHT. (3) Chip detector at bottom of oil separator.
Detector is wired to ENG CHIP caution light.
Inspect light for corroded lamp terminals, shorted or
broken wires, burned out lamp bulb or improper b. Drive system components:
security of light assembly.
(1) Debris monitor in transmission sump. Monitor
9-299.8 REMOVAL-SKID LANDING LIGHT. replaces pre-ODDS conventional filter.
Remove screws and ring securing bulb in canopy and (2) External filter, with 3-micron element, bracket-
remove bulb. Disconnect wires from bulb terminals. mounted on transmission case. Filter replaces pre-
Loosen compression nut on back of canopy and ODDS 25 micron filter.
remove wires. Cover wire ends with tape (C121).
Remove skid landing light assembly from crosstube. (3) Three chip detectors, one in debris monitor and
one each in 42 and 90 gearboxes. Detectors are
9-299.9 REPAIR-SKID LANDING LIGHT. wired to TRANS CHIP, 42 CHIP, and 90 CHIP
caution lights.
Replace faulty or damaged component parts.
c. Electrical system component: Power module, on
9-298.10 INSTALLATION - SKID LANDING LIGHT. pilots right console provides electrical power to pulse
(burn) away ferrous (iron or steel) debris less than
a. Secure skid landing light assembly to forward 0.005 inch in cross section. Larger debris will not pulse
crosstube. Remove protective tape from wires. Insert away, but bridges chip gap and closes the circuit to
wires through insulation sleeve RNF-100-1 (3 inches caution lights.
long) and secure wires in light canopy. Position
insulation sleeve over compression nut and apply heat 9-199.13. FUNCTIONAL TEST - ODDS
as necessary. Connect wires to bulb terminals and
place bulb in light canopy. Install bulb retaining ring. a. Apply external power to helicopter.
b. Check operation of light. b. Check that ODDS and CAUTION LIGHTS circuit
breakers are closed.
9-94.2 Change 20
TM 55-1520-236-23
c. At each chip detector or debris monitor listed (6) Remove paper clip. Caution capsule shall go
below (four locations), perform functional test as out. MASTER CAUTION light will go out when
follows: pressed. Separate chip detector from ground.
(1) Disconnect cable plug. (7) Disconnect cable plug from chip detector.
(2) Remove chip detector. (8) Install and connect chip detector probe. Safety
wire each chip detector connector with lockwire (C137).
(3) Connect chip detector to cable plug.
9-299-14. TROUBLESHOOTING - ODDS
(4) Ground body of detector to clean unpainted
surface of airframe. Use a jumper wire. - Refer to paragraph F-9 in Appendix F for wiring
diagram. Use Table 9-16.2 and perform checks as
(5) Place paper clip or similar iron or steel object necessary to isolate trouble. In the following table,
across chip gap of detector. The paper clip will draw a tripped circuit breakers are omitted from indications of
spark; caution light listed and MASTER CAUTION light trouble. Such trouble is usually easily detected and
shall come on. corrected.
Chip Caution NOTE
Detector Location Capsule
Before you use this table, be sure
1D851* Transmission TRANS you have performed all normal
(two chip CHIP operational checks. If you have a
gaps) malfunction which is not listed in
this table, notify the next higher
1B833 42 Gearbox 42 CHIP level of maintenance.
1B833 90 Gearbox 90 CHIP
B4443B Engine ENG CHIP
* Test each chip gap separately.
Table 9-16.2. Troubleshooting ODDS
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. During test, ENG CHIP caution light does not come on when pin 1 of oil separator cable plug is shorted
to ground.
STEP 1. If master caution light came on, replace ENG CHIP lamps or troubleshoot caution panel.
If master caution light did not come on, check continuity of wire W10C18 between pin 1
of oil separator cable plug and pin 8A2P1-J at caution panel. Repair wiring.
2. During test, 42 CHIP caution light does not come on when pin 1 of chip detector cable plug is shorted
to ground.
STEP 1. If master caution light came on, replace 42 CHIP lamps or trouble shoot caution system.
If master caution light did not come on, check continuity of wire W8C20 between pin 1 of
chip detector cable plug and pin 8A2P1-K at caution panel. Repair wiring.
Change 20 9-94.3
TM 55-1520-236-23
Table 9-16.2. Troubleshooting ODDS
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
3. During test, 90 CHIP caution light does not come on when pin 1 of chip detector cable plug is shorted
to ground.
STEP 1. If master caution light came on, replace 90 CHIP lamps or troubleshoot caution system.
If master caution light did not come on, check continuity of wire W9C20 between pin 1 of
debris monitor cable plug and pin 8A2P1-L at caution panel. Repair wiring.
4. During test, TRANS CHIP caution light does not come on when pin 1 of debris monitor cable plug is
shotted to ground.
STEP 1. If master caution light came on, replace TRANS CHIP lamps or trouble shoot caution system.
If master caution light did not come on, check continuity of wire W7C20 between pin 1 of
debris monitor cable plug and pin 8A2P1-M at caution panel. Repair wiring.
5. Debris collects across chip gap of any one of chip detectors.
STEP 1. Clean chip detector. Short across chip gap with screw driver or paper clip and check for spark.
Check power module if there is no spark.
STEP 2. Disconnect cable plug at power module. Check for 28V dc across pin 1 (+) and pin (2).
Replace power module if voltage is present. Troubleshoot wiring to ODDS circuit breaker if there is no
voltage.
6. Caution light stays on when chip gap is clean.
STEP 1. Remove chip detector probe or remove debris monitor. Use multimeter to check resistance
across chip gap. Minimum resistance is 1 megohm
Replace probe if resistance is less than 1 megohm.
STEP 2. If probe resistance is more than 1 megohm. troubleshoot wiring. Repair defective wiring.
9-94.4 Change 20
TM 55-1520-236-23
9-299.15. ODDS POWER MODULE 9-299.17. REMOVAL - POWER MODULE
9 - 2 9 9 . 1 6 . D E S C R I P T I O N - A four-channel power a. Remove the adf control (TM 11-1520-236-23).
module (8A3, figure 9-8) for oil debris detection system
(ODDS) is just aft of the caution panel on the pilots b. Disconnect cable plug.
right console, below the ADF control. Power module
responds to iron or steel chips across four chip c. Remove four screws and washers and remove
detectors by pulsing them. If chips are less than about power module.
0.005 inch in cross-section, the module will pulse (burn)
them away before caution light can respond. If chips 9-299.18. INSTALLATION - POWER MODULE
are larger, they will not burn away; they will bridge the
chip gap and light a caution light. The power module a. Position the power module on pilots right console,
is connected to chip detectors in oil system or oil supply receptacle outboard.
of engine, transmission, and two tail-rotor gearboxes.
Components of power module are encapsulated in a 3 b. Install four screws and washers.
x 3 x 1-1/2-inch black box. Twenty-eight volt dc for
operation is obtained from essential bus through ODDS c. Connect the cable plug to the power module.
circuit breaker. Connections to circuits are made
through a 12-pin electrical receptacle. d. Test the system (paragraph 9-299.13).
e. Install the adf control (TM 11-1520-236-23).
Change 20 9-94.5/(9-94.6 blank)
TM 55-1520-236-23
9-300. POSITION LIGHTS SYSTEM. b. Position BRT\DIM switch to DIM. Check that
the position lights are dim.
9 - 3 0 1 . DESCRIPTION - POSITION
LIGHTS SYSTEM.
c. Position POSITION LT switch to FLASH. Check
The position lights circuit includes a 5 ampere POS(N) that the red and green position lights, and the tail
LT circuit breaker (8CB1) located in dc circuit breaker lights are all on dim and flash at a rate of
panel (2A1), and two selector switches (8S1 and approximately 80 10 cycles per minute.
8S2), located on the pilot lighting control panel
(10A1). A flasher (821) is mounted in pilot section, d. Position BRT\DIM switch to BRT and repeat
right well. The position lights consist of a red light step c. Check that lights flash as before except that
(8DS1), a green light (8DS2), and white lights (8DS3) lights are brighter than that observed in preceding
(LH) and 8DS4) (RH). The red light is mounted in left step c.
wing tip, the green light is mounted in right wing tip,
and the white lights are located on either side of e. Open POSN LT circuit breaker (8CB1).
tail boom. Switch (8S1) controls
OFF/STEADY/FLASH and switch (8S2) controls
BRT/DIM position. The dimming circuit is provided by 9-303. TROUBLESHOOTING - POSITION
a dimming resistor (8R1) located on 1TB3, which is LIGHTS SYSTEM.
located in pilot section right well.
9-302. FUNCTIONAL TEST - POSITION Refer to paragraph F-9 in Appendix F for wiring
LIGHTS SYSTEM. diagram. Use Table 9-17 and perform checks as
necessary to isolate trouble. In the following table,
a. Close POS(N) LT PWR circuit breaker (8CB1). tripped circuit breakers are omitted from indications
Place POSITION LT switch (8S1) to STEADY. Position of trouble. Such trouble is usually easily detected and
BRT/DIM switch (8S2) to BRT. Check that the red and corrected. Broken wiring is always a probable cause
green position lights and tail lights are energized and of circuit malfunction or failure and has not been
are on bright. included.
NOTE
Before you use this table, be sure you
have performed all normal operational
checks. If you have a malfunction which
is not listed in this table, notify the next
higher level of maintenance.
Table 9-17. Troubleshooting Position Lights System
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. Position lights (8DS1, 8DS2, 8DS3 and 8DS4) fail to illuminate brightly.
STEP 1. With switch (8S1) to STEADY and switch (8S2) to BRT check for 28 Vdc nonessential bus voltage on
terminals 5 and 6 of switch (8S1).
Replace switch (8S1) if voltage is not present on terminal 6 (paragraph 9-16).
Change 16 9-95
TM 55-1520-236-23
Table 9-17. Troubleshooting Position Lights System (Cont)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
STEP 2. With switch (8S1 ) to STEADY and switch (8S2) to BRT, check for 28 Vdc nonessential bus voltage on
terminals 1 and 2 of switch (8S2).
Replace switch (8S2) if voltage is not present on terminal 1 (paragraph 9-16).
2. One light is dim or intermittent.
STEP 1. Determine if light is properly grounded.
Remove light, clean ground, replace light.
3. One light does not illuminate.
STEP 1. Check whether bulb is burned out and check lamp socket for corrosion.
Clean lamp socket and/or replace light (paragraph 9-304).
4. Lights fail to dim when switch (8S2) is placed to dim.
STEP 1. Check dimming resistor (8R1).
Replace dimming resistor (8R1) if it is defective (paragraph 9-16).
5. Lights fail to flash when switch (8S1) is placed to FLASH.
STEP 1. Determine if position lights flasher is defective.
Replace flasher if defective (paragraph 9-310).
9-304. POSITION LIGHTS. b. Remove grease, fungus, and ground-in dirt
with a clean, lint-free cloth dampened with dry
9-305. CLEANING - POSITION LIGHTS. cleaning solvent (C112).
a. Remove moisture and loose dirt with a clean, c. Remove dirt from electrical connectors with a
soft cloth. bristle brush.
9-306. INSPECTION - POSITION LIGHTS.
Cleaning solvent is flammable and toxic. lnspect lights for corroded lamp socket terminals,
Provide adequate ventilation. Avoid shorted or broken wires, cracked lens, burned out
prolonged breathing of solvent vapors lamp bulbs, or improper bonding of light case to
and contact with skin or eyes. airframe.
9-96 Change 16
TM 55-1520-238-23
9-307. REMOVAL POSITION LIGHTS. 9-313. REMOVAL POSITION LIGHT
FLASHER.
a. Check that all electrical power is OFF.
a. Ensure all electrical power is OFF.
b. Remove cover retaining screw. Remove
screws attaching light assembly to bracket, pull b. Disconnect electrical connector. Remove
assembly from helicopter, and disconnect wire from mounting hardware and lift from compartment.
light. Lift light assembly from helicopter. Cover loose
wire with tape (C121).
9-314. REPAIR POSITION LIGHTS
FLASHER.
9-308. REPAIR POSITION LIGHTS.
Replace faulty or damaged component parts (lens, Replace item if inspection requirements are not met.
lamp bulbs, etc.) If light case is damaged beyond
repair, complete unit must be replaced. 9-315. INSTALLATION POSITION LIGHTS
FLASHER.
9-309. INSTALLATION POSITION
LIGHTS. a. Position flasher in compartment and install
mounting hardware.
a. Remove tape from wire and connect wire to
light. Secure light to adapter bracket with screws. b. Connect electrical connector. Check for
Install cover with screw. proper operation.
b. Check operation of light. 9-315.1. NVG POSITION LIGHTS SYSTEM.
9-310. POSITION LIGHTS FLASHER.
9-315.2. DESCRIPTION NVG POSITION
LIGHTS SYSTEM.
9-311. CLEANING POSITION LIGHTS
FLASHER.
The NVG position lights circuit consists of a 5 ampere
NVG POSITION LT circuit breaker located in the dc
a. Remove moisture and loose dirt with a dean,
circuit breaker panel, a six position switch (OFF and 5
soft cloth.
levels of brightness) located on the pilots ECS/LTG
panel and five position lights (one on each wingtip, one
on each aft light fairing, and one on the tail fin fairing).
The position lights are compatible for use with the night
vision goggles.
Cleaning solvent is flammable and tox-
ic. Provide adequate ventilation. Avoid
prolonged breathing of solvent vapors 9-315.3. FUNCTIONAL TEST - NVG POSl-
and contact with skin or eyes. TION LIGHTS SYSTEM.
b. Remove grease, fungus, and ground-in dirt NOTE
with a dean, lint-free cloth dampened with dry cleaning
solvent (C112). Use locally fabricated NVG Iight test set.
c. Remove dirt from electrical connectors with a
Close the NVG POSITION LT circuit breaker. With the
bristle brush. NVG POSITION LIGHTS LT switch in the OFF posi-
tion, all NVG position Iights should be off. As the NVG
9-312. INSPECTION POSITION LIGHTS POSITION LT switch is rotated through the other five
FLASHER. positions, all NVG position lights should be energized
and increase in brightness with each step to the BRT
Inspect flasher case for dents or damage that could position. Rotate the switch back through five steps, all
impair normal operation of the unit. Check connector NVG position lights should decrease in brightness and
for broken or corroded pins and cracked inserts. should be de-energized in the OFF position.
Change 22 9-97
TM 55-1520-236-23
NOTE
Before using table 9-17.1, be sure you
have performed the functional test.
Table 9-17.1. Troubleshooting NVG Position Lights System
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. Individual NVG position light fails to illuminate.
STEP 1. Check if light is burned out.
Replace NVG position light assembly (paragraph 9-315.8).
2. All NVG position lights fail to illuminate.
STEP 1. With the NVG POSITION LT circuit breaker closed and the NVG POSITION LT switch
in the BRT position, check for 28 Vdc nonessential bus voltage on pins 11 and 16 of NVG position
light switch.
Replace NVG POSITION LT switch if voltage is present on pin 11 but not present on pin
16.
3. No brightness differential between two or more steps of NVG position light switch.
STEP 1. With the NVG POSITION LT circuit breaker closed and the NVG POSITION LT switch
selecting the dimmer position, measure and record the Vdc level at pin 16 of NVG position light
switch. Rotate NVG position light switch through each non-differentiating step and record the Vdc
level at pin 16 of NVG position light switch.
Replace NVG POSITION LT switch if there is no voltage increase between steps.
4. NVG position lights do not turn off.
Replace NVG POSITION LT switch.
9.315.4. TROUBLESHOOTING - NVG POSI- 9-315.5. NVG POSITION LIGHTS.
TION LIGHTS SYSTEM.
Refer to paragraph F-9 for wiring diagram, Use 9-315.6. CLEANING NVG POSITION
table 9.17.1 and perform checks as necessary to LIGHTS.
isolate trouble. Such trouble is usually easily
detected and corrected. Broken wiring is always a. Remove moisture and loose dirt with a
a probable cause of circuit malfunction or failure clean soft cloth.
and has not been included.
9-98 Change 10
TM 55-1520-236-23
9 - 3 1 6 . ANTI COLLISON LIGHT
SYSTEM.
Cleaning solvent is flammable and tox- 9-317. DESCRIPTION - ANTICOLLISION
ic. Provide adequate ventilation. Avoid SYSTEM.
prolonged breathing of solvent vapors
and contact with skin or eyes. The anticollision light circuit consists of a circuit
breaker (8CB2), a switch (8S3), and anticollision light
b. Remove grease, fungus, and ground-in dirt assembly (8DS5). Anticollision light is installed on
with a clean, lint-free cloth dampened with dry pylon fairing. Circuit breaker and switch are on dc
cleaning solvent (C112). circuit breaker panel (2A1) and pilot lighting control
panel (10A1) respectively,
c. Remove dirt from electrical connections
with a bristle brush. 9-318. F U N C T I O N A L T E S T -
ANTICOLLISION LIGHT SYSTEM.
9-315.7. INSPECTION - NVG POSITION
LIGHTS. a. Close ANTI-COLL LT circuit breaker.
Inspect lights for corrosion, shorted or broken b. Position ANTI-COLL LT switch (8S3) to ON and
wires, cracked Iens or frame, burned out light, or check that lamp(s) illuminate and that the light rotates
improper security of light assembly to airframe. giving 70 30 flashes per minute.
9-315.8. REMOVAL - NVG POSITION 9-319. T R O U B L E S H O O T I N G -
LIGHTS. ANTICOLLISION LIGHT SYSTEM.
Remove two screws, washers, and nuts. Discon- Refer to paragraph F-9 in Appendix F for wiring
nect wire splices and remove NVG position light. diagrams. Use Table 9-18 and perform checks as
necessary to isolate trouble. In the following table,
9-315.9. REPAIR-NVG POSITION LIGHTS. tripped circuit breakers are omitted from indications
of trouble. Such trouble is usually easily detected and
Replace faulty or damaged components. corrected. Broken wiring is always a probable cause
of circuit malfunction or failure and has not been
9-315.10. INSTALLATION - NVG POSITION included.
LIGHTS.
Remove excess sealant from around fixture loca-
tion. Apply bead of sealing compound (C107.5)
and install NVG position lights with two screws,
washers, and nuts. Connect wire splices.
Change 10 9-98.1
TM 55-1520-236-23
NOTE
Before you use this table, be sure you
have performed all normal operational
checks. If you have a malfunction which
is not listed in this table, notify the next
higher level of maintenance.
Table 9-18. Troubleshooting Anticollision Light System
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. Anticollision light (8DS5) fails to flash.
STEP 1. Set ANTI-COLL LT switch (8S3) to ON. Check for 28 Vdc NON-ESNTL BUS voltage on terminals 1
and 2 of switch (8S3).
Replace switch if voltage is not present on terminal 1. Replace bulb or light, as needed, if voltage
is present (paragraph 9-16),
2. Anticollision light (8DS5) fails to rotate.
STEP 1. Set ANTI-COLL LT switch (8S3) to ON. Check for 28 Vdc NON-ESNTL BUS voltage on terminals A
and B of connector (8DS5P1 ).
If voltage check indicates motor is defective, replace motor (paragraph 9-16).
9-320. ANTICOLLISION LIGHT. c. Remove dirt from electrical connectors with a
bristle brush,
9-321. CLEANING - ANTICOLLISION
LIGHT, 9-322. INSPECTION - ANTICOLLISION
LIGHT.
a. Remove moisture and loose dirt with a clean,
soft cloth, a. Inspect light for broken cover, lens or open
lamp filament.
b. Inspect light for damaged case, or broken
connector pins.
Cleaning solvent is flammable and toxic.
Provide adequate ventilation. Avoid c. Inspect motor for damage and proper
prolonged breathing of solvent vapors operation.
and contact with skin or eyes.
9-323. REMOVAL - A N T I C O L L I S I O N
b. Remove grease, fungus, and ground-in dirt LIGHT.
with a clean, tint-free cloth dampened with dry
cleaning solvent (C112), a. Be sure that all electrical power is OFF.
9-98.2 Change 10
TM 55-1520-236-23
b. Remove mounting screws around base of light, 9 - 3 2 8 . FUNCTIONAL TEST -
lift light up, and disconnect electrical connector. SEARCHLIGHT SYSTEM.
9-324. REPAIR - ANTICOLLISION LIGHT. a. Close SRCH LT PWR and SRCH LT CONT circuit
breakers. Position SRCH LT switch (8S5) to ON and
a. Loosen screw securing lens cover retaining check that searchlight illuminates. Return switch
ring, lift lens from light base. Install and secure lamp, (8S5) to OFF.
lens or cover in reverse order of removal procedure.
b. Position four-way SRCH LTswitch (8S4) to EXT
b. Replace complete unit if inspection (fwd position). Check that light extends and is stopped
requirements are not met. Return to depot for repair.
by extend limit switch at approximately 120 degrees
- extension.
9-325. INSTALLATION
ANTICOLLISION LIGHT. c . Position, switch (8S4) to RETR (aft position).
Check that light retracts.
a. Connect electrical connector to light and
secure with Iockwire (C136). d. With light partially extended, position switch
(8S4) to L and check that light rotates to the left.
b. Place light in recess and install mounting
screws and ground strap.
e. Position switch (8S4) to R and check that light
c. Check light for proper operation. rotates to the right.
9-326. SEARCHLIGHT SYSTEM. f. With light extended and rotated, position
switch (8S5) to STOW. Check that light retracts and is
9-327. DESCRIPTION - SEARCHLIGHT stopped by the retract limit switch and then rotates to
SYSTEM. its level stowed position and stops,
The searchlight (8DS6) is located under the gunner
section and the circuit consists of one controllable
light, two circuit breakers (8CB3 and 8CB4) located in
the dc circuit breaker panel (2A1), and two switches 9-329. T R O U B L E S H O O T I N G -
(8S4 and 8S5) located on the pilot collective stick SEARCHLIGHT SYSTEM.
(4A2). Switch (8S4) controls extend, retract, rotate
left, and rotate right motion. Switch (8S5) controls Refer to paragraph F-9 in Appendix F for wiring
OFF, ON, and STOW functions. diagram. Use Table 9-19 and perform checks as
necessary to isolate trouble. In the following table,
tripped circuit breakers are omitted from indications
of trouble. Such trouble is usually easily detected and
Do not operate searchlight in areas of corrected. Broken wiring is always a probable cause
combustible material, such as tall grass, of circuit malfunction or failure and has not been
etc. included.
Change 5 9-99
TM 55-1520-236-23
NOTE
Before you use this table, be sure you
have performed all normal operational
checks. If you have a malfunction which
is not listed in this table, notify the next
higher level of maintenance.
Table 9-19. Troubleshooting Searchlight System
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. Searchlight (8DS6) inoperative.
STEP 1. Set SRCH LT switch (8S5) to ON. Check for 28 Vdc NON ESNTL BUS voltage on terminals 1 and 2 of
switch (8S5).
Replace switch (8S5) if voltage is not present on terminal 1 (paragraph 9-16),
2. Light dim, constantly or intermittently.
STEP 1. Check for proper grounding.
Remove light, clean ground and replace light (paragraph 9-330).
3. Light out.
STEP 1. Remove lamp and check for open filament and corrosion.
Replace lamp unit or clean terminals as needed (paragrpah 9-330).
9-330. SEARCHLIGHT. b. Remove grease, fungus, and ground-in dirt
with a clean, lint-free cloth dampened with dry
9-3310 CLEANING - SEARCHLIGHT. cleaning solvent (C112).
a. Remove moisture and loose dirt with a clean, c. Remove dirt from electrical connectors with a
soft cloth. bristle brush.
9-332. INSPECTION - SEARCHLIGHT.
a. Check light for defective or broken sealed
beam unit and for cracked or broken IR lens.
Cleaning solvent is flammable and toxic.
Provide adequate ventilation. Avoid b. Check for loose connections, and damaged or
prolonged breathing of solvent vapors defective component parts (terminal strips, limit
and contact with skin or eyes. switches, drive motors, relays, etc.)
9-100 Change 10
TM 55-1520-236-23
9-333. REMOVAL SEARCHLIGHT. d. Check light for proper operation.
a. Be sure all electrical power is OFF. 9-336. TRANSMISSION OIL LEVEL LIGHT.
b. Remove attaching screws from Iight assembly 9-337. DESCRIPTION TRANSMISSION
mounting plate; lower Iight and plate. OIL LEVEL LIGHT.
c. Remove Iight mounting screws. The transmission oil level Iight (8DS16) is located
inside the transmission cowling on the right side of the
d. Remove terminal cover, disconnect and pro- helicopter. The Iight is used to illuminate the transmis-
tect wires. sion sump area so that the transmission oil level sight
gages will be visible when viewing through the trans-
e. Remove Iight assembly. mission oil level sight glass. The Iight is powered from
the battery system through a 5 ampere XMSN OIL
9-334. REPAIR SEARCHLIGHT. LEVEL LT circuit breaker (8CB11) located in the aft
electrical compartment. Pressing the XMSN OIL
a. Accomplish replacement of sealed beam LEVEL LT switch (8S8), located beside the sight glass,
lamp as follows. Remove three screws from lamp illuminates the light. Refer to paragraphs 9-18 through
retainer ring and/or IR cover, remove ring, if installed, 9-29 for maintenance procedures.
IR cover, and gasket, lift lamp and disconnect wiring.
9-338. FUNCTIONAL TEST TRANSMIS-
NOTE SION OIL LEVEL LIGHT
Observe position of lamp before a. Disconnect external power if applied. Connect
removal and install new unit in same battery.
position using reverse order of removal
procedure. a.1. Close XMSN OIL LEVEL LT circuit breaker.
b. Replace complete unit if inspection items are b. Press pushbutton switch (8S8). Check opera-
not met. Return unit to depot for repair. tion of the Iight through the sight glass in the right hand
transmission cowling.
9-335. INSTALLATION SEARCHLIGHT.
9-339. TROUBLESHOOTING TRANSMIS-
a. Connect wires and install terminal cover and SION OIL LEVEL LIGHT.
clamp.
Use Table 9-20 and perform checks as necessary to
b. Position Iight on mounting plate; secure with isolate trouble. In the following table, tripped circuit
mounting screws. breakers are omitted from indications of trouble. Such
trouble is usually easily detected and corrected.
c. Position plate and light assembly on fuselage Broken wiring is always a probable cause of circuit
and secure with mounting screws. malfunction or failure and has not been included.
Change 22 9-101
TM 55-1520-236-23
NOTE
Before you use this table, be sure you
have performed all normal operational
checks. If you have a malfunction which
is not listed in this table, notify the next
higher level of maintenance.
Table 9-20 Troubleshooting Transmission Oil Level Light
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. Transmission oil level light (8DS16) fails to illuminate.
STEP 1. Check for voltage at circuit breaker (8CB11) XMSN OIL LEVEL LT.
If check indicates circuit breaker (8CB11) is defective, replace it (paragraph 9-23).
STEP 2. Set XMSN OIL LEVEL LT SW (8S8) to the ON position. Check for bus voltage on
terminals 1 and 2 of switch (8S8).
Replace switch (8S8) if voltage is not present on terminal 1 (paragraph 9-16).
STEP 3. Check filament, lamp housing, and ground of XMSN OIL LEVEL LT (8DS16).
Replace bulb or lamp housing and clean ground as needed (paragraph 9-16).
SECTION VIl. MISCELLANEOUS EQUIPMENT
9 - 3 4 0 MISCELLANEOUS 9-342. ENGINE CONTROLS AND
EQUIPMENT. ACCESSORIES (ELECTRICAL),
9-341. DESCRIPTION 9-343. DESCRIPTION ENGINE
MISCELLANEOUS EQUIPMENT. CONTROLS AND ACCESSORIES
(ELECTRICAL).
Miscellaneous equipment includes engine controls Engine controls and accessories include engine de-
and accessories, flight control systems, heating and icing, engine oil bypass valve, fuel valve, fuel boost
cooling systems, stability and control augmentation pumps, governor control, and idle stop solenoid
system, and armament systems circuitry. circuitry.
9-102
TM 55-1520-236-23
9-344. ENGINE DE-ICE CIRCUITRY, b. Note that both switches (1S31) and (1S34) are
in the OFF position, then close ENG DE-ICE circuit
9-345. DESCRIPTION ENGINE DE-ICE breaker. Check that de-icing hot air solenoid valve has
CIRCUITRY. actuated.
The engine de-ice system is comprised of an engine c. Place (1S31) to DE-ICE. Check that hot air
hot air de-icing valve, located on the engine, pilot and solenoid valve is not energized.
gunner ENG DE-ICE switches (1S34) and (1S31), and
is protected by a 5 ampere ENG DE-ICE circuit breaker d. Return switch (1S31) to OFF position. Check
(1CB8). The system is energized from the 28 Vdc that hot air solenoid valve is again energized.
essential bus. The valve may be controlled by either
the gunner ENG DE-ICE switch (1S31), located on the e. Repeat steps c. and d., except substitute switch
gunner miscellaneous panel, or the pilot ENG DE-ICE (1S34) for switch (1S31).
switch (1S34), located on the pilot engine control
panel. The de-ice system is normally energized to
prevent the de-icing system from activating. If either
9-347. TROUBLESHOOTING ENGINE
switch (1S31) or (1S34) is placed to the DE-ICE
DE-ICE CIRCUITRY.
position, the circuit is broken and the de-icing system
is activated. (Refer to paragraphs 9-18 through 9-29
and TM 55-2840-229-24 for maintenance Refer to paragraph F-9 in Appendix F for wiring
procedures.) diagram. Use Table 9-21 and perform checks as
necessary to isolate trouble. In the following table,
9-346. FUNCTIONAL TEST ENGINE DE- tripped circuit breakers are omitted from indications
ICE CIRCUITRY. of trouble. Such trouble is usually easily detected and
corrected. Broken wiring is always a probable cause
a. Open all circuit breakers and return all of circuit malfunction or failure and has not been
switches to their normal positions. included.
NOTE
Before you use this table, be sure you
have performed all normal operational
checks. If you have a malfunction which
is not listed in this table, notify the next
higher level of maintenance.
Table 9-21. Troubleshooting Engine De-Ice Circuitry
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. De-icing hot air solenoid valve fails to de-energize when either ENG DE-ICE switch (1S31) or (1S34) is placed
tO DE-lCE position.
STEP 1. Determine that DE-ICE switches (1S31 and/or 1S34) are functional.
If DE-ICE switches (1S31 and/or 1S34) are not functioning properly, replace as required
(paragraph 9-16).
9-103
TM 55-1520-236-23
Table 9-21. Troubleshooting Engine De-Ice Circuitry (Cont)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
STEP 2. Defective de-icing hot air solenoid valve.
Replace adenoid valve In accordance with TM 55-2840-229-24.
9-348. ENGINE OIL BYPASS VALVE (2) Place ENG OIL BYP switch to AUTO.
CIRCUITRY. Check that position indicator on oil bypass valve
rotates clockwise (bypass condition.)
9-349. DESCRIPTION ENGINE OIL
BYPASS VALVE CIRCUITRY. d Perform following procedure for oil in tank
condition.
The engine oil bypass valve is energized from the 28
Vdc essential bus and protected by the FUEL/OIL
VALVE circuit breaker (1CB4). An oil bypass valve (1) Connect temporary shod circuit between
(1B1), located on the lower firewall forward left side, terminal 1 and 2 on (1T85). Check that position indica-
provides a means of by passing the flow of engine oil tor on oil bypass valve is rotated to its clockwise
extreme (bypass condition).
around the oil cooler in case of damage resulting in a
Ieak in the cooler. The valve is electrically actuated and
is included in a circuit with ENG OIL BYP switch (1S16) (2) Place ENG OIL BYP switch to OFF.
(manually operated), engine oil float switch (1S15), Check that position indicator on oil bypass valve
and oil bypass relay (1K6). Switch (1S16) is located on rotates to its full counterclockwise extreme (normal
the pilot engine control panel (1A1). Switch (1S15) is condition).
Iocated in the oil tank, and relay (1K6) is located
beneath the upper firewall. (Refer to paragraphs 8-18
through 9-29 and TM 55-2840-228-24 for mainte- (3) Remove temporary shod circuit. Oil
nance procedures.) bypass valve should not move.
9-350. FUNCTIONAL TEST ENGINE OIL (4) Place ENG OIL BYP switch to AUTO. Oil
BYPASS VALVE CIRCUIT. bypass valve should not move.
a Close FUEL/OIL VALVE circuit breaker
9-351. TROUBLESHOOTING ENGINE OIL
(1CB4).
BYPASS VALVE CIRCUITRY.
b. Place ENG OIL BYP switch to AUTO.
Refer to paragraph F-9 in Appendix F for wiring
c. Perform following procedure for empty tank diagram. Use Table 9-22 and perform check as neces-
condition. sary to isolate trouble. In the fallowing table, tripped
circuit breakers are omitted from indications of trouble.
(1) Place ENG OIL BYP switch to OFF. Such trouble is usually easily detected and corrected.
Check that position indicator on oil bypass valve Broken wiring is always a probable cause of circuit
rotates counterclockwise (normal condition). malfunction or failure and not been included.
9-104 Change 22
TM 55-1520-236-23
NOTE
Before you use this table, be sure you
have performed all normal operational
checks. If you have a malfunction which
is not listed in this table, notify the next
higher level of maintenance.
Table 9-22. Troubleshooting Engine Oil Bypass Valve Circuitry
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. Oil bypass valve (1B1) fails to operate with ENG OIL BYP switch (1S16) in AUTO position and oil float switch
(1S15) closed (oil tank low).
STEP 1. Determine that ENG OIL BYP switch (1S16) is functional.
If ENG OIL BYP switch (1S16) is not functioning properly, replace as required (paragraph 9-1 6).
STEP 2. Determine that oil float switch (1S15) is functional.
If oil float switch (1S15) is not functioning properly, replace as required (paragraph 9-1 6).
STEP 3. Check that OIL BYPASS relay (1K6) is functional.
Replace oil bypass relay (1K6) as required (paragraph 9-16).
STEP 4. Check that oil bypass valve (1B1) is functional
Replace oil bypass valve (1B1) in accordance with paragraph 9-16 and TM 55-2840-229-24.
9-352. FUEL VALVE CIRCUITRY. 9-354. FUNCTIONAL TEST - FUEL VALVE
CIRCUITRY.
9-353. DESCRIPTION - FUEL VALVE a. Close FUEL/OIL VALVE circuit breaker.
CIRCUITRY. Position FUEL switch (1S33) to FUEL. Check that fuel
valve opens.
An elec trically operated fuel shut-off valve (1B4)
located on the top of the aft fuel cell, provides a means b. Position FUEL switch (1S33) to OFF and check
of shutting off fuel to the engine. This valve is that fuel valve closes.
energized from the 28 Vdc essential bus and
protected by the FUEL/OIL VALVE circuit breaker 9-355. TROUBLESHOOTING - FUEL
(1CB4). The FUEL switch (1S33), on the pilot engine VALVE CIRCUITRY.
control panel (1 Al ), controls the operation of the
valve. Refer to paragraphs 9-18 through 9-29 and TM Refer to paragraph F-9 in Appendix F for wiring
55-2840-229-24 for maintenance procedures. diagram. Use Table 9-23 and perform checks as
9-105
TM 55-1520-236-23
necessary to isolate trouble. In the following table, corrected. Broken wiring is always a probable cause
tripped circuit breakers are omitted from indications of circuit malfunction or failure and has not been
of trouble. Such trouble is usually easily detected and included.
NOTE
Before you use this table, be sure you
have performed all normal operational
checks, If you have a malfunction which
is not listed in this table, notify the next
higher level of maintenance,
Table 9-23 Troubleshooting Fuel Valve Circuitry
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. Fuel shut-off valve (1B4) fails to open when FUEL switch (1S33) is placed to FUEL.
STEP 1. Check for 28 Vdc essential bus power on terminals 4 and 5 of fuel switch (1S33).
Replace fuel switch (1S33) if 28 Vdc is not on terminal 4 (paragraph 9-1 6).
STEP 2. Determine that fuel shut-off valve (1B4) is functional.
If fuel shut-off valve (1 64) is not functioning properly, replace valve in accordance with paragraph
9-16 and TM 55-2840-229-24.
9-356. FUEL BOOST PUMPS panel (1A1). Refer to paragraphs 9-18 through 9-29
CIRCUITRY. and chapter 10 for maintenance procedures.
9-357. DESCRIPTION - FUEL BOOST
PUMPS CIRCUITRY, 9-358, FUNCTIONAL TEST- FUEL BOOST
PUMPS CIRCUITRY.
Two electrically operated fuel boost pumps, one each
in the forward and aft fuel cell, are accessible from a. Open FUEL BOOST AFT circuit breaker and
the bottom of the cell. Both pumps are connected to a close FUEL BOOST FWD circuit breaker. Position
common fuel line. The forward fuel boost pump (1B5) FUEL switch (1S33) to ON. Check that the forward
is energized from the 28 Vdc essential bus and fuel pump is running.
protected by the FUEL BOOST FWD circuit breaker
(1CB9), located in the dc circuit breaker panel (2A1). b. Open FUEL BOOST FWD circuit breaker. Close
The aft fuel boost pump (1B6) is energized from the 28 FUEL BOOST AFT circuit breaker. Position FUEL
Vdc non-essential bus and protected by the FUEL switch (1S33) to ON. Check that the aft fuel pump is
BOOST AFT circuit breaker (1CB12) in the dc circuit running.
breaker panel. Both pumps are controlled by the FUEL
switch (1S33) located on the pilot engine control c. Open FUEL BOOST AFT circuit breaker.
9-106
TM 55-1520-236-23
9-359. T R O U B L E S H O O T I N G - FUEL tripped circuit breakers are omitted from indications
BOOST PUMPS CIRCUITRY, of trouble. Such trouble is usually easily detected and
corrected. Broken wiring is always a probable cause
Refer to paragraph F-9 in Appendix F for wiring
of circuit malfunction or failure and has not been
diagram. Use Table 9-24 and perform checks as included.
necessary to isolate trouble. In the following table,
NOTE
Before you use this table, be sure you
have performed all normal operational
checks. If you have a malfunction which
is not listed in this table, notify the next
higher level of maintenance.
Table 9-24. Troubleshooting Fuel Boost Pumps Circuitry
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. Either pump (1B5) or (1B6) fails to operate when FUEL switch (1S33) is placed to FUEL.
STEP 1. Determine if fuel switch (1S33) is functional.
If fuel switch (1S33) is not functioning properly, replace as required (paragraph 9-16)
STEP 2. Determine that fuel boost pumps (1B5 and/or 1B6) are functioning properly.
If fuel boost pumps (1B5 and/or 1B6) are not functioning properly, replace as required
(paragraph 10-25).
9-360. GOVERNOR CONTROL in the gunner miscellaneous control panel. The
SYSTEM CIRCUITRY. solenoid valve is energized by GOV switch (1S32)
located on pilot engine control panel, or by GOV
9-361. DESCRIPTION - GOVERNOR switch (1S28) located on gunner miscellaneous
CONTROL CIRCUITRY. control panel. Refer to paragraphs 9-18 through 9-29
and TM 55-2840-229-24 for maintenance
The governor control system is comprised primarily of procedures.
an engine fuel control solenoid valve located on the
engine, and a motor driven governor rpm actuator 9-362. FUNCTIONAL TEST - GOVERNOR
(1B3), also located on the engine. The 28 Vdc power to CONTROL CIRCUITRY.
the system is served and protected by a 5 ampere
GOV CONT circuit breaker (1CB5), which is located in a. Close GOV CONT circuit breaker (1CB5).
pilot dc circuit breaker panel (2A1). The actuator is Position GOV switch (1S32) on pilot engine control
energized either by RPM switch (1S35) located on panel, and (1S28) on gunner miscellaneous control
pilot collective stick, or by RPM switch (1S29), located panel to AUTO. Check for audible indication that the
9-107
TM 55-1520-236-23
fuel control solenoid valve on the engine is energized f. Position RPM switch (1S35) on pilot collective
in the automatic position. stick, to INCR and check that governor rpm actuator
on the engine retracts.
b. Place GOV switch (1S32) on pilot enaine
control panel to~EMER~~EMERG. Check ;hat
g. Position RPM switch (1S35)to DECR and check
the fuel control solenoid valve is energized in the
that actuator extends.
emergency position and that~ GOV EMER q ~
GOV EMERG indicators on the pilot and gunner
caution panels are illuminated. h. Repeat steps e. and f. using RPM switch (1S29)
on gunner miscellaneous control panel (1A2).
c. Return pilot GOV switch (1S32) to AUTO
position. Check that GOV EMER~ ~GOV EMERG
indicators on both caution panels are extinguished.
9-363. T R O U B L E S H O O T I N G -
d. Place GOV switch (1S28) on gunner GOVERNOR CONTROL CIRCUITRY.
miscellaneous control panel to
EM-ER~-~ EMERG. Check for audible
indication that the fuel control solenoid valve is Refer to paragraph F-9 in Appendix F for wiring
energized in the emergency position. Check that diagram. Use Table 9-25 and perform checks as
~GOV EMER~D GOV EMERG indicators on necessary to isolate trouble. In the following table,
the caution panels are-illuminated. tripped circuit breakers are omitted from indications
of trouble. Such trouble is usually easily detected and
e. Return GOV switch (1S28) to AUTO. Check that corrected. Broken wiring is always a probable cause
~GOV EMER ~ ~ GOV EMERG indicators are of circuit malfunction or failure and has not been
extinguished. included.
NOTE
Before you use this table, be sure you
have performed all normal operational
checks, If you have a malfunction which
is not listed in this table, notify the next
higher level of maintenance.
Table 9-25. Troubleshooting Governor Control Circuitry
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. Governor actuator fails to respond when either RPM switch (1S29) or (1S35) is placed to INCR or DECR
position.
STEP 1. Determine that RPM switches (1S29 and/or 1S35) are functioning properly.
Replace RPM switches (1S29 and/or 1S35) as required (paragraph 9-1 6).
STEP 2. Check for defective governor actuator.
Replace governor actuator, if defective, in accordance with TM 55-2840-229-24.
9-108
TM 55-1520-236-23
Table 9-25. Troubleshooting Governor Control Circuitry (Cent)
..
CONDITION
TEST OR lNSPECTION
CORRECTIVE ACTION
2. Actuator operates in reverse.
STEP 1. Switch (1S29 and/or 1S35) or actuator wiring reversed.
Check governor control system wiring diagram and correct wiring as necessary.
3. Fuel control solenoid valve fails to operate when either GOV switch (1S28) or (1S32) is actuated.
STEP 1. Determine that governor switches (1S28 and 1S32) are functioning properly.
Replace governor switches (1S28 and/or 1S32) as required (paragraph 9-1 6).
STEP 2. Check for defective fuel control solenoid valve.
Replace fuel control solenoid valve, if defective, in accordance with TM 55-2840-229-24.
4. Solenoid valve operates in reverse.
STEP 1. Switches (1S28 and/or 1S32) or solenoid valve wiring reversed.
Check governor control system wiring diagram and correct wiring as necessary.
9-364. IDLE STOP SOLENOID SYSTEM collective stick and check that the solenoid retracts
CIRCUITRY. when power is applied.
9-365. DESCRIPTION - IDLE STOP b. Release switch (1S37). Place IDLE STOP
SOLENOID SYSTEM CIRCUITRY. RELEASE switch (1S30) on gunner miscellaneous
control panel to the IDLE STOP RELEASE position.
The idle stop system includes a 5 ampere IDLE STOP Check that idle stop solenoid (1L5) retracts and
SOL circuit breaker (1CB3) on the dc circuit breaker remains retracted. Place switch (1S30) to OFF
panel (2A1), switches (1S37) and (1S30), located on position. Check that idle stop solenoid (1L5) is
pilot collective (4A2) and gunner miscellaneous panel released.
(1A2) respectively, and an idle stop solenoid (1L5)
located in oil cooler compartment. Solenoid (1L5) is 9-367. TROUBLESHOOTING - IDLE STOP
energized from 28 Vdc essential bus when circuit SOLENOID SYSTEM CIRCUITRY.
breaker (1CB3) and either (1S37) or(1S30) is pressed.
Refer to paragraph 9-18 through 9-29 and TM 55- Refer to paragraph F-9 in Appendix F for wiring
2840-229-24 for maintenance procedures. diagram. Use Table 9-26 and perform checks as
necessary to isolate trouble. In the following table,
9-366. FUNCTIONAL TEST - IDLE STOP tripped circuit breakers are omitted from indications
SOLENOID SYSTEM CIRCUITRY. of trouble. Such trouble is usually easily detected and
corrected. Broken wiring is always a probable cause
a. Close IDLE STOP SOL circuit breaker (1CB3). of circuit malfunction or failure and has not been
Actuate the idle stop release switch (1S37) on pilot included.
9-109
TM 55-1520-236-23
NOTE
Before you use this table, be sure you
have performed all normal operational
checks. If you have a malfunction which
is not listed in this table, notify the next
higher level of maintenance.
Table 9-26. Troubleshooting Idle Stop Solenoid System Circuitry
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. Engine idle Stop does not retract when IDLE STOP RELEASE switches (1S30) and/or (1S37) are
actuated.
STEP 1. Determine that idle stop switches (1S30 and/or 1S37) are functional.
If idle stop switches (1S30 and/or 1S37) are not functioning properly, replace as required
(paragraph 9-16).
STEP 2. Check that idle stop solenoid (1L5) is functional.
If idle stop solenoid (1L5) is not functioning properly, replace solenoid in accordance with
TM 55-2840-229-24.
2. Engine idle stop solenoid (1L5) does not extend after IDLE STOP RELEASE switch is released from
depressed position.
STEP 1. Repeat STEP 1 above.
STEP 2. Repeat STEP 2 above.
Paragraphs 9-367.1 through 9-367.4 have been deleted.
Page 9-110.1 and Table 9-26.1 have been deleted
9-110 Change 19
TM 55-1520-236-23
9-368. FLIGHT CONTROL SYSTEMS magnetic brake (9L3), and lateral force trim magnetic
(ELECTRICAL). brake (9L2). Magnetic brakes (9L1, (9L3), and (9L2)
are wired in parallel and energized and protected by a
9 - 3 6 9 . D E S C R I P T I O N - FLIGHT 5 ampere FORCE TRIM circuit breaker (9CB1), which
CONTROL SYSTEMS (ELECTRICAL). is located in the dc circuit breaker panel (2A1). The
FORCE TRIM momentary switch (9S1) located on
Flight control systems include the force trim system
pilot cyclic stick (4A3), FORCE TRIM selector switch
and hydraulic control system circuitry.
(9S2), located on pilot engine control panel (1A1),
9-370, FORCE TRIM SYSTEM FORCE TRIM switch (9S3), located on gunner cyclic
CIRCUITRY. stick (5A2), are all series wired. The entire system
serves to return pilot and gunner cyclic sticks to
9-371. DESCRIPTION - FORCE TRIM desired initial position when switch (9S2) is set to ON
SYSTEM CIRCUITRY. position. Switch (9S1 ) or (9S3) may be triggered to de-
energize brakes and eliminate centering force. With
The force trim system consists of an anti-torque force switch (9S2) set to OFF position, automatic trim force
trim magnetic brake (9L1), a fore and aft force trim is de-energized.
(9-110.1 blank)/9-110.2 Change 19
TM 55-1520-236-23
9-372. FUNCTIONAL TEST FORCE TRIM c. Repeat step b. using FORCE TRIM switch
SYSTEM CIRCUITRY. (9S3) on the gunner cyclic stick
d. Remove external hydraulic power.
a. Apply external hydraulic power.
9-373. TROUBLESHOOTING FORCE TRIM
SYSTEM CIRCUITRY.
a.1 Close FORCE TRIM circuit breaker (9CB1).
Position force trim switch (9S2) on pilot engine control
panel to FORCE TRIM. Check the cyclic stick and Refer to paragraph F-9 in Appendix F for wiring
pedals for centering force. diagram. Use Table 9-27 and perform checks as
necessary to isolate trouble. In the following table,
tripped circuit breakers are omitted from indications of
b. Depress force trim switch (9S1) on the pilot trouble. Such trouble is usually easily detected and
cyclic stick Check that the three magnetic brakes corrected. Broken wiring is always a probable cause of
de-energize and that there is no centering force in the circuit malfunction or failure and has not been
cyclic stick and pedals. included.
NOTE
Before you use this table, be sure you have
performed all normal operational checks. If
you have a malfunction which is not listed In
this table, notify the next higher level of
maintenance.
Table 9-27. Troubleshooting Force Trim System Circuitry
CONDITION
TEST OR INSPECTION
Corrective ACTION
1. All magneticbrakes (9L1), (9L2), and (9L3) fail to energize with FORCE TRIM switch (9S2) in FORCE TRIM
position.
STEP 1. Determine that force trim switches (9S1, 9S2, and 9S3) are functioning properly.
If force trim switches (9S1, 9S2, and 9S3) are not functioning properly, replace as required
(paragraph 9-16).
2. Any magnetic brake (9L1), (912), or (9L3) fails to energize with FORCE TRIM switch (9S2) in FORCE TRIM
position.
STEP 1. Determine that magnetic brakes (9L1, 9L2, and 9L3) are functioning properly.
If magnetic brakes (9L1, 9L2, and 9L3) are not functioning properly, replace as required
(paragraph 9-16).
Change 22 9-111
TM 55-1520-236-23
9-374. HYDRAULIC CONTROL SYSTEM (4) Position HYD TEST switch (1S17) on pilot
CIRCUITRY. engine control panel to SYS 1. Check that hydraulic
9-375. DESCRIPTION HYDRAULIC CON-
TROL SYSTEM CIRCUITRY.
The hydraulic control system is comprised primarily of
two hydraulic solenoid valves, system No. 1 (1L1) and caution panels illuminate.
system No. 2 (1L2), mounted on the bulkhead left and (5) Position HYD TEST switch to SYS. 2.
right, forward of the transmission. Each valve function
Check that hydraulic system NO. 1 solenoid (1L1)
may be tested by the HYDR TEST switch (1S17)
located on the pilot engine control panel (1A1). Each
solenoid valve is normally de-energized. Emergency
hydraulic solenoid valves (1L3 and 1L4) located in the
pylon section, serve to supply emergency hydraulic caution light on gunner caution panels illuminate.
pressure from the emergency hydraulic pump. The
valves are normally de-energized to prevent hydraulic (6) Repeat step (1) with external hydraulic
fluid flow and may be energized to permit fluid flow by power applied. Check that all controls take much less
setting EMER HYDR switches (1S22 or 1S23) on the force to operate.
pilot miscellaneous control panel (22A1) or gunner
instrument panel (5A1) to EMER HYDR. The system is (7) Open HYDR CONT circuit breakers.
supplied from the 28 Vdc essential bus and protected
by a 5 ampere HYD CONT circuit breaker (1CB1) (8) Remove external hydraulic power.
which is located on the dc circuit breaker panel (2A1). Perform test of emergency hydraulic system
b.
The EMER HYDR PUMP OVLD SW (1S24) located in as follows:
the aft electrical compartment and the EMER HYDR
pump circuit breaker (1CB2) located in the dc circuit (1) Close EMER HYDR PUMP circuit break-
breaker panel (2A1) protect the EMER HYDR system. er. Place EMER HYDR PUMP switch (1S22) on pilot
miscellaneous panel (22A1) to BORESIGHT position.
9-376. FUNCTIONAL TEST HYDRAULIC Check that emergency hydraulic pump (1B2) oper-
ates.
CONTROL SYSTEM CIRCUITRY.
a. Perform test of hydraulic solenoid as follows: (2) Place EMER HYDR PUMP switch to OFF
Close HYDR CONT and CAUT LT circuit breakers. position. Check that emergency hydraulic pump stops
operating.
(3) Place EMER HYDR PUMP switch to
PRESS caution lights on pilot caution panel (8A2) and EMER HYDR PUMP position. Check that emergency
hydraulic pump operates.
tion lights on gunner caution panel (8A3) are illumi- (4) Place EMER HYDR PUMP switch to OFF
nated. position. Check that emergency hydraulic pump stops
operating.
(1) Try to operate cyclic, collective, and direc-
tional controls. Note that controls take extreme force (5) Repeat steps (1) through (4) using EMER
and are very difficult to move. HYDR PUMP switch (1S23) on gunner instrument
panel in lieu of EMER HYDR PUMP switch (1S22).
(2) Apply external hydraulic pressure to
(6) Close HYDR CONT circuit breaker.
m Repeat steps (1) through (5). Note that
EMER HYDR SOLV (1L3) and (1L4) actuate and
PRESS caution light on gunner caution panels are emergency hydraulic pump operates.
extinguished.
(8) Open EMER HYDR PUMP circuit breaker.
(3) Repeat step (2) for hydraulic system NO.
2. (9) Remove external hydraulic power.
9-112 Change 22
TM 55-1520-236-23
9 - 3 7 7 . TROUBLESHOOTING isolate trouble. In the following table tripped circuit
HYDRAULIC CONTROL SYSTEM breakers are omitted from indications of trouble.
CIRCUITRY. Such trouble is usually easily detected and corrected.
Refer to paragraph F-9 Appendix F for wiring diagram. Broken wiring is always a probable cause of circuit
malfunction or failure and has not been included.
Use Table 9-28 and perform checks as necessary to
NOTE
Before you use this table, be sure you
have performed all normal operational
checks, If you have a malfunction which
is not listed in this table, notify the next
higher level of maintenance.
Table 9-28. Troubleshooting Hydraulic Control System Circuitry
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. Either solenoid (1L1 ) or (1L2) fails to actuate when selected by HYD TEST Switch.
STEP 1. Check that HYD TEST switch (1S17) is functioning properly.
If HYD TEST switch (1S17) is not functioning properly, replace (paragraph 9-16).
STEP 2. Check that solenoids (1L1 and 1L2) are functioning properly.
If solenoids (1L1 and/or 1L2) are not functioning properly, replace as required (paragraph 9-1 6).
2. Emergency solenoid (1L3 and 1L4) de-energized with EMER HYDR Switch (1S22) and (1S23) in EMER HYDR
PUMP position.
STEP 1. Check that EMER HYDR pump switches (1S22 and 1S23) are functioning properly.
If EMER HYDR pump switches (1S22 and/or 1S23) are not functioning properly, replace as
required (paragraph 9-1 6).
STEP 2. Check that EMERGENCY Solenoids (1L3 and 1L4) are functioning properly.
If EMERGENCY Solenoids (1L3 and/or 1L4) are not functioning properly, replace as required
(paragraph 9-16).
9-113
TM 55-1520-236-23
9-378. HEATING AND COOLING d. Simulate an overheat condition by grounding
SYSTEMS CIRCUITRY. terminal X2 (low side) or heater control relay (10K1).
Check that heater control relay (10K1) energizes and
9-379, DESCRIPTION - HEATING AND removes power from the bleed air valve causing it to
COOLING SYSTEM CIRCUITRY. close.
The heating and cooling systems include the e. Remove ground from relay (10K1). Check that
environmental control system (ECS), pitot heating heater control relay becomes de-energized and that
system, TOW blower cooling system, and radio the bleed air valve opens.
blower cooling system.
f. Position ECS switch (10S2) to OFF. Check that
bleed air valve closes.
9-380. ENVIRONMENTAL CONTROL
SYSTEM CIRCUITRY. NOTE
9-381. DESCRIPTION Steps g. through i. require that the
ENVIRONMENTAL CONTROL SYSTEM helicopter engine be operating.
CIRCUITRY.
g. Start helicopter engine and maintain an engine
The environmental control system (ECS) heats, cools, speed of 100 percent. Position ECS switch (10S2) to
and removes moisture from the air supplied to the HTR. Check that cooling turbine comes up to speed
crew compartment. It is composed of the and that airflow is detected at the cabin air inlets.
environmental control unit (ECU) (1021 ), duct
overheat switch (10S3), temperature sensing valve h. Rotate ECS temperature control (10R1) to
(1 061), bleed air valve (1OL1 ), and the heater control extreme COOL position. Check that cabin inlet airflow
relay (1 OK I ). The rain removal system is composed of becomes cool,
the rain removal solenoid (10L3), windshield thermal
switch (10S7), and rain removal mixing valve (10L4). i. Rotate ECS temperature control (10R1) to
These systems are energized from the non-essential extreme WARM position. Check that cabin inlet
bus by the ECS CONT circuit breaker (10CB1) and airflow becomes warm. Return temperature control
controlled by ECS switch (10S2) and ECS to midposition.
temperature control (10R1 ). Refer to paragraphs 9-18
through 9-29 and 13-2 for maintenance procedures. j. Stop helicopter engine. Check that the
environmental control unit stops operating and that
the bleed air valve closes.
9 - 3 8 2 . FUNCTIONAL TEST -
ENVIRONMENTAL CONTROL SYSTEM 9 - 3 8 3 . TROUBLESHOOTING
CIRCUITRY. ENVIRONMENTAL CONTROL SYSTEM
CIRCUITRY.
a. Close ECS CONT circuit breaker (10CB1).
Position ECS switch (10S2) to RAIN RMV, Check that Refer to paragraph F-9 in Appendix F for wiring
rain removal solenoid valve (10L3) opens. diagram. Use Table 9-29 and perform checks as
necessary to isolate trouble. In the following table,
b. Position ECS switch (10S2) to OFF. Check that tripped circuit breakers are omitted from indications
rain removal solenoid valve closes. of trouble. Such trouble is usually easily detected and
corrected. Broken wiring is always a probable cause
c. Position ECS switch (10S2) to HTR. Check that of circuit malfunction or failure and has not been
bleed air valve (10L1 ) opens. included.
9-114 Change 3
TM 55-1520-236-23
NOTE
Before you use this table, be sure you
have performed all normal operational
checks. If you have a malfunction which
is not listed in this table, notify the next
higher level of maintenance,
Table 9-29. Troubleshooting Environmental Control System Circuitry
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. Bleed air valve (10L1) fails to actuate with environmental control switch (10S2) set to HTR and
environmental control set to WARM.
STEP 1. Ensure 28 Vdc non-essential bus voltage is present between pins 3 and 6 of bleed air valve (10L1 ).
If bleed air valve fails to operate, replace bleed air valve (paragraph 13-4).
2. Bleed air valve (10L1) fails to energize with ENVIR CONT switch (10S2) set to HTR.
STEP 1. Ensure 28 Vdc non-essential bus voltage is present at connector pin F of dc circuit breaker panel
(2A1). Check for 28 Vdc non-essential bus voltage at pin D of pilot LTG/ECS panel (10A1 ).
If 28 Vdc non-essential bus voltage is not present at Pin D, replace environmental control switch
(10S2) (paragraph 9-16).
STEP 2. Ensure 28 Vdc non-essential bus voltage is present at pin D of connector for panel 10A1. Check for
presence of 28 Vdc at B3 of heater control relay (10K1).
Replace heater control relay (10K1) if 28 Vdc non-essential voltage is not present at B3
(paragraph 9-1 6).
3. Environmental control unit (10Z1 ) fails to energize with ECS switch (10S2) set to HTR.
STEP 1. Check if duct overheat switch (10S3) is defective.
Replace duct overheat switch (10S3) if defective (paragraph 9-16).
4. No air is detected at cabin inlets with ECS switch (10S2) set to HTR and ECS temperature control switch
(10R1) positioned to COOL or WARM.
STEP 1. Check environmental control unit (10Z1 ) (paragraph 13-4).
Replace or repair environmental control unit as necessary (paragraph 9-16).
5. Environmental control unit temperature control has no effect on cabin inlet air temperature.
STEP 1. Check temperature sensing valve (10B1) (paragraph 13-11).
If defective, replace temperature sensing valve (10B1) (paragraph 9-16).
9-115
TM 55-1520-236-23
Table 9-29. Troubleshooting Environmental Control System Circuitry (Cent)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
STEP 2. Check environmental control (10R1).
If defective, replace environmental control (1 OR 1 ) (paragraph 9-16),
STEP 3. Check environmental control unit (10Z1) (paragraph 13-5).
If defective, replace environmental control unit (1021) (paragraph 9-1 6).
6. Rain removal solenoid (10L3) fails to actuate with environmental control switch set to RAIN RMV.
STEP 1. Check rain removal solenoid (10L3).
If defective. replace rain removal solenoid (10L3) (paragraph 9-1 6).
7. Rain removal solenoid (10L4) fails to actuate with environmental control switch set to RAIN RMV.
STEP 1, Check RAIN REM switch (10S7).
If defective, replace switch (paragraph 9-16).
STEP 2. Check rain removal solenoid (10L4).
If defective, replace rain removal solenoid (10L4) (paragraph 9-16).
9-384. PITOT HEATING SYSTEM 9-386. FUNCTIONAL TEST - PITOT
CIRCUITRY. HEATING SYSTEM CIRCUITRY.
9-385. DESCRIPTION - PITOT HEATING
SYSTEM CIRCUITRY,
Do not leave pitot tube heater energized
The pitot heater system is comprised of the pitot tube for a prolonged period of time.
heater (10HR1), located on the upper left forward
section of the pylon fairing; PITOT/ADS switch a. Close PITOT HTR circuit breaker (10CB2).
(10S1), located on the PLTS LTG/ECS panel and a five
ampere PITOT HTR circuit breaker (10CB2). The b. Position PITOT/ADS switch to PITOT HTR.
system is powered from the 28 Vdc non-essential
bus. The pitot tube heater (10HR1) prevents the pitot c. Check that pitot heating element is energized
tube from icing over, The heating element is and heating. (Refer to TM55-1500-204 -25/1.)
energized manually by the PITOT/ADS switch (10S1).
Refer to paragraphs 9-18 through 9-29 and d. Position PITOT/ADS switch to OFF and open
paragraph 8-128 for maintenance procedures. PITOT HTR circuit breaker.
9-116
TM 55-1520-236-23
9-387. TROUBLESHOOTING - PITOT tripped circuit breakers are omitted from indications
HEATING SYSTEM CIRCUITRY. of trouble. Such trouble is usually easily detected and
corrected. Broken wiring is always a probable cause
Refer to paragraph F-9 in Appendix F for wiring of circuit malfunction or failure and has not been
diagram. Use Table 9-30 and perform checks as included.
necessary to isolate trouble. In the following table,
NOTE
Before you use this table, be sure you
have performed all normal operational
checks. If you have a malfunction which
is not listed in this table, notify the next
higher level of maintenance.
Table 9-30. Troubleshooting Pitot Heating System Circuitry
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. Pitot tube heater fails to heat. PITOT/ADS switch (10S1) to HTR.
STEP 1. Check PITOT HTR circuit breaker (10CB2) on DC circuit breaker panel (2A1).
If defective, replace PITOT HTR circuit breaker (10CB2) (paragraph 9-23).
STEP 2. Check PITOT/ADS switch (10S1).
If defective, replace PITOT/ADS switch (10S1 (paragraph 9-16).
STEP 3. Check pitot tube heating element (1OHR1).
If defective, replace pitot tube heating element (10HR 1) (paragraph 8-1 2).
9-388. TOW BLOWER COOLING portion of three-phase to single-phase inverter
SYSTEM. relay (3K4)/ g TMS INTLK relay (22A5A1K6).
The system is powered from the non-essential 28 Vdc
9-389. DESCRIPTION - TOW BLOWER bus and protected by a one ampere TOW BLO circuit
COOLING SYSTEM . breaker (10CB3). When temperature in the TOW
compartment reaches approximately 18.4 Celsius
The TOW blower cooling system is designed for (65F) TOW compartment overheat switch (10S4)
cooling the elect ronic/arma merit/avionics actuates (closes), applying 28 Vdc through 10CR1,
equipment mounted on the TOW compartment shelf through contacts S1 and S2 of TOW blower overload
in the tailboom. The cooling system is comprised of sensor (10S5) to coil Xl of TOW blower relay (10K2).
the TOW compartment blower (10B2). TOW The TOW blower relay then applies 28 Vdc through
compartment blower overload sensor (10S5), TOW contacts (L1 and L2) of TOW blower overload sensor
compartment blower relay (10K2), TOW (10S5) to TOW compartment blower (10B2). Thermal
compartment overheat switch (10S4, 10CR1), and a activation of the TOW compartment overheat switch
9-117
TM 55-1520-236-23
automatically causes the TOW blower to cycle on and (2) Reenergize heat gun and let TOW overheat
remain on as long as the circuit is energized. Overload sensor switch cool. After sensor switch cools, TOW
protection of the TOW blower is provided by the TOW blower should shut off.
blower overload sensor (10S5).
(3) Deleted.
FUNCTIONAL TEST
9-390. TOW
BLOWER COOLING SYSTEM. c. Perform the following steps for ambient
temperature above approximately 18.4 Celsius
a. Closem WPN CONT ARMT CONT (65F).
circuit breaker (10CB2). Place NON-ESS BUS switch
(2S2) to STBY (MANUAL) MASTER ARM switch (1) Close TOW BLO circuit breaker (10CB3).
(19S18) to STBY and TCP MODE SELECT switch to Check that TOW blower is energized and is circulating
air over the electronic equipment installed in the tail-
STBY TOW. Ensure gunner ELEC PWR-EMER OFF
boom.
switch (2S4), on gunner miscellaneous control panel,
is positioned to ELEC PWR. (2) Open TOW BLO circuit breaker. Check that
TOW blower is de-energized and shuts off.
b. Perform the following steps for ambient
9-391. TROUBLESHOOTING TOW
temperature below approximately 18.4 C (65F).
BLOWER COOLING SYSTEM.
Refer to paragraph F-9 in Appendix F for wiring
(1) Close TOW BLO circuit breaker (10CB3). diagram. Use table 9-31 and perform checks a s
Energize heat gun and direct its hot air a few inches necessary to isolate trouble. In the following table,
from the TOW overheat sensor switch (10S4), being tripped circuit breakers are omitted from indications
careful of other components or equipment in this of trouble. Such trouble is usually easily detected and
area. After a few seconds, check that TOW blower is corrected. Broken wiring is always a probable cause
operating and is circulating air over the electronic equip- of circuit malfunction or failure and has not been
ment installed in the tailboom. included.
NOTE
Before you use this table, be sure you
have performed all normal operational
checks. If you have a malfunction which
is not listed in this table, notify the next
higher level of maintenance.
Table 9-31. Troubleshooting TOW Blower Cooling System
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. TOW blower(10B2) fails to operate when temperature is above approximately 18.4 Celsius (65 F).
STEP 1. Ensure that 28 Vdc non-essential bus voltage is present at terminal A of connector (10B2P1) for
TOW compartment blower (10B2).
Repair connector if voltage is not present at terminal A (paragraph 9-1 6).
STEP 2. Remove blower and inspect for worn brushes.
Replace worn brushes as necessary or replace blower (paragraph 9-1 6).
9-118 Change 16
TM 55-1520-236-23
Table 9-31. Troubleshooting TOW Blower Cooling System (Cont)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
STEP 3. Check TOW compartment blower overload sensor (10S5).
Replace sensor (10S5) if defective (paragraph 9-16).
STEP 4. Check TOW COMPARTMENT OVERHEAT SWITCH (10S4).
Replace switch if defective (paragraph 9-16).
STEP 5. Check for 28 Vdc non-essential bus voltage through TOW BLO circuit breaker (10CB3) on panel
2A1 .
Replace circuit breaker if defective (paragraph 9-23).
STEP 6. Ensure 28 Vdc non-essential bus voltage is present through connector for TOW compartment
blower (10B2).
Replace blower if defective (paragraph 9-392).
STEP 7. Ensure actuating voltage is present at terminal X1 and ground potential is present at terminal X1
and ground potential is present at terminal X2 of TOW blower relay (10K2). Check for bus voltage at terminals
A1 and A2.
Replace TOW COMP BLO RELAY (10K2) if defective (paragraph 9-16).
9-392. TOW BLOWER. b. Remove grease, fungus, and ground-in dirt
with a clean, lint-free cloth dampened with dry
9-393. DESCRIPTION - TOW BLOWER. cleaning solvent (C112).
The TOW blower (10B2) powered by the 28 Vdc non- c. Remove dirt from electrical connectors with a
essential bus, provides cooling for the electronic bristle brush.
equipment mounted on the TOW compartment shelf
in the tailboom. 9-395. INSPECTION - TOW BLOWER.
a. Inspect TOW blower for any visible damage,
9-394. CLEANING - TOW BLOWER. proper bonding, and security of mounting.
a. Remove moisture and loose dirt with a clean, b. Check connectors for damaged or bent pins
soft cloth. and cracked connector inserts.
c. Check brush caps for dents.
d. Check brushes for wear.
Cleaning solvent is flammable and toxic.
Provide adequate ventilation. Avoid e. Check for proper operation.
prolonged breathing of solvent vapors
and contact with skin or eyes. f. Check case for cracks or damage.
9-119
TM 55-1520-236-23
9-396. REMOVAL - T O W B L O W E R . The radio blower cooling system includes the radio
blower (10B3), phasing capacitor (10C1), and radio
a. Open access door. blower overheat switch (10S6). The system receives
power from the 115Vac bus through the RADIO BLO
b. Disconnect electrical connector (10B2P1) from circuit breaker. The system cools the radio equipment
TOW blower. Protect receptacle and plug with caps or on the right side of pilot station. When air
electrical tape (C121). temperature around equipment increases to
approximately 43.3C (110F), the radio blower
c. D e l e t e d . overheat switch (10S6) closes and energizes the
radio blower, When air temperature decreases to
approximately 35.5C (96F), the radio blower
d. R e m o v e m o u n t i n g s c r e w s a n d w a s h e r s overheat switch opens and de-energizes radio
securing TOW blower to bulkhead and remove TOW blower.
blower and screen assembly.
9-397. REPAIR - TOW BLOWER. 9-401. FUNCTIONAL TEST - RADIO
BLOWER COOLING SYSTEM.
a. Tighten or correct loose or improperly installed
TOW blower. a. Ensure 115 Vac bus is energized.
b. Replace or repair connectors and replace brush b. Position ELEC PWR-EMER OFF switch to ELEC
caps or brushes as necessary. PWR.
c. Replace unit if case is cracked or damaged, or c. Close RADIO BLO circuit breaker.
TOW blower is defective or inoperative.
d. Using a heat gun (hairdryer), heat the radio
9-398. INSTALLATION - TOW BLOWER. blower overheat switch being careful to not overheat
surrounding components and equipment. After a few
a. Position screen assembly and TOW blower in seconds check that radio blower is operating.
place on bulkhead and secure with mounting screws
and washers. e. Allow radio blower overheat switch to cool and
check that radio blower ceases operating.
b. Deleted.
c. Remove protective caps or electrical tape from 9-402. TROUBLESHOOTING - RADIO
electrical connectors and connect plug (10B2P1) to BLOWER COOLING SYSTEM.
TOW blower receptacle.
Refer to paragraph F-9 in Appendix F for wiring
d. Close access door. diagram. Use table 9-32 and perform checks as
necessary to isolate trouble. In the following table,
9-399. RADIO BLOWER COOLING tripped circuit breakers are omitted from indications
SYSTEM. of trouble. Such trouble is usually easily detected and
corrected, Broken wiring is always a probable cause
9-400. DESCRIPTIONRADIO BLOWER of circuit malfunction or failure and has not been
COOLING SYSTEM. included.
9-120 Change 10
TM 55-1520-236-23
NOTE
Before you use this table, be sure you
have performed all normal operational
checks. If you have a malfunction which
is not listed in this table, notify the next
higher level of maintenance.
Table 9-32. Troubleshooting Radio Blower Cooling System.
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. Radio blower (10B3) does not operate when radio equipment on right side of pilot compartment becomes too
hot.
STEP 1. Ensure that 115 Vac is present at terminals T4 and T5 of radio blower and that terminal T1 is
grounded.
Replace radio blower motor (paragraph 9-403).
STEP 2. Ensure that 115 Vac is present at radio blower overheat switch (10S6).
Replace radio blower overheat switch (paragraph 9-8).
9-403. RADIO BLOWER. c. Remove dirt from electrical connector with a
bristle brush.
9-404. DESCRIPTION - RADIO BLOWER.
The radio blower (1CB3) powered by the 115 Vac bus, 9-406. INSPECTION - RADIO BLOWER.
provides cooling for the radio equipment mounted on
the right side of the pilot compartment. a. Inspect radio blower for any visible damage,
proper bonding, and security of mounting.
9-405. CLEANING - RADIO BLOWER.
b. Check connectors for damaged or bent pins
. a. Remove moisture and loose dirt with a clean, and cracked connector inserts.
soft cloth.
c. Check brush caps for dents.
d. Check brushes for wear.
Cleaning solvent is flammable and toxic. e. Check for proper operation.
Provide adequate ventilation. Avoid
prolonged breathing of solvent vapors f. Check case for cracks or damage.
and contact with skin or eyes.
b. Remove grease, fungus, and ground-in dirt 9-407. REMOVAL - RADIO BLOWER.
with a clean, lint-free cloth dampened with dry
cleaning solvent (C112). a. Open access door.
9-121
TM 55-1520-236-23
b. Disconnect electrical connections from radio b. Remove protective caps or electrical tape from
blower. Protect ends of wires with caps or electrical electrical wires. Connect wires to appropriate terminal
tape (C121). on motor.
c. Remove mounting screws and washers securing c. Close access door.
radio blower to bulkhead. Remove blower.
9-410. STABILITY AND CONTROL
9-408. REPAIR - RADIO BLOWER. AUGMENTATION SYSTEM (SCAS).
a. Tighten or correct loose or improperly installed
radio blower. 9-411. DESCRIPTION - STABILITY AND
CONTROL AUGMENTATION SYSTEM
b. Replace or repair connector and wiring as (SCAS).
required.
c. Replace unit if case is cracked, damaged, or The SCAS is a three-axis stability and control
radio blower is defective or inoperative. augmentation system. It is integrated into fore and aft,
lateral, and directional (anti-torque) flight controls to
9-409. INSTALLATION - RADIO improve stability and handling qualities of helicopter.
BLOWER. For a complete description and maintenance, refer to
paragraph 11-98 for flight control portion and TM
a. Position radio blower in place on bulkhead. 11-1520-236 series maintenance manuals for
Secure with mounting screws and washers. complete information.
SECTION VIII. ~ A R M A M E N T S Y S T E M S C I R C U I T R Y
9-412. q A R M A M E N T SYSTEMS supplement the appropriate armament wiring diagram
CIRCUITRY. and facilitate electrical troubleshooting. Tables 9-32.1
through 9-32.7 provide the switch positions that
9-413. ~ DESCRIPTION - ARMAMENT establish the weapon mode and the switches
SYSTEMS CIRCUITRY. controlling relay action. Each table provides a different
mode of weapon control. The operation of each relay is
The armament systems consist of the turret system, dependent on the weapon mode selected. The top
wing stores armament systems, M-136 helmet sight portion of the table establishes the weapon mode. The
system, and M65 TOW missile subsystem. Functional lower portion of the table indicates that a relay is
test and troubleshooting procedures are presented energized by an X under the controlling switch.
for each armament subsystem circuitry. References
are made to appropriate maintenance manuals b. Gunner Jettison Control Relay Matrix. Table
and/or chapters within this maintenance manual, 9-32.8 shows the gunner wing stores jettison system
where applicable. See figure 9-19 for armament operation. The 7- or 19-tube rocket launcher portion of
electrical equipment location illustrations and refer to the table defines the relays energized for jettison
paragraph F-9 in Appendix F for wiring diagrams. operation with 7- or 19-tube launchers installed. The
7-tube and tube-launched, optically-tracked, wire
command link (TOW) launcher portion of the table
defines the relays energized for jettison operation with
9-413.1 ~ ARMAMENT SYSTEM TOW and 7-tube launchers installed.
RELAYS.
a . Armament Relay Function Matrices. T h e
armament relay function matrices are designed to
9-122 Change 11
TM 55-1520-236-23
Table 9-32.1 q Relay Matrix, Pilot in Control Mode
Pilot Switches Gunner Switches
Instrument
TCP SHC Panel
WING ACQ
PLT STORES MOOE TRK PHS
OVRD SELECT SELECT STOW ACQ
OFF
I
Wing Reflex WING ARM
Stores FIRE
Pilot Switches Gunner Switches
MASTER WPN WG ST WING TRIGGER TURRET PLT TCP SHC Left-Hand Grip
ARM CONT ARM ARM FIRE OVRD TRIGGER
Relay FIRE ACQ
MODE TRK
SELECT STOW
INBD/ 1 ST 2 ND 1 ST 2 ND
STBY ARM PILOT OUTBD Pressed Detent Detent OFF OFF Detent Detent
1K5 Emer Hyd Sys Cent
2K3 Armament Power x x
19K1 Gun Clearing x x
19K31 Master Arm x
19K59 Pilot/ Gunner Control x
19K72 40mm Trigger Enable x x
19K80 Gunner Pilot Override
19K81 Fixed/ Forward
19K82 Pilot Trigger Disable
19K83 Pilot Action Disable x*
19K84 Gunner Action Disable
19K85 Pilot Trigger/Action
Switch Disable
19K86 Pilot Trigger and Action
Switch Activate x
19K87 TOW/Turret
19K88 Action Interrupt
19K90 Gunner Pilot Override
19K91 Gunner Armament
Light Dimming
19K92 Pilot Armament
Light Dimming
21K1 M-18 Power
209475-883
9-122.1
Change 11
TM 55-1520-236-23
Table 9-32.1 q Relay Matrix, Pilot in Control Mode (Cont)
Pilot Switches Gunner Switches I
WING TRIGGER TURRET PLT TCP SHC Left-Hand Grip
ARM FIRE OVRO TRIGGER
Relay FIRE ACQ
MODE TRK
SELECT STOW
INBD/ 1 ST 2 ND 1 ST 2 ND
STBY ARM PILOT OUTBD
21K2 Jettison Control
21K3 Pilot Jettison Switch
21K4 Pilot Jettison Control
21K5 Gunner Jettison Control
21K6 Wina Stores Disable
21K7 Turret Interrupt x
X Relay energized.
* Helmet must be connected.
209475-883-2
9-122.2 Change 11
TM 55-1520-236-23
Table 9-32.2
Change 11 9-122.3
TM 55-1520-236-23
Table 9-32.2
9-122.4 Change 11
TM 55-1520-236-23
Table 9-32.3
Change 11 9-122.5
TM 55-1520-236-23
Table 9-32.3
9-122.6 Change 11
TM 55-1520-237-23
Table 9-32.4
Change 11 9-122.7
TM 55-1520-236-23
Table 9-32.4
9-122.8 Change 11
TM 55-1520-236-23
Table 9-32.5
Change 11 9-122.9
TM 55-1520-236-23
Table 9-32.5
9-122.10 Change 11
TM 55-1520-236-23
Table 9-32.6
Change 11 9-122.11
TM 55-1520-236-23
Table 9-32.6
9-122.12 Change 11
TM 55-1520-236-23
Table 9-32.7 q Relay Matrix, Pilot Override Mode
Change 11 9-122.13
TM 55-1520-236-23
Table 9-32.7
9-122.14 Change 11
TM 55-1520-236-23
Table 9-32.8 Relay Matrix, Gunner Jettison Mode
Ensure jettison cartridges are removed from
ejector racks before performing checks.
NOTE
Ensure WING STORES JTSN, GNR JTSN, and
PLT JTSN circuit breakers are closed.
7-or 19-Tube Rocket Launcher -4 Stations
I
Relay
off On OUTBD BOTH INBD
21 KS Gunner Jettison Control On x x
TOW Launcher Outboard -7 -Tube Rocket Launcher Inboard
I Gunner Instrument Panel
Relay
I WING STORES
JETTISON Switch I JTSN SEL Switch
off On OUTBD BOTH INBD
21K2 Jettison Control * * * * *
O n X** X**
21K5 Gunner Jettison Control
x Relay energized
* Relay 21K2 is not controlled by any switch; rather, it is energized anytime right or left
lower outboard TOW launcher is electrically connected.
* Relay 21K5 cannot be energized if 21K2 is energized.
209475-882
Change 11 9-122.15
TM 55-1520-237-23
Table 9-32.9 q Relay Matrix, Pilot Jettison Mode
Ensure jettison cartridges are removed from
ejector racks before performing checks.
NOTE
Ensure WING STORES JTSN, GNR JTSN, and
PLT JTSN circuit breakers are closed.
x Relay energized
* Relay 21K2 is not controlled by any switch; rather, it is energized anytime right or left
lower outboard TOW launcher is electrically connected.
** Relay 21K4 cannot be energized if 21K2 is energized; also, relay 21K4 cannot be
energized unless 21K3 is energized.
209475-881
9-122.16 Change 11
TM 55-1520-236-23
c. Pilot Jettison Control Relay Matrix. Table 9-32.9 b. 2K3 - Armament Power Relay.
shows the pilot wing stores jettison system operation.
The 7- or 19-tube rocket launcher portion of the table (1) Purpose To provide power to the M-28 turret
defines the relays energized for jettison operation with to drive the guns.
7- or 19-tube launchers installed. The 7-tube and TOW
launcher portion of the table defines the relays (2) Function. This relay is controlled by the gun
energized for jettison operation with TOW and 7-tube clearing relay (19K1) to supply battery voltage to the
launchers installed. turret for gun drive. This is a 200-amp, single-pole
relay.
d. Armament System Relay Locations. Relay
locations are shown in Appendix F, figure F-18.1. (3) Relay contact logic. Contacts are used to
connect the battery bus to the gun control assemblies.
9-413.2 DESCRIPTION -
ARMAMENT SYSTEM RELAYS. c. 19K1 - Gun Clearing Relay.
a. 1K5 - Emergency Hydraulic System Control (1) Purpose. To disconnect the battery from the
Relay. generator bus and connect it to the gun control for
firing.
(1) Purpose. To enable activation of emergency
hydraulic pump when pressure is lost in hydraulic (2) Function. To provide battery power to drive
system 2. the gun motors and to maintain the voltage for 0.5
second after the TRIGGER TURRET FIRE switch is
(2) Function. The primary function of this relay is released to provide gun clearing. This is a 10-amp,
to turn on the emergency hydraulic pump relay to 2-pole, time-delay-on-dropout relay. The delay time is
provide hydraulic pressure for flight controls. The 0.5 second.
secondary function is to turn off power to the TOW
launcher hydraulic solenoid and turret hydraulic (3) Relay contact logic.
solenoid. This relay is bypassed in the boresight
function for ground operation when boresighting the (a) Contacts A. Contacts A (pins H, D, and G)
TOW launchers. This is a 10-amp, 4-pole, open the battery relay (2K2) to remove the battery
socket-mounted relay. from the bus.
(3) Relay contact logic. (b) Contacts B. Contacts B (pins C, F, and B)
close the armament power relay (2K3) to apply the
(a) Contacts A. Contacts A are used in the battery to the left and right gun speed control box for
deenergized position to supply voltage to the TOW firing the gun.
launcher hydraulic solenoid from the servo electronic
control unit (SECU). These contacts are open when the d. 19K31 - Master Arm Relay.
relay is energized.
(1) Purpose. To provide master arm power to the
(b) Contacts B. Contacts B are used in the wing stores system and to control status indicators.
deenergized position to supply voltage to the
armament hydraulic solenoid (19L1) from the turret (2) Function. The master arm relay is controlled
control system. These contacts are open when the by the MASTER ARM switch. Master arm power is
relay is energized. required to fire any weapon. This is a 10-amp, 4-pole,
screw-terminal relay.
(c) Contacts C. Contacts C are used in the
energized position to control the emergency hydraulic (3) Relay contact logic.
pump relay (1K4).
(a) Contacts A. Contacts A are used in the
(d) Contacts D. Contacts D are not used. energized position to turn on the ARMED tight in the
pilot and gunner armament control panels.
Change 11 9-122.17
TM 55-1520-236-23
(b) Contacts B. Contacts B are used in the (h) Contacts D - energized. Contacts D in the
deenergized position to light the STBY light. In the energized position will illuminate the left 40 light on the
energized position, the STBY light is turnad off. pilot armament control panel if a 40-mm launcher is
installed on left side of the turret.
(c) Contacts C. Contacts C are not used.
(i) Contacts E - deenergized. Contacts E in
(d) Contacts D. Contacts D are used in the the deenergized position will illuminate the right 7.62
energized position to provide arm power to the wing Iight on the gunner armament control panel if a
stores system. 7.62-mm gun is installed on the right side of the turret.
e. 19K59 - Pilot/Gunnar Control Relay. (j) Contacts E - energized. Contacts E in the
energized position will illuminate the right 7.62 light on
(1) Purpose. To switch the turret weapon and the pilot armament control panel if a 7.62-mm gun is
indicator lights from gunner to pilot. installad on the right side of the turret.
(2) Function. The control of TURRET SELECT (k) Contacts F - deenergized. Contacts F in
switch and 7.62 and 40 lights is switched the deenergized position will illuminate the right 40
automatically to the pilot anytime the pilot has control light on the gunner armament control panel if a 40-mm
of the turret. This is a 10-amp, 6-pole, socket-mounted launcher is installed on the right side of the turret.
relay.
(l) Contacts F - energized. Contacts F in the
(3) Relay contact logic. energized position will illuminate the right 40 light on
the pilot armament control panel if a 40-mm launcher is
(a) Contacts A - deenergized. Contacts A in installed on the right side of the turret.
the deenergized position allow selection of the right
turret weapon by the gunner. f. 19K72 - 40-mm Trigger Enable Relay.
(b) Contacts A - energized. Contacts A in the (1) Purpose. To allow the 40-mm launcher to be
energized position allow selection of the right turret fired from the cyclic grip or telescopic sight unit (TSU)
weapon by the pilot. left-hand grip (LHG).
(c) Contacts B - deenergized. Contacts B in (2) Function. To apply the trigger signal to the
the deenergized position allow selection of the left 40-mm Iauncher circuit anytime it is applied to the
turret weapon by the gunner. 7.62-mm gun circuit and allow either weapon, that is
installed and selected, to fire. This is a 10-amp, 2-pole,
(d) Contacts B - energized. Contacts Bin the socket-mounted relay.
energized position allow selection of the left turret
weapon by the pilot. (3) Relay contact logic.
(e) Contacts C - deenergizad. Contacts C in (a) Contacts A - deenergized. Contacts A in
the deenergized position will illuminate the left 7.62 the deenergized position are open.
light on the gunner armament control panel if a
7.62-mm gun is installed on the left side of the turret. (b) Contacts A - enargized. Contacts A in the
energized position apply the trigger signal to the
(f) Contacts C - energized. Contacts C in the 40-mm launcher input on the turret control.
energized position will illuminate the left 7.62 light on
the pilot armament control panel if a 7.62-mm gun is (c) Contacts B. Contacts B are not used.
installed on the left side of the turret.
g. 19K80 - Gunner Pilot Override Relay.
(g) Contacts D - deenargized. Contacts D in
the deenergized position will illuminate the left 40 light (1) Purpose. To allow the gunner to take control
on the gunner armament control panel if a 40-mm of the weapons system if the pilot is disabled and to
launcher is installed on the left side of the turret. arm the system if the pilot has not armed it.
9-122.18 Change 11
TM 55-1520-236-23
(2) Function. The override mode allows the and provide weapon control voltage to the turret and
gunner to fire the turret and rockets from his cyclic grip wing stores.
while flying the helicopter. This is a 10-amp, 6-pole, h. 19K81 - Fixed/Forward Relay.
socket-mounted relay.
(1) Purpose. To switch added circuits when the
(3) Relay contact logic. pilot WPN CONT switch is in the FIXED position.
(a) Contacts A - deenergized. Contacts A in (2) Function. To open the turret action circuit and
the deenergized position provide standby power to the switch the pilot cyclic TRIGGER TURRET FIRE switch
pilot WPN CONT switch. to the fixed mode. This is a 10-amp, 4-pole,
socket-mounted relay.
(b) Contacts A - energized. Contacts A in the
energized position provide standby power to the (3) Relay contact logic.
gunner cyclic TRIGGER ACTION switch and the
electronic control assembly. (a) Contacts A - deenergized. Contacts A in
the deenergized position connect the pilot TRIGGER
(c) Contacts B - deenergized. Contacts B in TURRET FIRE switch (first detent) to the same point as
the deenergized position provide arm power to the pilot the gunner TRIGGER TURRET FIRE switch (first detent)
WPN CONT switch. so that the trigger that is enabled will fire the turret
weapon.
(d) Contacts B - energized. Contacts B in the
energized position provide arm power to the gunner (b) Contacts A - energized. Contacts A in the
TRIGGER TURRET FIRE switch. energized position connect the pilot TRIGGER TURRET
FIRE switch (first detent) directly to the electronic
(e) Contacts C - deenergized. Contacts C in control assembly for forward firing.
the deenergized position provide weapon fire voltage to
the pilot WING ARM FIRE switch. (c) Contacts B - deenergized. Contacts B in
the deenergized position connect the pilot TRIGGER
(f) Contacts C - energized. Contacts C in the TURRET FIRE switch (second detent) to the same point
energized position provide weapon fire voltage to the as the gunner TRIGGER TURRET FIRE switch (second
gunner WING ARM FIRE switch. detent) so that the trigger that is enabled will fire the
turret weapon.
(g) Contacts D - deenergized. Contacts D in
the deenergized position provide power from the pilot (d) Contacts B - energized. Contacts B in the
WPN CONT switch to the gunner TURRET SELECT energized position connect the pilot TRIGGER TURRET
switch. FIRE switch (second detent) directly to the electronic
control assembly for forward firing.
(h) Contacts D - energized. Contacts D in the
energized position provide arm power directly to the (e) Contacts C - deenergized. Contacts C in
gunner TURRET SELECT switch. the deenergized position connect the pilot TRIGGER
ACTION switch to the same point as the gunner
(i) Contacts E - deenergized. Contacts E in TRIGGER ACTION switch circuit so that the TRIGGER
the deenergized position are open. ACTION switch that is enabled will control the turret.
(j) Contacts E - energized. Contacts E in the (f) Contacts C - energized. Contacts C in the
energized position apply weapon fire voltage to C energized position are an open circuit, since the action
contacts of relay 19K80. signal is not needed for fixed forward firing.
(k) Contacts F - deanergized. Contacts F in (g) Contacts D. Contacts D are not used.
the deenergized position supply weapon control
voltage to the TOW control panel. i. 19K82 - Pilot Trigger Disable Relay.
(1) Purpose. Relays 19K82 and 19K85 are used
(l) Contacts F - energized. Contacts F in the together to provide a controlled sequence to interrupt
energized position open the circuit to the TOW system the turret during TOW missile launch.
Change 11 9-122.19
TM 55-1520-236-23
(2) Function. Relay 19K82 is controlled by the (3) Relay contact logic.
launcher activate signal from the TOW stabilization
control amplifier (SCA) and provides a ground for the (a) Contacts A - deenergized. Contacts A in
coil of 19K85. This is a 10-amp, 2-pole, time-delay-on- the deenergized position open the action circuit from
dropout relay. The delay time is set at 0.5 second. the gunner TRIGGER ACTION switch to the turret.
(3) Relay contact logic. (b) Contacts A - energized. Contacts A in the
energized position close the action circuit to the gunner
(a) Contacts A. Contacts A (pins B, F, and C) in TRIGGER ACTION switch to allow turret control when
the energized position provide a ground for the coil of in the PLT OVRD mode.
19K85 relay.
(c) Contacts B - deenergized. Contacts B in
(b) Contacts B. Contacts B (pins G, D and H) the deenergized position provide the action signal to
are not used. the interface control unit (IFCU) from the left-hand grip
(LHG) when the helmet sight is disconnected to allow
j. 19K83 - Pilot Action Disable Relay. the TSU to control the turret.
(1) Purpose. To detect separation of pilot helmet (d) Contacts B - energized. Contacts B in the
sight from the control arm. energized position provide the action signal from the
left-hand grip to the turret.
(2) Function. To open the pilot action circuit to
the turret and turn off the sight reticle if the arm is (e) Contacts C - deenergized. Contacts C in
disconnected from the pilot helmet. This is a 10-amp, the deenergized position open the ground circuit to the
2-pole, socket-mounted relay. gunner helmet sight reticle.
(3) Relay contact logic. (f) Contacts C - energized. Contacts C in the
energized position complete the ground circuit to the
(a) Contacts A - deenergized. Contacts A in gunner helmet sight reticle.
the deenergized position open the pilot action circuit to
the turret. (g) Contacts D. Contacts D are not used.
(b) Contacts A - energized. Contacts A in the l. 19K85 - Pilot Trigger/Action Switch Disable
energized position complete the circuit from the pilot Relay.
TRIGGER ACTION switch to the turret.
(1) Purpose. To disable pilot TRIGGER TURRET
(c) Contacts B - deenergizad. Contacts B in FIRE and TRIGGER ACTION switches during TOW
the daenergized position open the ground circuit to the missile launch.
pilot helmet sight reticle.
( 2 ) F u n c t i o n . The TOW trigger signal will
(d) Contacts B - energized. Contacts B in the energize 19K85 if 19K82 is closed. This provides a
energized position complete the ground circuit to the controlled interrupt sequence of the pilot trigger and
pilot helmet sight reticle. action circuitry to the turret of approximately 3.0
seconds during TOW missile launch. This is a 10-amp,
2-pole, socket-mounted relay.
k. 19K84 - Gunner Action Disable Relay.
(3) Relay contact logic.
(1) Purpose. To detect separation of gunner
helmet sight from the sight control arm. (a) Contacts A - deenergized. Contacts A in
the deenergized position provide standby power to the
(2) Function. To open the gunner action circuit to pilot TRIGGER ACTION switch.
the turret and turn off the helmet sight reticle if the
control arm is disconnected from the helmet. This is a (b) Contracts A - energized. Contacts A in the
10-amp, 4-pole, socket-mounted relay. energized position open the standby power circuit to
the pilot TRIGGER ACTION switch.
9-122.20 Change 11
TM 55-1520-236-23
(c) Contacts B - deenergized. Contacts Bin (b) Contacts A - energized. Contacts A in the
the deenergized position provide power to the pilot energized position open the left-hand grip (LHG)
TRIGGER TURRET FIRE switch when in the TOW ACTION switch circuit.
mode.
(c) Contacts B - deenergized. Contacts B in
(d) Contacts B - energized. Contacts B in the the deenergized position are open.
energized position apply power to the coil of 19K85
and latch it in. It will remain latched in until 19K82 (d) Contacts B - energized. Contacts B in the
opens the ground on the coil. energized position control 19K86 to switch control of
the turret to the pilot TRIGGER TURRET FIRE and
m. 19K86 - Pilot Trigger and Action Switch TRIGGER ACTION switches.
Activate Relay.
(e) Contacts C - deenergized. Contacts C in
(1) Purpose. To provide the pilot control of the the deenergized position are in the circuit from the TSU
turret when the gunner is in TOW mode. left-hand grip (LHG) TRIGGER switch (second detent)
to the turret.
(2) Function. To provide voltage to the pilot
TRIGGER ACTION and TRIGGER TURRET FIRE (f) Contacts C - energized. Contacts C in the
switches when a TOW mode is selected by the gunner. energized position open the TSU left-hand grip (LHG)
This is a 10-amp, 2-pole, socket-mounted relay. TRIGGER switch (second detent) circuit.
(3) Relay contact logic. (g) Contacts D - deenergized. Contacts D in
the deenergized position are in the circuit from the TSU
(a) Contacts A - deenergized. Contacts A in left-hand grip (LHG) TRIGGER switch (first detent) to
the deenergized position are open. the turret.
(b) Contacts A - energized. Contacts A in the (h) Contacts D - energized. Contacts D in the
energized position provide a voltage to the pilot energized position open the TSU left-hand grip (LHG)
TRIGGER ACTION switch. TRIGGER switch (first detent) circuit from the turret
and connect it to the TOW system.
(c) Contacts B - deenergized. Contacts B in
the deenergized position are open. o. 19K88 - Action Interrupt Relay.
(d) Contacts B - energized. Contacts B in the (1) Purpose. To open the action circuit to the
energized position are used to provide a voltage to the turret during acquisition mode.
pilot TRIGGER TURRET FIRE switch.
(2) Function. This relay is controlled by the
n. 19K87 - TOW/Turret Relay. gunner acquisition switches, either pilot or gunner, to
open the turret action circuit when a sight signal is not
(1) Purpose. To transfer the gunner TSU
available to the turret. This is a 10-amp, 2-pole,
left-hand grip (LHG) TRIGGER switch circuit from the
socket-mounted relay.
turret to the TOW system.
(3) Relay contact logic.
(2) Function. Selection of a standby or armed
mode on the TOW control panel will energize the
TOW/turret relay (19K87) and control 19K86 to give (a) Contacts A - deenergized. Contacts A in
the pilot control of the turret. the deenergized position are in the action circuit to the
turret.
(3) Relay contact logic.
(b) Contacts A - energized. Contacts A in the
(a) Contacts A - deenergized. Contacts A in energized position open the action circuit to the turret.
the deenergized position are in the circuit from the
gunner TSU left-hand grip (LHG) ACTION switch to the (c) Contacts B. Contacts B are not used.
turret.
Change 11 9-122.21
TM 55-1520-236-23
p. 19K90 - Gunner Pilot Override Relay. (d) Contacts D. Contacts D switch the gunner
left 40 light from bright to dim if a 40-mm launcher is
(1) Purpose. To allow the gunner to control his installed on the left side of the turret.
night vision lighting from the cyclic grip LTS switch
when in the override mode. (e) Contacts E. Contacts E switch the gunner
right 7.62 light from bright to dim if a 7.62-mm gun is
(2) Function. To switch night vision lighting installed on the right side of the turret.
control from the gunner miscellaneous control panel to
the gunner cyclic grip when in the override mode. This (f) Contacts F. Contacts F switch the gunner
is a 10-amp, 2-pole, socket-mounted relay. right 40 light from bright to dim if a 40-mm launcher is
l
installed on the right side of the turret.
(3) Relay contact logic.
(a) Contacts A - deenergized. Contacts A in r. 19K92 - Pilot Armament Light Dimming Relay.
the deenergized position allow the LT switch on the
gunner miscellaneous control panel to control gunner NOTE
night vision lighting.
NVG light dimming system will be
(b) Contacts A - energized. Contacts A in the deactivated with the incorporation of MWO
energized position allow the LTS switch on the gunner 55-1520-236-50-4.
cyclic grip to control gunner night vision lighting.
(c) Contacts B. Contacts B are not used. (1) Purpose. To provide automatic dimming of
the pilot armament lights when NVG mode is selected.
q . 1 9 K 9 1 - Gunner Armament Light Dimming
Relay. (2) Function. To switch the pilot armament lights
from bright to dim. This is a 10-amp, 6-pole,
NOTE socket-mounted relay.
NVG light dimming system will be (3) Relay contact logic.
deactivated with the incorporation of MWO
55-1520-236-50-4. (a) Contacts A. Contacts A switch the pilot
STBY light from bright to dim.
(1) Purpose. To provide automatic dimming of
the gunner armament lights when night vision goggles (b) Contacts B. Contacts B switch the pilot
(NVG) mode is selected. ARMED light from bright to dim.
(2) Function. To switch the gunner armament (c) Contacts C. Contacts C switch the pilot left
lights from bright to dim. This is a 10-amp, 6-pole, 7.62 light from bright to dim if a 7.62-mm gun is
socket-mounted relay. installed on the left side of the turret.
(3) Relay contact logic. (d) Contacts D. Contacts D switch the pilot
left 40 light from bright to dim if a 40-mm launcher is
(a) Contacts A. Contacts A switch the gunner installed on the left side of the turret.
STBY light from bright to dim.
(e) Contacts E. Contacts E switch the pilot
(b) Contacts B. Contacts B switch the gunner right 7.62 light from bright to dim if a 7.62-mm gun is
ARMED light from bright to dim. installed on the right side of the turret.
(c) Contacts C. Contacts C switch the gunner (f) Contacts F. Contacts F switch the pilot right
left 7.62 light from bright to dim if a 7.62-mm gun is 40 light from bright to dim if a 40-mm launcher is
installed on the left side of the turret. installed on the right side of the turret.
9-122.22 Change 11
TM 55-1520-236-23
s. 21K1 - M-18 Power Relay. (d) Contacts B - energized. Contacts B in the
energized position open the gunner inboard stores
(1) Purpose. To provide power to the inboard jettison circuits and send the inboard jettison signal to
wing stations for M-18 battery charging. the outboard stores stations.
(2) Function. This relay is energized anytime the u. 21K3 - Pilot Jettison Switch Relay.
MASTER ARM switch is in the STBY position. This is a
20-amp, 3-pole, screw-terminal relay. (1) Purpose. To ensure the pilot jettison signal is
maintained long enough for jettison sequence
(3) Relay contact logic. completion.
(a) Contacts A. Contacts A in the energized ( 2 ) F u n c t i o n . When the pilot releases his
position apply power from the RH MINI GUN circuit JETTISON pushbutton switch, 21K3 will maintain the
breaker to the inboard right wing station for M-18 jettison command for 1.0 second. This is a 10-amp,
battery charging. 2-pole, time-delay-on-dropout relay. The time delay is
1.0 second.
(b) Contacts B. Contacts B in the energized
position apply power from the LH MINI GUN circuit (3) Relay contact logic.
breaker to the inboard left wing station for M-18
battery charging. (a) Contacts A. Contacts A (pins H, D, and G)
apply voltage to the pilot JETTISON SELECT switches
(c) Contacts C. Contacts C are not used. when the relay is energized.
t. 21K2 - Jettison Control Relay. (b) Contacts B. Contacts B (pins C, F, and B)
are not used.
(1) Purpose. To prevent jettison of an inboard
wing store if lower missile launchers are installed v. 21K4 - Pilot Jettison Control Relay.
outboard.
(1) Purpose. To prevent simultaneous jettison of
(2) Function. Relay 21K2 will open the inboard inboard and outboard wing stores. Inboard stores are
jettison circuits and route the jettison signal to the always delayed for 0.5 second.
outboard stations if inboard stores are selected for
jettison when lower missile launchers are installed. (2) Function. When the pilot presses the
When the electrical connector of each lower missile JETTISON pushbutton switch, 21K4 relay will delay
launcher separates, relay 21K2 will reenergize and for 0.5 second and then energize and send a signal to
route the jettison signal to the inboard stations. This is the inboard stations to jettison stores. This is a
a 10-amp, 2-pole, socket-mounted relay. 10-amp, 2-pole, time-delay-on-pull-in relay. The time
delay is 0.5 second.
(3) Relay contact logic. (3) Relay contact logic.
(a) Contacts A - deenergized. Contacts A in (a) Contacts A. Contacts A (pins C, F, and B)
the deenergized position connect the pilot inboard are not used.
stores jettison circuits to the inboard stations.
(b) Contacts B. Contacts B (pins H, D, and G)
(b) Contacts A - energized. Contacts A in the close after 0.5 second and apply voltage to the inboard
energized position open the pilot inboard stores jettison stores jettison circuits.
circuits and send the inboard jettison signal to the
outboard stores stations. w. 21K5 - Gunner Jettison Control Relay.
(c) Contacts B - deenergized. Contacts B in (1) Purpose. To prevent simultaneous jettison of
the deenergized position connect the gunner inboard inboard and outboard wing stores. Inboard stores are
stores jettison circuits to the inboard stores stations. always delayed for 0.5 second.
Change 11 9-122.23
TM 55-1520-236-23
(2) Function. This relay delays the gunner released. This is a 10-amp, 2-pole, time-delay-on-
inboard stores jettison signal for 0.5 second and then dropout relay. The time delay is 0.5 second.
aends it to the inboard stations to jettison stores. This
is a 10-amp, 2-pole, time-delay-on-pull-in relay. The (3) Relay contact logic.
time delay is 0.5 second.
(a) Contacts A. Contacts A (pins B, C, and F)
are used in the energized position to open the turret
(3) Relay contact logic.
trigger circuit.
(a) Contacts A. Contacts A (pins C, F, and B)
are not used. (b) Contacts B. Contacts B (pins D, G, and H)
are not used.
(b) Contacts B. Contacts B (pins H, D, and G) 9-414. q TURRET SYSTEM CIRCUITRY
close after 0.5 second and apply voltage to the inboard
stores jettison circuits. 9-415. q D E S C R I P T I O N - T U R R E T
SYSTEM CIRCUITRY.
x. 21K6 - Wing Stores Disable Relay.
The M28A3 turret system interfaces, by means of
auxiliary equipment, with the M136 helmet sight
(1) Purpose. To disable rocket fire when the TOW
subsystem (HSS) and the turret control portion of the
missile is fired.
stabilized telescopic sight unit (TSU) of the M65 TOW
missile subsystem. The interconnecting airframe wiring
(2) Function. This relay prevents rocket firing
integrates the three subsystem components through
from the time the left-hand grip TRIGGER is pressed
the interface control unit (IFCU), electronic interface
until after the TOW wire is cut. This is a 10-amp,
assembly, and the pilot and gunner armament control
2-pole, socket-mounted relay.
panels. For additional information pertaining to the
M28A3 turret system, refer to TM 9-1090-203 series
(3) Relay contact logic.
maintenance manuals. For additional information
pertaining to the Ml 36 helmet sight subsystem, refer
(a) Contacts A. Contacts A are not used.
to TM 9-1270-212-14. For additional information
pertain ingtothe TSUand M65 TOW missile
(b) Contacts B. Contacts B when energized
subsystem, refer to paragraph 9-427 and TM
open the circuit to the pilot WING ARM FIRE switch.
9-1425-473 series maintenance manuals.
y. 21K7 - Turret Interrupt Relay. 9 - 4 1 6 . FUNCTIONAL TEST -
TURRET SYSTEM CIRCUITRY.
(1) Purpose. To intarrupt turret fire when rockets
are fired. a. Requirements.
(2) Function. This relay opens the trigger circuit (1) Test equipment.
to the turret when rockets are fired and keeps it open
for 0.5 second after the WING ARM FIRE switch is (a) Auxiliary power. Ground power unit (T14).
9-122.24 Change 11
TM 55-1520-236-23
(b) Hydraulic. Hydraulic ground test cart AMMO RSV PERCENT - RIGHT 50
(T11). AMMO RSV PERCENT - LEFT 50
TURRET SELECT BOTH
COMP OFF
HSS reticle brightness knob midpoint
TURRET DEPR LIMIT DEPR LIMIT
All weapons shall be dry fired. Only
RANGE 500
dummy ammunition with smooth cases
like live ammunition shall be used.
(e) TOW control panel.
(2) Special tools. Airspeed simulator (T10).
MODE SELECT OFF
b. Preparation for Testing.
(5) Electrical power. Check that the aircraft
(1) General. Qualified armament personnel
battery is connected, then apply 28-volt dc external
shall be present during following tests.
electrical power. (Refer to paragraph 1-51.)
(2) Configuration. For the purpose of this test,
the M28A3 turret will be assumed to havea 7.62 mm (6) Circuit breakers. Engage the following
weapon on right side, 40mm weapon on left side, and circuit breakers:
7.62 mm/40 mm ammo drums installed.
(a) DC circuit breaker panel.
(3) Weapon system preparation.
GEN FIELD
(a) Check all system components for proper DC VM
installation. CAUT LT
GEN BUS RESET
(b) Check that 7.62 mm weapon and feeder INV MAIN
are properly timed.
(4) Control switch positions. Position the (b) Ac circuit breaker panel.
following switches as indicated:
TOW PWR
(a) Pilot armament control panel. WPM CONT
WPM FIRE
MASTER ARM OFF HSS
WPN CONT GUNNER REF XFMR
TURRET BOTH SECU
HSS RCTL brightness knob midpoint TURRET CONT
RKT PWR
(b) Pilot miscellaneous control panel.
(c) Ammo Compartment
INBD JETTISON SELECT OFF
OUTBD JETTISON SELECT OFF XM28 GUN PWR LH
XM28 GUN PWR RH
(c) Pilot rocker control panel.
WG ST ARM OFF (7) Power switch positions. P o s i t i o n t h e
RKT PR SEL 1 following switches as shown:
(d) Gunner armament control panel. INV MAIN
BAT ON
PILOT OVRD OFF NON-ESNTL BUS MANUAL
WING STORES SELECT OFF ELEC PWR/EMER OFF ELEC PWR
Change 14 9.123
TM 55-1520-236-23
(f) Hold gunner helmet sight line-of-sight
(LOS) at 0 degrees elevation and 0 degrees azimuth,
press LHG ACTION switch on TSU and slowly rotate
LOS downward. The weapon should reach the
depression limit at 20 5 degrees. The reticle should
Before proceeding, clear turret area of flash when helmet LOS is out of coincidence with
any obstructions and warn personnel to commanded gun line. Release ACTION switch.
remain on exterior of safety barrier.
(g) Position TURRET DEPR LIMIT switch to
OFF.
Do not apply hydraulic power to system
unless electrical power is applied.
(8) Hydraulic power. Apply 1500 25 p s i If weapons are installed, excessive
hydraulic power. downward movement of LOS can cause
barrels to strike ground.
c. Testing Procedures.
(h) H o l d g u n n e r h e l m e t s i g h t L O S a t 0
(1) Gunner turret control. With test personnel degrees elevation and 0 degrees azimuth, press LHG
in the pilot and gunner positions, connect helmet ACTION switch on TSU and slowly rotate LOS
sight linkages to built-in test (BlT) brackets at the downward. Confirm that gun barrels move past the
forward support points. 20 5 degrees down position. Release ACTION
switch.
(a) With MASTER ARM switch and PILOT
OVRD switch in OFF, check that there is no action or (i) Return TURRET DEPR LIMIT switch to
firing of any armament system from any of the action DEPR LIMIT.
and trigger switches (pilot and gunner cyclic grips and
gunner LHG). (j) Press ACTION switch and check that
turret traverses in both azimuth and elevation.
(b) Position pilot MASTER ARM switch to Movement should be free and in accordance with
STBY. Observe that pilot and gunner green STBY position commands from the sight.
indicators and gunner right 7.62 and left 40 amber
indicators are illuminated. (k) M o v e t u r r e t t h r o u g h t o t a l e l e v a t i o n ,
depression and azimuth limits. Check that retitles
(c) P o s i t i o n H S S B I T s w i t c h o n g u n n e r flash while turret is against the azimuth and elevation
control panel to BIT and release. Check that a GO limits. Check that no binding or interference occurs.
indication appears on HSS indicator.
(l) Rotate sight rapidly both in azimuth and
NOTE elevation. Check that slight reticle flashes
momentarily as turret and HSS LOS are out of
Completion of BIT circuit requires coincidence.
approximately two seconds.
(m) Release ACTION switch on LHG grip and
(d) Remove pilot and gunner linkage from BIT check that turret returns to stowed (forward) position.
brackets and check for freedom of movement in all
directions. (n) Hold the sight in approximately the 0
degrees azimuth and 0 degrees elevation position and
(e) C h e c k t h a t H S S r e t i c l e i l l u m i n a t i o n press ACTION switch on LHG grip. Attempt to fire the
controls on both armament control panels are weapons with gunner and pilot triggers. The weapons
functioning properly. Turn reticle brightness control should not fire.
knob from OFF to BRT and check for corresponding
proper light intensity. Move reticle TEST switch to (o) Position pilot MASTER ARM switch to
TEST and check that HSS reticle is still illuminated. ARM. Check that pilot red ARMED, gunner amber
9-124
TM 55-1520-236-23
WEAPON MIX, and gunner red ARMED indicators are (x) Position pilot WG ST ARM switch to INBD.
illuminated and that pilot and gunner green STBY Check that pilot amber WG ST ARMED light
indicators are extinguished. illuminates.
(p) P o s i t i o n C O M P s w i t c h o n g u n n e r (y) C h e c k t h a t l i g h t e x t i n g u i s h e s w h e n
armament control panel to ON. MASTER ARM switch is in STBY position. Reposition
MASTER ARM to ARM.
(q) H o l d g u n n e r h e l m e t s i g h t L O S a t
(z) While firing 7.62mm weapon with gunner
approximately 0 degrees elevation and 90 degrees LHG, press pilot cyclic stick WING ARM FIRE button.
azimuth. Check that 7.62mm firing is interrupted and that,
when WING ARM FIRE button is released, a short
(r) Press ACTION switch and move RANGE time delay occurs before the weapon resumes firing.
switch to 1000, then 1500 meters. Check that turret
elevation increases with increased range settings. (aa) Position gunner TURRET SELECT switch
Check that helmet sight reticle does not flash at any to L and repeat step (z), except fire the 40mm weapon.
range setting. Release ACTION switch and return
RANGE switch to 500.
(ab) Return gunner TURRET SELECT switch
to R and position pilot WG ST ARM switch to OUTBD.
(s) Position gunner TURRET SELECT switch
toL. Hold gunner helmet sight LOS at approximately 0 (ac) Repeat steps (Z) and (aa).
degrees elevation and 90 degrees azimuth.
(ad) Position pilot WG ST ARM switch to OFF.
(t) Press ACTION switch and move RANGE
switch to 1000, then 1500 meters. Check that turret (ae) P o s i t i o n g u n n e r T U R R E T s w i t c h t o
elevation increases with increased range selection. BOTH. Check that 7.62mm weapon fires and that
Check that helmet sight reticle does not flash at any 40mm will not fire.
range setting. Release ACTION switch. Return
RANGE switch to 500. Return COMP switch to OFF. (2) Pilot turret control.
(u) Press LHG ACTION switch and move LHG (a) Position MASTER ARM switch to STBY.
trigger on gunner TSU to either detent. Check that
40mm weapon fires at 10 1 second burst. Release (b) Position pilot WPN CONT switch to PILOT.
ACTION switch and press the trigger. The weapon Check that blue PILOT IN CONT indicator on gunner
should not fire. control panel illuminates and that amber WEAPON
MIX indicator extinguishes. Check that pilot amber
(v) Position gunner TURRET SELECT switch WEAPON MIX indicator illuminates.
to R. Press LHG ACTION switch and move LHG trigger
on TSU to first detent and check that 7.62mm weapon (c) Press LHG ACTION switch. Check that
fires a 6 1 second duration burst at the low rate of gunner helmet sight has no control of the turret.
fire. Release trigger. Press trigger to second detent
and check that weapon fires at the higher rate of fire. (d) Press gunner cyclic grip ACTION switch.
Release ACTION switch and trigger. Check that gunner helmet sight has no control of the
turret.
(w) With pilot WPN CONT switch in GUNNER
position, press the pilot ACTION switch and trigger. (e) Press ACTION switch on pilot cyclic grip
Check that the weapons do not move or fire. and check that turret follows helmet sight LOS in the
same manner as that described for gunner in
subparagraph (1), steps (f) through (m).
(f) Position MASTER ARM switch to ARM.
Before conducting the following steps, (g) Position COMP switch on the gunner
verify that all wing stores (launchers, control panel to ON.
pods, etc.) electrical connections have
been disconnected. (h) Position pilot TURRET switch to R.
9-125
TM 55-1520-236-23
(i) H o l d p i l o t h e l m e t s i g h t L O S a t (v) Position pilot WG ST ARM switch to OFF.
approximately 0 degrees elevation and 90 degrees
azimuth. (3) Pilot override by gunner.
(j) Press pilot cyclic stick ACTION switch and (a) 7.62mm weapon.
move range switch to 1000, then 1500 meters. Check
that turret elevation increases with increased range 1 Position gunner PLT OVRD switch to PLT
settings. Check that helmet sight reticle does not OVRD.
flash at any range setting. Release ACTION switch
and return RANGE switch to 500. 2 Check that amber WEAPON MIX
indicator on gunner armament control panel
(k) Position pilot TURRET switch to L. Hold
illuminates and that blue PILOT INCONT indicator
pilot helmet sight LOS at approximately 0 degrees
extinguishes. Check that pilot amber WEAPON MIX
elevation and 90 degrees azimuth. indicator extinguishes. Check that gunner red
ARMED indicator illuminates.
(l) Press ACTION switch and move RANGE
switch to 1000, then 1500 meters. Check that turret 3 Position gunner TURRET SELECT switch
elevation increases with increased range settings.
to R or BOTH. Depress gunner cyclic stick ACTION
Check that helmet sight reticle does not flash at any
switch. Check that only gunner cyclic stick trigger will
range setting. Release ACTION switch and return fire the 7.62mm weapon and that 40mm weapon will
RANGE switch to 500. Return COMP switch to OFF.
not fire. The gunner helmet sight subsystem (HSS)
should control the turret.
(m) Position pilot TURRET SELECT switch to
BOTH. 4 Press gunner LHG ACTION switch and
trigger. Check that turret does not respond to helmet
(n) Check that only the pilot cyclic stick
sight and weapon does not fire.
trigger fires only the 7.62mm weapon; low rate at first
detent and high rate at second detent. 5 Press pilot cyclic stick ACTION switch
and trigger. Check that pilot helmet sight will not
(o) Position pilot TURRET switch to L. Check control turret and that weapon does not fire.
that only pilot cyclic stick trigger fires only the 40mm
weapon in either detent. 6 Position pilot MASTER ARM switch to
OFF and check that both pilot and gunner red ARMED
(P) position pilot TURRET switch to R. Check lights remain on. Check that only gunner cyclic stick
that only the 7.62mm weapon fires from the pilot trigger will fire the 7.62mm weapon.
cyclic stick trigger.
7 Position pilot WPN CONT switch to
(q) Position pilot WG STARM switch to INBD. GUNNER. Check that only gunner cyclic stick trigger
Check that pilot amber WG ST ARMED light
will fire the 7.62mm weapon.
illuminates.
(b) 40mm weapon.
(r) While firing 7.62mm weapon from the
pilot cyclic grip, press pilot cyclic stick WING ARM
1 Position gunner TURRET SELECT switch
FIRE button. Check that 7.62mm firing is interrupted
to L. Check that only gunner cyclic stick trigger will
and that, when WING ARM FIRE button is released, a fire the 40mm weapon.
short time delay occurs before the weapon resumes
firing. 2 Observe that both right and left round
counters have moved toward zero.
(s) Position pilot TURRET switch to L and
repeat step (r), except fire the 40mm weapon.
(4) Turret airspeed compensation.
(t) Return pilot TURRET switch to R and
position pilot WG ST ARM switch to OUTBD. (a) Apply air pressure to pitot system to
simulate 100 5 knots airspeed for steps (b) through
(u) Repeat steps (r) and (s). (f).
9-126
TM 55-1520-236-23
(b) Rotate turret approximately 90 degrees to trace malfunctioning circuit loop, using standard
the right to check airspeed compensator operation. electronic troubleshooting procedures, and standard
test equipment. Localize malfunctioning components
(c) P o s i t i o n C O M P s w i t c h o n g u n n e r and repair or replace, as required.
armament control panel to ON. Observe aft turret
rotation (indicating airspeed data is being fed to turret b. Turret System. R e f e r t o T M 9 - 1 0 9 0 - 2 0 3
positioning circuits). series maintenance manuals for troubleshooting
procedures pertaining to the M28A3 turret system.
(d) Position gunner TURRET SELECT switch
to R or BOTH.
c. Helmet Sight Subsystem. Refer to TM 9-
1270-212-14; for troubleshooting procedures
(e) C h e c k that compensation is greater for
pertaining to the M136 helmet sight subsystem.
40mm weapon.
d. Telescopic Sight Unit. Refer to TM 9-1425-
(f) Position pilot MASTER ARM to STBY and
473 series maintenance manuals for troubleshooting
return gunner PLT OVRD and COMP switches to OFF.
procedures pertaining to the telescopic sight unit
Remove air pressure from pitot system.
portion of the M65 TOW missile subsystem.
(5) Fixed mode firing.
9-418. m M 1 3 6 E L E C T R O N l C
INTERFACE ASSEMBLY.
(a) Position pilot WPN CONT to FIXED.
9-419. q DESCRIPTION - M136
(b) Press pilot cyclic grip ACTION switch.
ELECTRONIC INTERFACE ASSEMBLY.
Check that turret does not follow helmet sight.
The electronic interface assembly is a component of
(c) Press gunner LHG ACTION switch and
the M136 helmet sight subsystem that provides
regulated 28 Vdc power and contains the electronic
components necessary for the operation of the HSS.
The electronic interface assembly is the point of
(d) Position MASTER ARM switch to ARM.
integration with the interface control unit (IFCU)
which interfaces the HSS and TSU sighting systems
(e) Press pilot cyclic grip ACTION switch and
with the M28A3 turret system. The electronic
trigger. Check that 7.62mm weapon fires but that
interface assembly is mounted to the rear cockpit
turret does not follow helmet sight.
bulkhead (see figure 9-19). The electronic interface
assembly contains buffer amplifiers and circuitry
d. Conclusion of Tests. Upon completion of the
required by the linkage resolvers, azimuth and
preceding armament circuitry tests, accomplish the
elevation alignment controls and associated circuitry
following:
for boresighting each linkage assembly, and the BITE
circuits and controls necessary to provide the HSS
(1) Return control switches to OFF or normal
self-test capability. For additional information and
positions.
maintenance procedures pertaining to the electronic
interface assembly, refer to TM 9-1270-212-14.
(2) Reset (disengage) circuit breakers used.
9-420. m I N T E R F A C E CONTROL
(3) Turn off and disconnect hydraulic power UNIT (IFCU).
cart.
9-421. ~ DESCRIPTION - INTERFACE
(4) Turn off and disconnect 28 Vdc external CONTROL UNIT (IFCU).
power source.
The interface control unit (IFCU) contains the signal
9-417. TROUBLESHOOTING - TURRET switching, buffering and alignment, range
SYSTEM CIRCUITRY. compensation, airspeed compensation, and
depression limit circuitry necessary to interface the
a. Airframe Circuitry and Components. Refer to h e l m e t s i g h t s u b s y s t e m (HSS) and stabilized
paragraph F-9 in Appendix F for wiring diagram and telescopic sight unit (TSU) with the M28A3 turret
9-127
TM 55-1520-236-23
system. The IFCU is located in the right access accomplished in the IFCU with the use of relay logic.
compartment below the wing (see figure 9-19). When Once the sighting unit is selected, turret positioning
the gunner selects the gun mode in the TOW system, signals are routed from the sight back through the
the computing resolver chain contained within the IFCU integrated circuit buffer amplifiers to the
turret system is connected to similar resolvers selected sight resolver. The amplifiers ensure that the
located in the TSU. Elevation and azimuth commands computing accuracy of the resolver chain is
and a range reference function are then developed in maintained and provide a means of changing outputs
the TSU and are returned to the turret system through for compensation purposes. In addition to the gun
the IFCU as positioning signals for the turret mode, an acquisition mode is provided in which either
assembly. In this manner, as the TSU tracks the helmet sight positions the TSU. The acquisition mode
target, the turret assembly is commanded to follow thus allows either the pilot or the gunner to acquire a
the TSU line-of-sight. Operation with either the pilot target for the TOW missile or turret gun by utilizing
or gunner helmet sight is accomplished in a like the helmet sight. The relay logic in the IFCU also
manner. The function of the IFCU is to receive signals provides a dual mode capability. If the gunner has
from the three sighting units, control panel switching, selected the TOW mode, the pilot has the capability of
and airspeed transducer and provide the appropriate directing the turret assembly with the helmet sight. In
circuit response, depending upon the mode activated addition, either helmet sight may be directing the
by the system operator. This interchange of signals is turret assembly while the other helmet sight is used
Sheet 1
9-128
TM 55-1520-236-23
Figure 9-19.
to acquire a target for the TOW missile or turret gun.
Pitch and roll trim resolvers within the IFCU resolve
any installation misalignment existing between the
TSU and the turret assembly. These resolvers are Cleaning solvent is flammable and toxic.
aligned during system boresighting and then locked Provide adequate ventilation. Avoid
in the corrected position. Other IFCU inputs and prolonged breathing of solvent vapors
outputs include airspeed d a t a f o r t u r r e t and contact with skin or eyes.
compensation, helmet sight reticle voltage, and a
turret coincidence signal which provides an b. Remove grease, fungus, and ground-in dirt
indication as to turret/sight alignment. The turret with a clean, lint-free cloth dampened with dry
depression limit circuitry in the IFCU limits the down cleaning solvent (C112).
elevation of the turret to approximately 25 degrees to
prevent damage which could result if gun strikes the c. Remove dirt from electrical connectors with a
ground. Depression limit is activated when gunner bristle brush.
positions TURRET DEPR LIMIT switch from OFF to
TURRET DEPR LIMIT. 9-423. ~ I N S P E C T I O N - I N T E R F A C E
- INTERFACE CONTROL UNIT (IFCU).
9-422. ~ CLEANING
CONTROL UNIT (IFCU). a. Inspect IFCU case for cracks or damage.
a. Remove moisture and loose dirt with a clean, b. Inspect electrical connectors for broken pins or
soft cloth. cracked connector inserts.
9-129
TM 55-1520-236-23
c. Inspect IFCU for secure mounting. and procedures pertaining to M65 TOW missile
subsystem components, refer to TM 9-1425-473
9-424. ~ REMOVAL - INTERFACE series maintenance manuals. For information and
CONTROL UNIT (IFCU). maintenance procedures pertaining to the interface
control unit (IFCU), refer to paragraph 9-420.
a. Ensure all electrical power is OFF.
9-429. q F U N C T I O N A L T E S T - M 6 5
b. Remove IFCU access panel (right side, below TOW MISSILE SUBSYSTEM CIRCUITRY.
wing).
a. Requirements.
c. Disconnect three electrical connectors from
(1) Test equipmant.
IFCU. Protect receptacles and plugs with caps or
electrical tape (C121),
(a) Auxiliary power. G r o u n d p o w e r u n i t
(T14).
d. Remove mounting screws and washers, and
remove IFCU from wall.
(b) Hydraulic. Hydraulic ground test cart (T11).
9-425. q REPAIR - INTERFACE
CONTROL UNIT (IFCU). (2) Special tools. TOW simulator evaluation
missiIe (TSEM) (T70).
a. Repair connectors, and tighten or replace loose
or missing mounting screws. b. Preparation for Testing.
b. Replace IFCU if case is damaged or defective. (1) General. Qualified armament personnel
Evacuate removed IFCU to higher echelon for shall be present during following tests.
disposition.
(2) Configuration. For the purpose of this test,
9-426. ~ INSTALLATION - INTERFACE the M28A3 turret will be assumed to have a 7.62mm
CONTROL UNIT (IFCU). weapon on the right side, a 40mm weapon on the left
side, and 7,62mm/40mm ammo drums installed.
a. Position IFCU in place on wall and install
mounting screws and washers. NOTE
For functional test of M65 TOW missile
b. Remove protective caps or electrical tape from launcher system refer to TM 9-1425-
three electrical connectors and install on IFCU. 473 series maintenance manuals.
9-427. ~ M65 TOW MISSILE SUB- (3) Weapon system preparation.
SYSTEM CIRCUITRY.
(a) Check all systems components for proper
9-428. ~ D E S C R I P T I O N - M 6 5 T O W installation.
MISSILE SUBSYSTEM CIRCUITRY.
(b) V e r i f y t h a t l a u n c h e r s a r e p r o p e r l y
The M65 TOW missile subsystem circuitry provides connected, four launchers are installed, and TSEM is
the capabilities to acquire and track a target, installed in No. 1 missile position. (See figure 9-20.)
compensate for effects of helicopter motion, launch a
TOW missile, and guide the missile to the target. The (c) Open (off) all circuit breakers.
telescopic sight unit (TSU) portion of the TOW missile
subsystem interfaces with the M28A3 turret system (4) Control switch positions. Position the
circuitry, serving as a flexible sighting unit, and also following switches as indicated:
interfaces with the helmet sight subsystem for use
during target acquisition. For description and (a) Pilot armament control panel.
additional information pertaining to M65 TOW
missile subsystem components, refer to TM 55- MASTER ARM OFF
1520-236-10 and TM 9-1425-473 series WPN CONT GUNNER
maintenance manuals. For maintenance information TURRET RIGHT
9-130
TM 55-1520-236-23
Figure 9-20.
(b) Pilot rocket control panel. (5) Electrical power. Check that aircraft
battery is connected, then apply 28-volt dc external
WG ST ARM OFF electrical power.
(6) Circuit breakers. Engage the following
(c) Gunner armament control panel. circuit breakers:
WING STORES SELECT OFF
(a) DC circuit breaker panel.
TURRET DEPR LIMIT DEPR LIMIT
PLT OVRD OFF GEN FIELD
TURRET SELECT BOTH DC VOLTMETER
COMP ON CAUTION LTS
RANGE 500 GEN BUS RESET
AMMO RSV PERCENT-RIGHT 50 INV MAIN
AMMO RSV PERCENT-LEFT 50
(b) Ac circuit breaker panel.
(d) Tow control panel (TCP).
TOW PWR
MODE SELECT OFF WPN CONT
CAMERA OFF WPN FIRE
MISSILE SELECT 1 HSS
EXPOSURE BRT REF XFMR
SECU PWR
(e) Sight hand control (SHC). TURRET CONT
RKT PWR
STOW/TRK/ACQ STOW
(c) Ammo compartment.
(f) Telescopic sight unit (TSU).
XM28 GUN PWR LH
FILTER SELECT LEVER CLEAR XM28 GUN PWR RH
9-131
TM 55-1520-236-23
(7) P o w e r s w i t c h p o s i t i o n s . Position the (d) Verify that within 140 seconds after TCP
following switches as shown: system status indicator reads TEST in step (c), the TCP
system status indicator moves to PWR ON.
INVERTERS MAIN
BATTERY ON (e) Verify that all BIT indicators onTCP are IN
NON-ESS BUS MANUAL go condition (black on black).
ELEC PWR/EMER OFF ELEC PWR
(f) Move HI/LO MAG switch on LHG to LO
MAG .
(g) M o v e S T O W / T R K / C Q s w i t c h t o T R K .
Before proceeding, clear turret area of Observe that TSU turret follows inputs from SHC
any obstructions and warn personnel to transducer stick and that status flag in TSU shows
remain on exterior of safety barrier. GUNS. Verify that gun does not follow the sight.
(h) Position TURRET DEPR LIMIT switch to
OFF.
(i) Press ACTION switch on LHG. Observe
To ensure immediate control of the that turret weapon follows TSU turret when moved
system, do not apply hydraulic power to through the limits with SHC transducer stick.
system unless electrical power is applied. Observe that GUNS flag in TSU sight flashes when at
the limit stops of the turret weapon.
(8) Hydraulic power. Apply 1500 *25 psi
hydraulic power to system No. 2. (j) Release ACTION switch. Observe that
turret weapon returns to STOW.
(9) Special test equipment. Position the
following test equipment switches or controls as (k) Move LOS of TSU to approximately O
indicated: degrees azimuth and elevation and press LHG
ACTION switch and trigger. Observe that turret
TOW system evaluator missile (TSEM). weapon will not fire.
POWER OFF (l) Release ACTION switch. Position pilot
FUNCTION LAMP TEST MASTER ARM switch to ARM.
c. Testing Procedures. (m) Move LOS on TSU to approximately O
degrees azimuth and elevation and press LHG
(1) Initial system tests. Perform the following ACTION switch and trigger. Observe that turret
steps for initial system tests: weapon fires.
NOTE (n) Release ACTION switch and position
MASTER ARM switch on pilot armament control
For this test, one technician will be
panel to STBY.
required in the gunner position, one
technician in the pilot position, and one (o) R e t u r n STOW/TRK/ACQ switch to
technician outside the helicopter. STOW.
(a) Position pilot MASTER ARM switch to (p) R e t u r n TURRET DEPR LIMIT switch to
STBY and WPN CONT to GUNNER. DEPR LIMIT.
(b) Position TCP MODE SELECT switch to (2) Telescopic sight controls. Perform the
TSU/GUN. following steps for initial system turn-on:
(c) Verify that system status indicator on TCP (a) Position MODE SELECT switch on TOW
moves from OFF to TEST after approximately 10 control panel (TCP) to STBY TOW. Verify that TCP
seconds. system status indicator remains at PWR ON.
9-132
TM 55-1520-236-23
(b) Position STOW/TRK/ACQ switch to TRK 10-second delay from OFF to TEST onthe TCP system
and press LHG ACTION switch. Observe that turret status indicator.
weapon will not follow inputs from SHC transducer
(m) With system status indicator reading
stick.
TEST from step (k), position STOW/TRK/ACQ switch
(c) Release LHG ACTION switch and return on sight hand control to TRK and return it to STOW.
STOW/TRK/ACQ switch to STOW. Verify that system status indicator cycles from TEST
to PWR ON to TEST during this sequence.
(d) Position TCP MODE SELECT switch from
STBY TOW to ARMED MAN. Verify that TCP system (n) W i t h s y s t e m s t a t u s i n d i c a t o r r e a d i n g
status indicator remains at PWR ON. TEST from step (l), position MASTER ARM switch on
pilot armament control panel from STBY to ARM to
(e) Position MASTER ARM switch on pilot OFF. Verify that system status indicator on TCP
armament control panel from STBY to ARM to STBY. moves from TEST to ARMD to OFF during this
Verify that system status indicator on TCP moves sequence.
from PWR ON to ARMD to PWR ON during this (o) Position pilot MASTER ARM switch to
sequence. ARM, the STOW/TRK/ACQ switch on the SHC to TRK
and position TCP MODE SELECT switch to STBY
(f) P o s i t i o n W P N C O N T s w i t c h o n p i l o t TOW.
armament control panel to PLT.
(p) Position TSU optics to HI MAG using
(g) Position MASTER ARM switch from STBY HI/LO MAG switch on TSU LHG. Observe that TSU is
to ARM to STBY. Verify that system status indicator now in the HI MAG mode.
on TCP remains at PWR ON during this sequence.
(q) While holding ACTION switch, use SHC
(h) P o s i t i o n W P N C O N T s w i t c h o n p i l o t stick to drive TSU from stop to stop horizontally and
armament control panel to FIXED and repeat step (g). vertically. Verify that TSU can be driven stop to stop
horizontally in less than 50 seconds and vertically in
(i) Return WPN CONT switch to GUNNER. less than 30 seconds.
(j) Position STOW/TRK/ACQ switch on SHC (r) Position TSU optics to LO MAG using
to TRK and return to STOW. Verify that system status HI/LO MAG switch on TSU LHG.
indicator remains in PWR ON position during this
sequence. (s) Use SHC stick to drive TSU to stop,
horizontally and vertically. Verify that TSU can be
NOTE driven from stop to stop horizontally in less than 3
seconds and vertically in less than 2 seconds.
Steps (k), (l), (m), and (n) should be done Release ACTION switch.
in rapid succession in order to maintain
the TEST indication. Read these steps (t) Position TSU OPTICS to HI MAG using the
before their initiation. Hl/LO MAG switch and position TCP MODE SELECT
switch to TSU/GUN.
(k) Press and hold BIT pushbutton on TCP. (u) Use SHC stick to drive TSU from stop to
Verify that ATTACK, RDY, and GUNS flags are visible stop horizontally and vertically. Verify that TSU can be
in TSU eyepiece. Verify that ascend and descend driven stop to stop horizontally in 8 seconds and
pointers and ATTACK, RDY, and FIRE flags are visible vertically in 4 seconds.
on pilot steering indicator. Release BIT SWITCH after
verifying the above and check that system status (v) Return STOW/TRK/ACQ switch to
indicator on TCP reads TEST. STOW.
(l) Position TCP MODE SELECT switch from (3) Helmet sight tracking.
ARMED MAN to OFF to ARMED MAN in less than 5
seconds. Verify that system status indicator on TCP (a) Position MASTER ARM switch on pilot
moves from TEST to OFF to TEST. There should be no panel to STBY.
9-133
TM 55-1520-236-23
(b) Connect helmet sight linkages to BUILT- (d) Press LHG ACTION switch.
IN TEST (BIT) brackets.
(e) U s i n g S H C , a d j u s t T S U p o s i t i o n f o r
(c) P o s i t i o n H S S B I T s w i t c h o n g u n n e r azimuth and elevation LOS to be zero.
control panel to BIT and release. Check that GO
indication appears on HSS test indicator. (f) Verify PSI azimuth needle is
approximately one-third from center to right when AZ
NOTE and EL LOS is zero.
Completion of BIT circuit requires (g) Select missile number 2.
approximately two seconds.
(h) Adjust TSU position for azimuth and
elevation LOS to be zero and depress LHG ACTION
(d) Connect pilot and gunner linkages to
switch.
respective helmets and check for freedom of
movement in all directions. Adjust helmet sight
(i) Verify PSl azimuth needle is approximately
reticle on helmet until full reticle pattern can be seen.
one-third from center to the left when the AZ and EL
LOS is zero.
(e) Position STOW/TRK/ACQ switch to TRK.
Press and hold PHS ACQ and check that gunner
(j) M o v e T S U L O S t h r o u g h a z i m u t h a n d
helmet sight reticle retracts automatically. Check that
elevation; observe that PSI indicates the movement of
TSU does follow pilot helmet sight as it is aimed to
TSU LOS.
left, right, up, and down. Release PHS ACQ switch.
(k) Release LHG ACTION switch.
(f) If installed, return gunner helmet sight
reticle to down position.
(l) Return STOW/TRK/ACQ switch to STOW.
(g) H o l d S T O W / T R K / A C Q s w i t c h i n A C Q
(5) L a u n c h e r / T S U a l i g n m e n t a n d s l a v i n g
position. Verify that TSU follows gunner helmet sight
test.
as it is aimed to left, right, up, and down. Release
STOW/TRK/ACQ switch and check that gunner (a) Apply hydraulic power to the helicopter.
helmet sight reticle retracts. Position TCP MODE SELECT switch to ARMED MAN
and MASTER ARM switch to ARM on pilot armament
(h) P o s i t i o n S T O W / T R K / A C Q s w i t c h t o control panel. Position TSU HI/LO MAG switch to HI.
STOW.
(b) Select missile number 1 on TCP. Verify
(4) P i l o t s t e e r i n g i n d i c a t o r c o m m a n d s a n d that missile status indicator on TCP for missile
constraints test. Pilot steering commands on the PSI number 1 reads MSL.
are a function of TSU AZ and EL gimbal angles.
Azimuth PSI steering is biased plus 0.75 degree right (c) Set STOW/TRK/ACQ switch on SHC to
for left missiles and minus 0.75 degree left for right TRK and track TSU to 0 degrees azimuth and 0
missiles. Logic prevents prefiring a TOW missile until degrees elevation.
LOS rate, gimbal angle, attack logic, launcher
position status, and roll constraint requirements are (d) Press and hold ACTION switch on LHG.
satisfied. Verify that left launcher is slaving to TSU LOS in
elevation.
(a) Position pilot MASTER ARM switch to
ARM. (e) Drive TSU up slowly in elevation until
elevation needle on PSI falls outside the inner
(b) Position TCP MODE SELECT switch to rectangle. Verify that PSI RDY flag disappears.
ARMED MAN.
(f) Recenter elevation needle and verify
(c) Position SHC STOW/TRK/ACQ switch to reappearance of RDY flag. Drive TSU down until
TRK and HI/LO MAG switch to HI. Select missile elevation needle falls below the inner rectangle and
number 1. verify that RDY flag disappears.
9-134
TM 55-1520-236-23
(g) Press and hold ACTION switch on LHG 3 When TSEM is fired in a normal
and drive TSU with the SHC stick vertically from stop- sequence, the following will be observed on rear
to-stop. Verify that right launcher does not move and panel of TSEM:
that left launcher follows vertical motion of TSU
within limits of the launchers mechanical stops. a The START and WIRE SIGNAL AMPL
lights illuminate simultaneously, then PREFIRE and -
(h) With TSU at the lower stop, release LHG 12 lights will illuminate in sequence.
ACTION switch and verify that after a short delay (0.5
second), the launcher moves back to its stowed b The YAW, PITCH, FIRE, MSL GONE,
position. and ZERO lights will illuminate in sequence.
(i) Select missile number 2 and repeat steps c The WIRE CUT and SQUIB DISC lights
(a) through (h), verifying the action of right launcher. will illuminate and WIRE SIGNAL AMPL light
extinguishes.
(6) Armament control tests. Operation during
d The previously mentioned lights will
preparation for launch and guidance of a missile shall
remain illuminated until RESET button is pressed.
be verified as follows:
Exception: t h e S H E A R P I N l i g h t w i l l r e m a i n
illuminated until launcher arming lever is raised.
(a) Pilot turret control and firing while in
TOW mode.
NOTE
1 Position WPN CONT switch on pilot
In first simulated firing following TMS
armament control panel to PILOT and MASTER ARM
turn on, or following a BIT sequence, the
switch to ARM.
PITCH and YAW balance lights may not
illuminate. This should not be interpreted
2 With MODE SELECT switch on TCP in
as an abnormal firing sequence unless
any of the TOW modes (STBY TOW, ARMED MAN, or
the PITCH and YAW lights fail to
ARMED AUTO) and STOW/TRK/ACQ switch on SHC
illuminate on successive firings.
in either TRK or STOW, check that pilot amber
WEAPON MIX indicators and gunner blue PILOT
4 At end of test, or when use of TSEM is not
INCONT indicator are illuminated and that pilot can
called for in a test, or when TSEM is to be down
fire the selected turret weapons with his helmet
loaded, position POWER switch to OFF. (An
sight.
unpowered TSEM loaded into a launcher will not
affect outcome of tests not requiring the TSEM.)
3 Position WPN CONT switch to GUNNER.
(c) Manual missile selection and firing.
4 With MODE SELECT switch on TCP in
any of the TOW modes (STBY TOW, ARMED MAN, or
NOTE
ARMED AUTO) and STOW/TRK/ACQ switch on the
SHC in either TRK or STOW, check that pilot amber Shear pin depression limits must be
WEAPON MIX indicators are illuminated and that within tolerance for the launcher to be
pilot can fire the selected turret weapons with his acceptable for firing. Both pods of all
helmet sight. launchers must be verified. To avoid a
double effort, check upper outboard
(b) TSEM operating procedure. Installation position last.
and operation of the TSEM shall be as follows:
1 Move Iauncher armament control handle
1 After loading TSEM into launcher and to up position.
lowering arming lever, position POWER switch to ON.
Check that POWER light and SHEAR PIN light 2 Turn TSEM to ON and press reset button.
illuminate.
3 Connect TSEM power cable to TSEM and
2 Position SELF TEST switch to AUTO and to DC power connector located in the ammunition
press RESET button. bay.
9-135
TM 55-1520-236-23
4 Position TSEM mode select switch to 18 Position TSEM mode select switch to
AUTO and power switch to ON. MSL GONE. Verify that RDY flags disappear on PSI
and in eyepiece of TSU. Position TSEM mode select
5 Press TSEM RESET switch and verify switch to AUTO.
that power lamp is illuminated.
NOTE
6 Rotate mode select switch to LAMP TEST
and verify that all TSEM lamps illuminate.
The ACTION and trigger switch on pilot
7 Rotate mode select switch to SP GO cyclic grip will be depressed and held
and verify that shear pin light illuminates. through steps 19 through 21. Read all of
these steps before depression of the
8 Rotate launcher armament control trigger.
handle to ARMED position and secure it with the
captive locking pin. Verify that shear pin light goes
19 Hold pilot helmet sight at 0 degree
out.
elevation and 0 degree azimuth and press pilot cyclic
stick ACTION and trigger switch. Verify that 7.62mm
9 Rotate TSEM mode select switch to SP
weapon fires.
GO and verify that shear pin lights illuminate. If
shear pin light does not illuminate, this launcher
20 Press trigger and ACTION switch on
position should not be used until readjustment and
LHG. Verify that 7.62mm weapon firing is
verification of shear pin depression is accomplished.
interrupted.
10 Push RESET button.
21 Verify that 7.62mm weapon resumes
firing after a time delay of 2.8 TO 3.2 s e c o n d s .
11 Position MASTER ARM switch on pilot
Release pilot cyclic grip trigger and ACTION switch.
armament control panel to ARM.
22 Verify the appearance of FIRE flag on
12 Position MODE SELECT switch on TCP
PSI. The FIRE flag will disappear at completion of
to ARMED MAN. Verify that MISSILE SELECT switch
firing sequence, approximately 23 seconds.
is on missile position No. 1.
23 Using TSEM, verify that proper firing
13 Verify that missile status indicator on
sequence takes place. Lights on TSEM will show
TCP for missile No. 1 indicates MSL.
proper sequence according to subparagraph (b)3
above.
14 Set STOW/TRK/ACQ switch on SHC to
TRK.
24 Verify that indicator for missile No. 1 on
TCP switches from MSL to barber pole pattern.
15 Set HI/LO MAG switch on LHG to HI.
25 W h e n F I R E f l a g d i s a p p e a r s , p r e s s
16 Verify the appearance of ATTK flag in
RESET button on TSEM and verify that indicator for
the eyepiece of TSU and on PSI.
missile No. 1 on TCP again indicates MSL.
NOTE
26 Press and hold ACTION switch on LHG
anddrive TSU LOS out of constraints in elevation. Pull
Within constraint limitations means that
trigger to confirm missile will not fire.
elevation and azimuth needles are within
inner rectangle and ascend and descend
27 Press CONST OVRD switch on SHC.
pointers are not visible.
Verify the appearance of ATTK flag in eyepiece of TSU
and on PSI RDY flag should not appear.
17 W h i l e o b s e r v i n g t h e P S I , m a i n t a i n
maneuver indicators within constraint limitations 28 Momentarily press trigger on LHG. The
using SHC tracking stick. Verify that RDY flags are ACTION switch may be released with the trigger
visible on PSI and in eyepiece of TSU. switch.
9-136
TM 55-1520-236-23
2 9 Reset TSEM and with TSU LOS in pressed and stop with the loss of fire flag indication
constraints, pull ACTION switch and trigger switch on on the PSI.
LHG. Push gunner wire cut switch and observe wire
cut indicator on TSEM. 1 2 Position gunner PLT OVRD switch to
PLT OVRD. Observe that TCP system status indicator
3 0 Repeat step 29 using pilot wire cut moves to OFF.
button.
1 3 Turn TSEM off.
3 1 Remove TSEM from missile position
No. 1, cycle (install) TSEM through remaining missile 1 4 Place pilot MASTER ARM to OFF, PLT
positions, and repeat steps 3 through 31 for each OVRD to OFF, and TCP MODE SELECT switch to OFF.
position selected.
15 Turn CAMERA (if available) switch to
(d) Automatic selection and firing. OFF.
1 Install TSEM in missile position No. 1. d. Conclusion of Tests. Upon completion of the
preceding tests, de-energize and disconnect auxiliary
2 Set mode select switch on TSEM to power unit and hydraulic ground test cart. Remove
AUTO. TSEM from launcher.
3 Set MASTER ARM switch on pilot 9-430. ~ TROUBLESHOOTING - M65
armament control panel to ARM. Set MODE SELECT TOW MISSILE SUBSYSTEM CIRCUITRY.
switch on TCP to ARMED AUTO.
a. Airframe Circuitry and Components. Refer to
4 Set STOW/TRK/ACQ switch on SHC to paragraph F-9 in Appendix F for wiring diagram and
TRK. trace malfunctioning circuit loop, using standard
electronic troubleshooting procedures and standard
5 Set HI/LO MAG select switch on LHG to test equipment. Localize malfunctioning components
HI. and repair or replace, as required.
6 Depress LHG ACTION switch and, by b. M65 TOW Missile Subsystem.
observing the PSI, maintain indications within Troubleshooting of the M65 TOW missile subsystem
maneuver constraints. is accomplished during BIT (built-in test) procedures
and also by use of Test Set, Guided Missile System
7 Momentarily press trigger on LHG. Note (TSGMS). Refer to TM 9-1425-473 series
the completion of firing sequence by observing a loss maintenance manuals for troubleshooting
of FIRE flag on the PSI. Verify that TSEM firing procedures.
sequence is in accordance with subparagraph (b) 3
above. 9-431. SERVO ELECTRONIC
CONTROL UNIT (SECU).
8 Return STOW/TRK/ACQ switch to
STOW. 9-432. ~ DESCRIPTION - SERVO
ELECTRONIC CONTROL UNIT (SECU).
9 Check that MISSILE SELECT switch on
TCP has automatically selected missile No. 2 or the The servo electronic control unit (SECU) provides
next available missile. Check pilot L-R TOW indicator. regulated power and contains signal switching, servo
amplifier, logic, and buffering circuitry necessary to
1 0 Repeat steps 5 through 9 for all align the pitch angle of the TOW missile launchers
remaining missile positions. Verify that PSI and TCP with the pitch angle of the line-of-sight (LOS) of the
indications are normal and verify TSEM firing telescopic sight unit (TSU). Slaving of the two pitch
sequence. angles ensures that the TOW missile will reliably
enter the field of view of the infrared receiver of the
1 1 For missile position No. 8, set TCP TSU. The TOW missile can be guided to target only if
CAMERA switch to AUTO. Verify that camera the initial launch thrust positions the missile within
operations (if available) start when the LHG trigger is this field of view. During the attack mode, when the
9-137
TM 55-1520-236-23
gunner selects a missile for firing, the launcher 9-434. ~ INSPECTION - SERVO
containing the selected missile is activated, Upon ELECTRONIC CONTROL UNIT (SECU).
activation, the SECU initial command drives the
launcher up. Angular position signals from the TSU a. Inspect SECU case for cracks or dents.
resolver are routed to the SECU, processed through
buffer amplifier stages, then applied to the respective b. Inspect SECU for secure mounting.
launcher resolver. The launcher resolver output
provides position feedback to the servo amplifier loop, c. Inspect electrical connectors for broken pins or
and the accelerometer provides launcher cracked inserts.
acceleration feedback to the servo amplifier loop, The
servo amplifier output to the hydraulic actuator servo d. Inspect printed wiring assemblies for crocked,
coil allows the hydraulic actuator to change the pitch broken, loose or missing hardware and components;
angle of the activated launcher when hydraulic burned components and wiring; cracked, chipped, or
pressure is provided to the actuator. The SECU also broken wiring board.
has a detector circuit which decreases the servo
amplifier gain when the launcher approaches the 9-435. ~ REMOVAL - SERVO
mechanical elevation stop at either extreme, ELECTRONIC CONTROL UNIT (SECU).
Hydraulic pressure is applied to the activated
launcher through the hydraulic solenoid valve and a. Ensure all electrical power is OFF.
the launcher pitches from stow position tothecorrect
pitch angle relative to the TSU LOS, When fired, the b. O p e n l e f t a m m o c o m p a r t m e n t d o o r j u s t
missile is launched into the field of view of the forward of wing.
infrared receiver, and wire transmitted command
signals from the M65 guidance and command
functional group steers the missile along the TSU c. R e m o v e a c c e s s p a n e l o n a f t a m m o
compartment bulkhead.
LOS. After launch, the SECU activate signal ceases
and the launcher is returned to stow position. The
hydraulic solenoid is turned off after a q delay of d. Disconnect electrical connectors trom SECU.
Protect receptacles and plugs with caps or electrical
1.50 0.75 seconds, The SECU is located just aft of
tape (C121).
the ammunition compartment (see figure 9-19).
e. Remove mounting s c r e w s a n d w a s h e r s
securing SECU to structure and remove SECU.
9-433. q CLEANING - SERVO
ELECTRONIC CONTROL UNIT (SECU). f. L o o s e n t w o s c r e w a s s e m b l i e s o n f r o n t o f
SECU. Open door assembly and slide printed wiring
a. Remove moisture and loose dirt with a clean,
assemblies out, if required.
soft cloth.
9-436. ~ R E P A I R SERVO
ELECTRONIC CONTROL UNIT (SECU).
a. Repair connectors, and tighten or replace loose
or missing mounting screws.
Cleaning solvent is flammable and toxic.
b. Replace SECU if case is damaged or defective,
Provide adquate ventilation, Avoid
Evacuate removed SECU to higher echelon for
prolonged breathing of solvent vapors
disposition.
and contact with skin or eyes.
C. Replace printed wiring assemblies as required.
b. Remove grease, fungus, and ground-in dirt
with a clean, lint-free cloth dampened with dry
cleaning solvent (C112).
c. Remove dirt from electrical connectors with a
bristle brush.
9-138 Change 12
TM 55-1520-236-23
9-437.
INSTALLATION - SERVO
ELECTRONIC CONTROL UNIT (SECU).
a. P o s i t i o n S E C U i n p l a c e a n d s e c u r e w i t h
mounting screws and washers.
b. Remove protective caps or electrical tape from
connectors and connect to respective receptacles on
SECU.
c. Close and secure access panel.
d. Close left ammo compartment door.
e. Install printed wiring assembly in SECU case.
Close dear and fasten two screw assemblies.
Change 12 9-138.1/(9-138.2 blank
TM 55-1520-236-23
9-438. ~ WING STORES ARMAMENT and fire either or both XM-18 mpniguns mounted on
SYSTEMS CIRCUITRY. inboard wing stations. With the system armed, either
or both miniguns may be fired by depressing either
9-439. ~ D E S C R I P T I O N - WING the pilot WING ARM FIRE switch or gunner WING
STORES ARMAMENT CIRCUITRY. ARM FIRE switch (when in PLT OVRD mode).
The wing stores armament systems consist of the The wing stores jettison circuitry enables the pilot
rocket launcher circuitry, XM-18 minigun circuitry, to select wing station weapons (inboard or outboard)
and wing stores jettison circuitry. Functions of the to be jettisoned in an emergency situation. Selected
wing stores armament systems are as follows: wing station weapons are jettisoned by depressing
the pilot or gunner WING STORES JETTISON switch.
The rocket launcher circuitry enables the pilot to
select and control the release (or firing) of rockets 9-440. ~ FUNCTIONAL TEST - WING
from rocket launchers mounted on any or all of the STORES ARMAMENT SYSTEM CIRCUITRY.
four wing stations. With the system armed, rockets
may be released (or fired) by pressing either the pilot a. Requirements. The following functional tests
WING ARM FIRE switch or gunner WING ARM FIRE are designed to be performed using a test set such as
switch (when in PLT OVRD mode). indicated by figures 9-21 and 9-22, or a suitable
equivalent, and a 28 Vdc, 300 ampere auxiliary power
The XM-18 minigun circuitry enables the pilot or unit. Refer to TM 9-1090-203-12 for test of
gunner (when in PILOT OVERRIDE mode) to select intervalometer.
Figure 9-21. ~ Wing Stores Armament Test Panel
9-139
TM 55-1520-236-23
Figure 9-22.
9-140 Change 12
TM 55-1520-236-23
and No. 2 pairs of OUTBOARD ROCKET lights do not
illuminate, but No. 3 pair, and then No. 4 pair,
illuminate briefly, then extinguish.
Ensure no live ammunition is present in
(4) Release WING ARM FIRE switch. Place RKT
any of the armament systems. Only PR SEL switch to position 4. Depress and hold WING
dummy ammunition with smooth cases ARM FIRE switch on pilot cyclic stick. Check that the
like live ammunition shall be used.
No. 1, No. 2, No. 3 and No. 4 pairs of OUTBOARD
b. Preparation for Testing. ROCKET lights do not illuminate, but that No. 5, No. 6,
No. 7, and No. 8 pairs illuminate briefly in turn, then
(1) Open all circuit breakers and place all extinguish, leaving no lights illuminated.
switches to their OFF or normal positions. Connect
the appropriate rocket test set cable to each of the (5) Release WING ARM FIRE switch. Place RKT
four rocket pod connectors (21A4P1, 21A5P1, PR SEL switch to position 7. Depress and hold WING
21A6P1, and 21A7P1) located at the wing stores ARM FIRE switch on pilot cyclic stick. Check that the
disconnect areas in the wings of the helicopter. No. 1 through No. 8 pairs of OUTBOARD ROCKET
lights do not illuminate, but that No. 9 through No. 15
(2) Connect the two XM-18 test set cables to rocket pair lights illuminate briefly in turn, then
connectors (21A8P1 and 21A9P1) at inboard wing extinguish, leaving no lights illuminated.
stores disconnect area in wings on the helicopter.
(6) With RKT PR SEL switch still in position 7,
(3) Connect test set wing stores jettison cables release and depress WING ARM FIRE switch. Check
on test set to respective helicopter receptacles that rocket pair lights No. 1 through No. 15 do not
(21SQ1J1, 21SQ2J1, 21SQ3J1 and 21SQ4JI). illuminate, but No. 16 through No. 19 rocket pairs
illuminate breifly in turn, then extinguish, leaving no
(4) Connect a 28 Vdc external power source to lights illuminated.
helicopter external power receptacle and energize
power source. (7) Open, then close RKT PWR circuit breaker
to reset the intervalometer memory. Place RKT PR
NOTE SEL switch to position 19. Depress and hold WING
No test set lights shall be illuminated at ARM FIRE switch on pilot cyclic stick. Check that each
any time, except as indicated in the pair of OUTBOARD ROCKETS lights illuminate briefly
folIowing test procedures. and then extinguish, beginning with No. 1 and
continuing through No. 19, and that no lights remain
C. Rocket Launcher Circuitry Test (Pilot illuminated.
Controlled Firing).
(8) Release WING ARM FIRE switch. Open and
(1) Place XM-18/ROCKETS switch SW-1 on close RKT PWR circuit breaker to reset intervalometer
armament test set to INBD RKTS. Close WPN FIRE memory. With RKT PR SEL switch still set to position
and RKT PWR circuit breakers. Position MASTER 19, depress WING ARM FIRE switch on pilot cyclic
ARM switch to ARM. Position WG ST ARM switch stick, and hold until 7 to 10 of the light pairs have
(21S6) to OUTBD. Place RKT PR SEL switch to illuminated briefly in turn, and then extinguished.
position 1. Depress WING ARM FIRE switch on pilot Release WING ARM FIRE switch. Check that none of
cyclic stick. Check that No. 1 pair of OUTBOARD the previously illuminated light pairs become
ROCKET lights on test set illuminate briefly and then illuminated, and that each remaining pair illuminates
extinguish. briefly, and then extinguishes until all rocket pair
lights have illuminated briefly and extinguished. No
(2) Depress WING ARM FIRE switch on pilot lights shall remain illuminated.
cyclic stick again. Check that No. 1 pair of OUTBOARD
ROCKET lights on test set do not illuminate, and that (9) Release WING ARM FIRE switch. Open and
No. 2 pair illuminate briefly, and then extinguish. close the RKT PWR circuit breaker to reset the
intervalometer memory. Place RKT PR SEL switch to
(3) Release WING ARM FIRE switch. Place RKT position 19. Depress and hold WING ARM FIRE
PR SEL switch to position 2. Depress and hold WING switch on pilot cyclic stick. Check that each pair of
ARM FIRE switch on pilot cyclic stick. Check that No. 1 OUTBOARD ROCKETS lights illuminate briefly and
9-141
TM 55-1520-236-23
then extinguish, beginning with No. 1 and continuing (2) Repeat test described in preceding step c(9),
through No. 19, and that no lights remain illuminated. substituting WING ARM FIRE switch on pilot cyclic
stick for WING ARM FIRE switch on gunner cyclic
(10) Release WING ARM FIRE switch. Open stick. Check that the pilot WING ARM FIRE switch will
and close the RKT PWR circuit breaker to reset the fire wing stores armament.
intervalometer memory. Depress and hold, then
release WING ARM FIRE switch on gunner cyclic (3) Place MASTER ARM switch to the OFF
stick. Check that gunner WING ARM FIRE button has position. Depress WING ARM FIRE switch on gunner
no control, and that no light pairs on test set become cyclic stick. Check for no response on the test set.
illuminated.
(11) Repeat steps (1) through (9), except place
e. XM-18 Minigun Circuitry Test.
WG ST ARM switch to INBD position and observe
(1) Place XM-18 INBD RKTS switch on test set
INBOARD ROCKET light pairs instead of OUTBOARD
to XM-18 position. Place gunner PLT OVRD switch to
ROCKET light pairs on test set.
OFF. Place pilot WG ST ARM switch (21S6) to INBD.
Close TURRET PWR, RH MINIGUN, and LH MINIGUN
(12) Open and close the RKT PWR circuit
circuit breakers. Place MASTER ARM switch to STBY.
breaker to reset the intervalometer memory. Set RKT
Check that XM-18 BAT CHG lights on test set
PR SEL switch to position 7. Depress WING ARM FIRE
illuminate.
switch on pilot cyclic stick and hold until 7 inboard
light pairs have successively illuminated briefly and
(2) Depress WING ARM FIRE switch on pilot
then extinguished, and no light pairs remain
cyclic stick. Check that XM-18 FIRED lights on test set
illuminated. Place WG ST ARM switch to OUTBD
do not illuminate.
position, but do not reset intervalometer memory.
Depress WING ARM FIRE switch on pilot cyclic stick
(3) P l a c e M A S T E R A R M s w i t c h t o A R M .
and hold until 7 outboard light pairs have successively
Depress and hold pilot WING ARM FIRE switch.
illuminated briefly and then extinguished and no light
Check that XM-18 FIRED lights illuminate.
pairs remain illuminated. Place WG ST ARM switch to
INBD position, but do not reset intervalometer
(4) Release pilot WING ARM FIRE switch.
memory. Depress and hold WING ARM FIRE switch
until 7 additional pairs of inboard rockets lights Check that XM-18 FIRED lights extinguish.
beginning with No. 8 have illuminated briefly and
extinguished. No light pairs shall remain illuminated. (5) Place pilot WG ST ARM switch to OFF.
Depress pilot WING ARM FIRE switch. Check XM-18
FIRED lights do not illuminate.
(13) Place WG ST ARM switch to OUTBD. Do
not reset the intervalometer memory. Depress and
hold the pilot WING ARM FIRE switch. Check the (6) Place PLT OVRD switch to ON. Set gunner
WG ST ARM switch to INBD. Depress and hold pilot
outboard rocket light pairs No. 8 through No. 14
WING ARM FIRE switch. Check that XM-18 FIRED
illuminate briefly and then extinguish. No light pairs
lights illuminate.
should remain illuminated.
(7) Release gunner WING ARM FIRE switch.
d. Rocket Launcher Circuitry Test (Gunner Check that XM-18 FIRED lights extinguish.
Controlled Firing).
(8) Place gunner WG ST ARM switch to OFF.
(1) XM-18/ROCKETS switch, SW-1, on the Depress gunner WING ARM FIRE switch. Check that
test set shall remain in INBD RKTS position. Unlock XM-18 FIRED Iights do not illuminate. Return gunner
PLT OVRD switch on gunner armament control panel WG ST ARM switch to INBD.
and position it to PLT OVRD. Position MASTER ARM
switch to ARM. Repeat all tests in preceding steps c(1) (9) Depress pilot WING ARM FIRE switch.
through c(8) and steps c(10) through c(12), except the Check that XM-18 FIRED lights do not illuminate.
test described in step c(9), substituting WING
STORES SELECT switch for WG ST ARM switch, and (10) Place pilot WG ST ARM switch to INBD.
WING ARM FIRE switch on gunner cyclic stick f o r Depress and hold pilot WING ARM FIRE switch.
WING ARM FIRE switch on pilot cyclic stick. Check that XM-18 FIRED lights illuminate.
9-142
TM 55-1520-236-23
(11) Release pilot WING ARM FIRE switch.
Check that XM-18 FIRED lights extinguish.
Ensure cartridges are removed before
(12) P l a c e M A S T E R A R M s w i t c h t o O F F .
performing circuitry tests.
Depress and hold the pilot WING ARM FIRE switch.
Check that XM-18 FIRED lights do not illuminate. f. Wing Stores Jettison Circuitry Test. Open all
armament circuit breakers. Ensure that JETTISON
SELECT switches (21S4 and 21S5) on pilot
(13) Release WING ARM FIRE switch. Check miscellaneous panel are in OFF position. Ensure that
that XM-18 FIRED lights extinguish. WING STORES JETTISON switch (21S1) on gunner
instrument panel is in the down position and that
metal guard is in place over the switch toggle. Close
(14) Place gunner PLT OVRD switch to OFF. WING STORES JTSN circuit breaker. Check that no
Check that neither WING ARM FIRE switch will cause JETTISON lights on test set are illuminated and
XM-18 FIRED lights to illuminate and that XM-18 perform checkout procedures in accordance with
BAT CHG lights are extinguished. Table 9-33.
Table 9-33. Wing Stores Jettison Checklist Chart
Pilots OUTBD Pilots INBD Gunners Pilots CLTV Gunners CLTV
JETTISON JETTISON JETTISON JETTISON JETTISON
SELECT SELECT SELECT Switch Switch Results
Switch Switch Switch (21S3) (21S1) Test Set
STEP (21S5) (21S4) (21S2) Jettison Lights
(a) Close PLT JTSN Circuit breaker. No test set
jettison lights
(b) OFF OFF BOTH Depress & OFF No test set
Release jettison lights
(c) OFF OFF INBD Depress & OFF No test set
Release jettison lights
(d) OFF OFF OUTBD Depress & OFF No test set
Release jettison lights
(e) OUTBD OFF BOTH Depress & OFF Outboard lights
Release illuminate &
extinguish
approximately
0.5 second later
(f) OFF INBD BOTH Depress & OFF Inboard lights
Release illuminate &
extinguish
approximately
0.5 second later
(g) OUTBD INBD BOTH Depress & OFF Outboard and
Release inboard lights
illuminate &
extinguish
approximately
0.5 second later
9-143
TM 55-1520-236-23
Table 9-33. ~ Wing Stores Jettison Checklist Chart (Cont)
Pilots OUTBD Pilots INBD Gunners Pilots CLTV Gunners CLTV
JETTISON JETTISON JETTISON JETTISON JETTlSON
SELECT SELECT SELECT Switch Switch Results
Switch Switch Switch (21S3) (21S1) Test Set
STEP (21S5) (21S4) (21S2) Jettison Lights
(h) OUTBD INBD BOTH Released JTSN No test set
jettison lights
(i) OUTBD OFF BOTH Released JTSN No test set
jettison lights
(j) OFF INBD BOTH Released JTSN No test set
jettison lights
(k) OFF OFF BOTH Released OFF No test set
jettison lights
(1) Close GNR JTSN circuit breaker. No test set
jettison lights
(m) OFF OFF INBD Released JTSN Inboard lights
illuminate
(n) OFF OFF OUTBD Released JTSN Outboard lights
illuminate
(o) OFF OFF BOTH Released JTSN Outboard &
inboard lights
illuminate
(p) Insert jumper wires between pins A & C for both connectors 20P8J01 & 20S8J01
(q) OFF INBD BOTH Depress & OFF Outboard lights
Release illuminate &
extinguish
approximately
0.5 second later
(r) OFF OFF INBD Released JTSN Same as above,
except outboard
lights remain
illuminated
(s) Repeat step (n)
(t) Open GNRJTSN circuit breaker
(u) Repeat steps (b) through (k)
(v) Remove jumper wires from connectos 20P8J01 & 20S8J01
9-144
TM 55-1520-236-23
9-441. ~ TROUBLESHOOTING - WING applied to the main dc and ac buses, and
STORES ARMAMENT SYSTEMS the applicable circuit breakers are closed.
CIRCUITRY.
a. Troubleshooting - Rocket Launcher
Refer to paragraph F-9 in Appendix F for wiring Circuitry. Use Table 9-34 and perform checks as
diagram. necessary to isolate trouble. In the following table,
tripped circuit breakers are omitted from indications
NOTE of trouble. Such trouble is usually easily detected and
corrected. Broken wiring is always a probable cause
In the following troubleshooting of circuit malfunction or failure and has not been
procedures it is assumed that power is included.
NOTE
Before you use this table, be sure you
have performed all normal operational
checks. If you have a malfunction which
is not listed in this table, notify the next
higher level of maintenance.
Table 9-34. ~ Troubleshooting Rocket Launcher Circuitry
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. With MASTER ARM switch positioned to ARM, pilots and gunners amber ARMED indicators illuminated,
and WG ST ARM switch in either INBD or OUTBD position, amber wing stores ARMED light is not
illuminated.
STEP 1. Check for defective light, wiring and WG ST ARM switch.
Replace light or switch if defective. Repair any defective wiring (paragraph 9-16).
STEP 2. Check for defective turret system circuitry.
Refer to TM 9-1090-203 series maintenance manuals.
2. With WPNS FIRE and RKT PWR circuit breakers closed, MASTER ARM switch positioned to ARM, WG ST
ARM switch in either INBD or OUTBD position, amber wing stores ARMED light illuminated, but rockets do
not fire when WING STORES FIRE switch on pilot cyclic stick is pressed.
STEP 1. Check for defective wiring.
Repair any defective wiring (paragraph 9-16).
STEP 2. Check for defective WG ST ARM switch.
If defective, replace WG ST ARM switch (paragraph 9-16).
9-145
TM 55-1520-236-23
Table 9-34. ~Troubleshooting Rocket Launcher Circuitry (Cont)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
STEP 3. Check for defective WING ARM FIRE switch on pilot cyclic stick.
Handle in accordance with instruction pertinent to the cyclic stick (paragraph 11-30).
STEP 4. Check for defective master arm relay (19K31).
If defective, replace relay (paragraph 9-16).
STEP 5. Check for defective intervalometer.
If defective, replace intetvalometer.
With WPNS FIRE and RKT PWR circuit breakers closed, MASTER ARM switch positioned to ARM, WG ST
ARM switch in either INBD or OUTBD position, amber wing stores ARMED light illuminated, 19 rockets fire
when WING ARM FIRE switch on pilot cyclic stick is pressed, regardless of position of RKT PR SEL switch.
STEP 1. Check for defective RKT PR SEL switch.
If defective, replace switch (paragraph 9-16).
NOTE
Open circuit at RKT PR SEL switch fires all 19 rockets.
With WPNS FIRE and RKT PWR circuit breakers closed, MASTER ARM switch positioned to ARM, WG ST
ARM switch in either INBD or OUTBD position, amber wing stores ARMED light illuminated, one left wing
rocket fires but the right wing rocket does not fire when WING ARM FIRE switch is pressed.
STEP 1. Inspect for defective ground connections to airframe on right wing.
If defective, repair ground connectors.
STEP 2. Check for defective wiring.
If defective, repair wiring.
STEP 3. Check for defective connector (21J2) or (21P2), (21J4) or (21P4).
If defective, replace connector (paragraph 9-16).
STEP 4. Check for defective intervalometer.
If defective, replace intervalometer.
With WPNS FIRE and RKT PWR circuit breakers closed, MASTER ARM switch positioned to ARM, WG ST
ARM switch in either INBD or OUBD position, amber wing stores ARMED light illuminated, the right wing
rocket fires but the left wing rocket does not fire when WING ARM FIRE switch is pressed.
9-146
TM 55-1520-236-23
Table 9-34. ~ Troubleshooting Rocket Launcher Circuitry (Cont)
CONDTION
TEST OR INSPECTION
CORRECTIVE ACTION
STEP 1. Inspect for defective ground connections to airframe on left wing.
If defective, repair ground connections.
STEP 2. Check for defective wiring.
If defective, repair wiring.
STEP 3. Check for defective connector (21J1) or (21P1), (21J3) or (21P3).
If defective, replace connector (paragraph 9-16).
STEP 4. Check for defective intervalometer.
If defective, replace intervalometer.
6. With WPNS FIRE and RKT PWR circuit breakers closed, MASTER ARM switch positioned to ARM, WG ST
ARM switch in either INBD or OUTBD position, amber wing stores ARMED light illuminated, the OUTBD
rockets fire normally from both sides but the INBD rockets will not fire when pilot WING ARM FIRE switch is
pressed.
STEP 1. Check for defective wiring.
If defective, repair wiring.
STEP 2. Check for defective WG ST ARM switch.
If defective, replace switch (paragraph 9-16).
7. With WPNS FIRE and RKT PWR circuit breakers closed, MASTER ARM switch positioned to ARM, WG ST
ARM switch in either INBD or OUTBD position, amber wing stores ARMED light illuminated, the INBD
rockets fire normally from both sides but the OUTBD rockets will not fire when pilot WING ARM FIRE switch
is pressed.
STEP 1. Check for defective wiring.
If defective, repair wiring.
STEP 2. Check for defective WG ST ARM switch.
If defective, replace switch (paragraph 9-16).
8. With WPNS FIRE, RKT PWR, and TURRETPWR circuit breakers closed, PILOT OVRD switch in gunner control
panel in PILOT OVRD, WING STORES SELECT switch in either INBD or OUTBD position, rockets will not fire
when WING ARM FIRE switch on gunner cyclic stick is pressed.
9-147
TM 55-1520-236-23
Table 9-34. ~Troubleshooting Rocket Launcher Circuitry (Cont)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
STEP 1. Check for defective wiring.
If defective, repair wiring.
STEP 2. Check for defective WING ARM FIRE switch on gunner cyclic stick.
Handle in accordance with instructions pertinent to the cyclic stick (paragraph 11-54).
STEP 3. Check for defective RKT PR SEL switch (See item 3.)
If defective, replace switch (paragraph 9-16).
STEP 4. Check for defective RKT PWR circuit breaker.
If defective, replace circuit breaker (paragraph 9-23).
STEP 5. Check for defective master arm relay (19K31).
If defective, replace relay (paragraph 9-16).
STEP 6. Check for defective connector (21A1J1).
If defective, replace connector (paragraph 9-16).
STEP 7. Check for defective intervalometer.
If defective, replace intetvalometer.
STEP 8. Check for defective turret system circuitry.
Refer to TM 9-1090-203 series maintenance manuals.
9. With WPNS FIRE, RKT PWR, and TURRET PWR circuit breakers closed, PILOT OVRD switch in gunner control
panel in PILOT OVRD, WING STORES SELECT switch in either INBD or OUTBD position, the OUTBD rockets
fire normally from both sides, but INBD rockets do not fire when gunner WING ARM FIRE switch is pressed.
STEP 1. Check for defective wiring.
If defective, replace wiring.
STEP 2. Check for defective turret system circuitry.
Refer to TM 9-1090-203 series maintenance manuals.
9-148
TM 55-1520-236-23
Table 9-34. ~ Troubleshooting Rocket Launcher Circuitry (Cont)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
10. With WPNS FIRE, RKT PWR, and TURRET PWR circuit breakers closed, PILOT OVRD switch in gunner control
panel in PILOT OVRD, WING STORES SELECT switch in either INBD or OUTBD position, the INBD rockets fire
normally from both sides, but OUTBD rockets do not fire when gunner WING ARM FIRE switch is pressed.
STEP 1. Check for defective wiring.
If defective, replace wiring.
STEP 2. Check for defective turret system circuitry.
Refer to TM 9-1090-203 series maintenance manuals.
11. With switches and circuit breakers positioned to fire rockets, either INBD or OUTBD, rockets do not fire, from
the pilot cyclic stick, in the correct numbers of pairs as indicated by the setting of the RKT PR SEL switch.
STEP 1. Check for defective wiring.
If defective, repair wiring.
STEP 2. Check for defective RKT PR SEL switch, causing 19 pairs to fire.
If defective, replace switch (paragraph 9-16).
STEP 3. Check for defective intervalometer.
If defective, replace intervalometer.
9-149
TM 55-1520-236-23
b. Troubleshooting - X M - 1 8 M i n i g u n checks. If you have a malfunction which
Circuitry. is not listed in this table, notify the next
NOTE higher level of maintenance.
Before you use this table, be sure you
have performed all normal operational
Table 9-35. ~Troubleshooting XM-18 Minigun Circuitry
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. With WPNS FIRE and both L and R MINIGUN circuit breakers closed, MASTER ARM switch positioned to
ARM, WG ST ARM switch in INBD position, XM-18 minigunsdo not fire when pilot WING ARM FIRE switch is
pressed.
STEP 1. Check for defective wiring.
If defective, repair wiring.
STEP 2. Check for defective master arm relay (19K31).
If defective, replace relay (paragraph 9-16).
STEP 3. Check for defective WG ST ARM switch.
If defective, replace switch (paragraph 9-16).
STEP 4. Check for defective WING ARM FIRE switch on pilot cyclic stick.
Handle in accordance with instructions pertinent to the cyclic stick (paragraph 11-40).
2. With WPNS FIRE and both L and R MINIGUN circuit breakers closed, MASTER ARM switch positioned to
ARM, WG ST ARM switch in INBD position, one XM-18 minigun fires, but the other does not fire.
STEP 1. Check for defective ground connection to airframe on the side which does not fire.
If defective, repair ground connection.
STEP 2. Check for defective wiring.
If defective, repair wiring.
STEP 3. Check for defective wing disconnect connector (21Jl - 21P1 or 21J2 - 21P2) on the side which
does not fire.
If defective, replace connector (paragraph 9-16).
9-150
TM 55-1520-236-23
Table 9-35. Troubleshooting XM-18 Minigun Circuitry (Cont)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
STEP 4. Check for defective WING STORES MINIGUN circuit breaker which controls the side that does not
fire.
If defective, replace circuit breaker (paragraph 9-23).
3. With TURRET PWR circuit breakers and both L and R MINIGUN circuit breakers closed, PILOT OVRD switch
positioned to PILOT OVRD, and WING STORES SELECT switch in INBD position, neither XM-18 minigun
fires when AING ARM FIRE switch on gunner cyclic stick is pressed.
STEP 1. Check for defective wiring.
If defective, repair wiring.
STEP 2. Check for defective TURRET CONT circuit breaker.
If defective, replace circuit breaker.
STEP 3. Check for defective WING ARM FIRE switch on gunner cyclic stick.
Handle in accordance with instructions pertinent to the cyclic stick (paragraph 11-40).
STEP 4. Check for defective connector (21A9P1), (21A8P1), (21J1 - 21P1), (21J2 - 21P2).
If defective, replace connector (paragraph 9-16).
STEP 5. Check for defective turret system circuitry.
Refer to TM 9-1090-203 series maintenance manuals.
4. With TURRET CONT circuit breakers and both L and R MINIGUN circuit breakers closed, PILOT OVRD switch
positioned to PILOT OVRD, and WING STORES SELECT switch in INBD position, one XM-18 minigun fires,
but the other does not fire when gunner WING ARM FIRE switch is pressed.
STEP 1. Check for defective wiring.
If defective, repair wiring.
STEP 2. Check for defective TURRET CONT circuit breaker.
If defective, replace circuit breaker (paragraph 9-23).
STEP 3. Check for defective WING ARM FIRE switch on gunner cyclic stick.
Handle in accordance with instructions pertinent to the cyclic stick (paragraph 11-40).
9-151
TM 55-1520-236-23
Table 9-35. ~Troubleshooting XM-18 Minigun Circuitry (Cont)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
STEP 4. Check for defective connector (21A9P1), (21A8P1), (21J1 - 21P1), (21J2 - 21P2).
If defective, replace connector (paragraph 9-16).
STEP 5. Check for defective turret system circuitry.
Refer to TM 9-1090-203 maintenance manuals.
c. Troubleshooting - Wing Stores Jettison NOTE
Circuitry.
Before you use this table, be sure you
have performed all normal operational
checks. If you have a malfunction which
is not listed in this table, notify the next
higher level of maintenance.
Table 9-36. ~Troubleshooting Wing Stores Jettison Circuitry
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. WING STORES JTSN and PLT JTSN circuit breakers are closed. Pilot JETTISON SELECT switches are
positioned as required to jettison appropriate wing stores. Gunner JTSN SEL switch is in BOTH position and
gunner JETTISON switch is in OFF position. The appropriate (outboard, inboard, or both) wing stores do not
jettison when pilot collective JETTISON switch is depressed.
STEP 1. Check for defective wiring.
Replace or repair wiring.
STEP 2. Check for defective PLT JTSN or WING STORES JTSN circuit breakers. (21CB1 and/or 21CB2).
Replace defective circuit breaker(s) (paragraph 9-23).
9-152
TM 55-1520-236-23
Table 9-36. Troubleshooting Wing Stores Jettison Circuitry (Cont)
CONDTION
TEST OR INSPECTION
CORRECTIVE ACTION
STEP 3. Check for defective pilot collective JETTISON switch (21S3).
Replace defective switch (paragraph 9-16).
STEP 4. Check for defective pilot JETTISON SELECT switches (21S4 and/or 21S5).
Replace defective switch(es) (paragraph 9-16).
STEP 5. Check for defective or incorrectly installed diodes (21CR3, 21CR4).
Replace defective diodes (paragraph 9-16).
STEP 6. Check for defective pilot jettison switch relay (21K3).
Replace defective relay (paragraph 9-16).
STEP 7. Check for defective jettison control relay (21K2) or pilot jettison control relay (21K4).
Replace defective relay (paragraph 9-16).
2. With conditions same as condition 1, appropriate wing stores are jettisoned on one side, but not on the other
side when pilot collective JETTISON switch is depressed.
STEP 1. Check for defective wiring.
Replace defective connector (paragraph 9-16).
STEP 2. Check for defective wing disconnect connectors (21J1/21P1, 21J3/21P3 or 21J2/21P2,
21J4/21P4) on side that does not jettison properly.
Repair wiring if defective (paragraph 9-16).
3. WING STORES JETSN, PLT JTSN, and GNR JETSN circuit breakers are closed. Pilot JETTISON SELECT
switches are both positioned to OFF. Gunner JTSN SEL switch is positioned as required to jettison
appropriate wing stores. Pilot collective JETTISON switch is released. The appropriate (outboard, inboard, or
both) wing stores do not jettison when gunner JETTISON switch is positioned to JTSN.
STEP 1. Check for defective wiring.
Replace or repair wiring.
STEP 2. Check for defective GNR JTSN circuit breaker (21CB5).
Replace circuit breaker (paragraph 9-23).
STEP 3. Check for defective gunner JETTISON switch (21S1).
Replace defective switch (Refer to paragraph 9-16).
9-153
TM 55-1520-236-23
Table 9-36. Troubleshooting Wing Stores Jettison Circuity (Cont)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
STEP 4. Check for defective gunner JTSN SEL switch (21S2).
Replace defective switch (paragraph 9-16).
STEP 5. Check for defective or incorrectly installed diodes (21CR5, 21CR6)
Replace defective diodes (paragraph 9-16).
STEP 6. Check for defective gunner jettison control relay (21K5).
Replace defective relay (paragraph 9-16).
STEP 7. Check for defective jettison control relay (21K2).
Replace defective relay (paragraph 9-16).
4. With conditions same as condition 3, appropriate wing stores are properly jettisoned on one side but not on
the other side when gunner JETTISON switch is positioned to JTSN.
STEP 1. Check for defective wiring.
Repair wiring, if defective.
STEP 2. Check for defective wing disconnectors (21J1/21P1 , 21J3/21P3)or(21J2/21P2, 21J4/21P4)on
side that does not jettison properly.
Replace defective connector (paragraph 9-16).
SECTlON lX. ARMAMENT SYSTEMS CIRCUITRY
9-442. ARMAMENT SYSTEMS management subsystem, M-136 helmet sight
CIRCUITRY. system, and M65TOW missile subsystem. Functional
test and troubleshooting procedures are presented
for each armament subsystem circuitry. References
9-443. DESCRIPTION ARMAMENT are made to appropriate maintenance manuals
SYSTEMS CIRCUITRY. and/or chapters within this maintenance manual,
where applicable. See figure 9-23 for armament
The armament systems consists of the turret system, electrical equipment location illustrations and refer to
wing stores armament systems, XM-138 rocket paragraph F-9 in Appendix F for wiring diagrams.
9-154
TM 55-1520-236-23
Figure 9-23. q Armament Equipment Location (Sheet 1 of 2)
9-443.1 g ARMAMENT SYSTEM portion of the table establishes the weapon mode. The
RELAYS. lower portion of the table indicates that a relay is
energized by an X under the controlling switch.
a. Armament Relay Function Matrices. T h e b. Gunner Jettison Control Relay Matrix. Table
armament relay function matrices are designed to 9-36.7 shows the gunner wing stores jettison system
supplement the appropriate armament wiring diagram operation. The 7- or 19-tube rocket launcher portion of
and facilitate electrical troubleshooting. Tables 9-36.1 the table defines the relays energized for jettison
through 9-36.6 provide the switch positions that operation with 7- or 19-tube launchers installed. The 7-
establish the weapon mode and the switches tube and tube-launched, optically-tracked, wire
controlling relay action. Each table provides a different command link (TOW) launcher portion of the table
mode of weapon control. The operation of each relay is define the relays energized for jettison operation with
dependent on the weapon mode selected. The top TOW and 7-tube launchers installed.
Change 11 9-155
TM 55-1520-236-23
Figure 9-23
c. Pilot Jettison Control Relay Matrix. Table 9-36.8 (2) Function. The primary function of this relay is
shows the pilot wing stores jettison system operation. to turn on the emergency hydraulic pump relay to
The 7- or 19-tube rocket launcher portion of the table provide hydraulic pressure for flight controls. The
defines the relays energized for jettison operation with secondary function is to turn off power to the TOW
7- or 19-tube launchers installed. The 7-tube and TOW launcher hydraulic solenoid. This relay is bypassed in
launcher portion of the table define the relays energized the boresight function for ground operation when
for jettison operation with TOW and 7-tube launchers boresighting the TOW launchers. This is a 10-amp,
installed. 4-pole, socket-mounted relay.
d. Armament System Relay Locations. Relay (3) Relay contact logic.
locations are shown in Appendix E figure F-38.1.
(a) Contacts A - deenergized. Contacts A in
9-443.2 DESCRIPTION - the deenergized position supply voltage to the TOW
ARMAMENT a
SYSTEM RELAYS. launcher hydraulic solenoid from the servo electronic
control unit (SECU).
a . 1K5 - Emergency Hydraulic System Control
Relay.
(b) Contacts A - energized. Contacts A in the
energized position are open.
(1) Purpose. To enable activation of emergency
hydraulic pump when pressure is lost in hydraulic
(c) Contacts B. Contacts B are not used.
system 2.
9-156 Change 11
TM 55-1520-237-23
Table 9-36.1 Relay Matrix, Gunner in Control Mode - HSS Controlling Turret
209475-896-1
Change 11 9-156.1
TM 55-1520-236-23
Table 9-36.1 Relay Matrix, Gunner in Control Mode HSS Controlling Turret (Cont)
209475-896-2
9-156.2 Change 11
TM 55-1520-236-23
Table 9-36.2 Relay Matrix, Gunner in Control Mode TSU Controlling Turret
209475-895-1
Change 11 9-156.3
TM 55-1520-236-23
Table 9-36.2 Relay Matrix, Gunner in Control Mode - TSU Controlling Turret (Cont)
209475-895-2
9-156.4 Change 11
TM 55-1520-236-23
Table 9-36.3 Relay Matrix, Gunner Controlling TOW and Pilot Controlling Turret and Wing Stores Mode
209475-894-1
Change 11 9-156.5
TM 55-1520-236-23
Table 9-36.3 Relay Matrix, Gunner Controlling TOW and Pilot Controlling Turret and Wing Stores Mode (Cont)
9-156.6 Change 11
TM 55-1520-236-23
Table 9-36.4 q Relay Matrix, Pilot in Control Mode
209475-893-1
Change 11 9-156.7
TM 55-1520-236-23
Table 9-36.4 Relay Matrix, Pilot in Control Mode (Cont)
209475-893-2
9-156.8 Change 11
TM 55-1520-236-23
Table 9-36.5 Relay Matrix, Pilot Override Mode
209475-892-1
Change 11 9-156.9
TM 55-1520 -236-23
Table 9-36.5 Relay Matrix, Pilot Override Mode (Cont)
209475-892-2
9-156.10
Change 11
TM 55-1520-236-23
Table 9-36.6 Relay Matrix, TSU Acquisition of Target with Gunner or Pilot HSS Mode
209475-891-1
Change 11 9-156.11
TM 55-1520-236-23
Table 9-36.6 Relay Matrix, TSU Acquisition of Target with Gunner or Pilot HSS Mode (Cont)
209475-891-2
9-156.12
TM 55-1520-236-23
Table 9-36.7 Relay Matrix, Gunner Jettison Mode
Ensure jettison cartridges are removed from
ejector racks before performing checks.
NOTE
Ensure WING STORES JTSN, GNR JTSN, and
PLT JTSN circuit breakers are closed.
x Relay energized
* Relay 21K2 is not controlled by any switch; rather, it is energized anytime right or left
lower outboard TOW launcher is electrically connected.
** Relay 21K5 cannot be energized if 21K2 is energized.
209475-882
Change 11 9-156.13
TM 55-1520-237-23
Table 9-36.8
Ensure jettison cartridges are removed from
ejector racks before performing checks.
NOTE
Ensure WING STORES JTSN, GNR JTSN, and
PLT JTSN circuit breakers are closed.
x Relay energized
* Relay 21K2 is not controlled by any switch; rather, it is energized anytime right or left
lower outboard TOW launcher is electrically connected.
** Relay 21K4 cannot be energized if 21K2 is energized; also, relay 21K4 cannot be
energized unless 21K3 is energized.
209475-881
9-156.14 Change 11
TM 55-1520-236-23
(d) Contacts C - deenergized. Contacts C in deenergized position are in the circuit from the TRU bus
the deenergized position are open. to the coil of 2K12.
(e) Contacts C - energized. Contacts C in the (e) Contacts auxiliary 13 and 14 - energized.
energized position turn on the emergency hydraulic Auxiliary contacts 13 and 14 in the energized position
pump relay (1K4). are open and 2K12 cannot be energized.
(f) Contacts D. Contacts D are not used. d. 2K17 - Armament Control Relay.
b. 2K12 - Transformer Rectifier Unit Armament (1) Purpose. This relay controls which voltage
Relay. source is supplied to the armament bus.
(1) Purpose. To supply voltage to the armament (2) Function. If the generator is operating, 2K13
bus from the transformer rectifier unit (TRU). will supply voltage to the armament bus. If the
generator is not operating and the alternator is, the
(2) Function. This relay supplies voltage to the TRU will supply voltage to the armament bus through
armament bus when the MASTER ARM switch is on if 2K12. This is a 10-amp, 4-pole, socket-mounted relay.
there is no voltage on the transfer bus. Relay 2K12
cannot be energized if 2K13 is energized. This is a (3) Relay contact logic.
200-amp, single-pole relay.
(a) Contacts A - deenergized. Contacts A in
(3) Relay contact logic. the deenergized position are open.
(a) Contacts A - deenergized. Contacts A in (b) Contacts A - energized. Contacts A in the
the deenergized position are open. energized position will allow 2K12 to energize if 2K13
is not energized.
(b) Contacts A - energized. Contacts A in the
energized position connect the TRU bus to the (c) Contacts B - deenergized. Contacts Bin
armament bus. the deenergized position are open.
c. 2K13 - Armament Relay. (d) Contacts B - energized. Contacts B in the
energized position provide voltage to the coil of 2K13.
(1) Purpose. To supply voltage to the armament
bus from the generator or the ground power unit. (e) Contacts C - deenergized. Contacts C in
the deenergized position are open.
(2) Function. This relay supplies voltage to the
armament bus when the MASTER ARM switch is on (f) Contacts C - energized. Contacts C in the
and there is voltage on the transfer bus. This is a 200- energized position determine the voltage source for the
amp, single-pole relay, with auxiliary contacts. armament system, i.e., generator, external power, or
TRU.
(3) Relay contact logic.
(g) Contacts D. Contacts D are not used.
(a) Contacts A - deenergized. Contacts A in
the deenergized position are open.
e. 2K20 - Reverse Current Control in Action
(b) Contacts A - energized. Contacts A in the Relay.
energized position connect the armament bus to the
transfer bus. (1) Purpose. To lock the reverse current relay in
the on condition during turret action.
(c) Contacts auxiliary 11 and 12. Auxiliary
contacts 11 and 12 are not used. (2) Function. To eliminate contact chatter during
turret operation. This is a 10-amp, 2-pole, time-delay-
(d) Contacts auxiliary 13 and 14 - on-dropout relay.
deenergized. Auxiliary contacts 13 and 14 in the
Change 11 9-156.15
TM 55-1520-236-23
(3) Relay contact logic. (2) Function. This relay is controlled by the turret
gun control assembly. When the standby power is
(a) Contacts A - deenergized. Contacts A in applied to the gun control assembly, it turns on the
the deenergized position are open. 19K7 relay approximately 2.0 seconds later. This is a
200-amp, single-pole relay.
(b) Contacts A - energized. Contacts A (pins
C, F, and B) in the energized position connect the (3) Relay contact logic.
reverse current relay terminal APP to terminal SW.
(a) Contacts A - deenergized. Contacts A in
(c) Contacts B. Contacts B (pins D, H, and G) the deenergized position are open.
are not used.
(b) Contacts A - energized. Contacts A in the
f. 19K5 - Turret Gun Power Relay. energized position connect the armament bus to the
turret control assembly.
(1) Purpose. This relay supplies voltage to the
turret for gun motor drive. i. 19K8 - Burst Limit Relay.
(2) Function. When the TRIGGER TURRET FIRE (1) Purpose. To control turret gunfire mode either
burst limit or continuous fire.
switch is pressed, the turret logic control will close
19K5 to fire the gun if all the turret fire constraints have
(2) Function. This relay is in the burst limit circuit
been complied with. This is a 100-amp, single-pole
relay. to the turret gun control assembly and is controlled by
the second detent of the TRIGGER TURRET FIRE
switch. This is a 10-amp, 2-pole, socket-mounted
(3) Relay contact logic.
relay.
(a) Contacts A - deenergized. Contacts A in
(3) Relay contact logic.
the deenergized position are open.
(a) Contacts A - deenergized. Contacts A in
(b) Contacts A - energized. Contacts A in the the deenergized position are in the circuit to the gun
energized position apply voltage to the gun drive motor
control assembly to provide burst limit anytime the
in the turret.
TRIGGER TURRET FIRE switch is pressed.
g. 19K6 - Ammo Load Relay.
(b) Contacts A - energized. Contacts A in the
energized position open the burst limit circuit to allow
(1) Purpose. This relay provides the power for continuous turret fire.
the ammo booster motor on the ammo can.
(c) Contacts B. Contacts B are not used.
(2) Function. This relay is controlled by the turret
system to assist ammo feed during gunfire. This is a j. 19K31 - Master Arm Relay.
25-amp, single-pole relay.
(1) Purpose. To provide master arm power to
(3) Relay contact logic. each weapon system.
(a) Contacts A - deenergized. Contacts A in
(2) Function. The master arm relay is controlled
the deenergized position are open.
by the ARM position of the MASTER ARM switch,
Master arm power is required to fire any weapon. This
(b) Contacts A - energized. Contacts A in the is a 10-amp, 4-pole, screw-terminal relay.
energized position apply voltage to the ammo booster
motor on the ammo can.
(3) R e l a y contact logic.
h. 19K7 - Turret Power Relay. (a) Contacts A - deenergized. Contacts A in
the deenergized position supply voltage through the
(1) Purpose. To supply 28 Vdc power to the weapon standby relay (19K38) to the pilot and gunner
turret control assembly for turret drive. STBY light.
9-156.16 Change 11
TM 55-1520-236-23
(b) Contacts A - energized. Contacts A in the (f) Contacts C - energized. Contacts C in the
energized position supply voltage through the weapon energized position provide standby power to 19TB4
standby relay (19K38) to the pilot and gunner ARMED block 4 for distribution and logic control.
light.
(g) Contacts D - deenergized. Contacts D in
(c) Contacts B - deenergized. Contacts B in the deenergized position are open.
the deenergized position are open.
(h) Contacts D - energized. Contacts D in the
(d) Contacts B - energized. Contacts B in the energized position supply 115 Vac from the TURRET
energized position supply voltage from the TURRET PWR circuit breaker to the turret gun control assembly.
CONTR circuit breaker to the turret gun control
assembly. l. 19K59 - Weapon Control Relay.
(e) Contacts C. Contacts C are not used. (1) Purpose. To switch the turret range control
from the gunner to the pilot when the pilot has control
(f) Contacts D - deenergized. Contacts D in of the turret.
the deenergized position are open.
(2) Function. In the pilot-in-control mode or TOW
(g) Contacts D - energized. Contacts D in the mode, the pilot has control of the turret and 19K59 is
energized position supply voltage from the WING energized. This is a 10-amp, 4-pole, socket-mounted
STORE PWR circuit breaker to the rocket management relay.
system.
(3) Relay contact logic.
k. 19K38 - Weapon Standby Relay. (a) Contacts A. Contacts A are not used.
(1) Purpose. To provide standby power and (b) Contacts B. Contacts B are not used.
control for each weapon system.
(c) Contacts C - deenergized. Contacts C in
(2) Function. The weapon standby relay allows the deenergized position connect the MED (1.5 km)
control and operation of each weapon system. It is position of the gunner RANGE switch to the interface
controlled by the STBY position of the MASTER ARM control unit (IFCU).
switch. This is a 10-amp, 4-pole, socket-mounted
relay. (d) Contacts C - energized. Contacts C in the
energized position connect the MED (1.5 km) position
(3) Relay contact logic. of the pilot RANGE switch to the IFCU.
(a) Contacts A - deenergized. Contacts A in (e) Contacts D - deenergized. Contacts D in
the deenergized position are open. the deenergized position connect the SHORT (1 km)
position on the gunner RANGE switch to the IFCU.
(b) Contacts A - energized. Contacts A in the
energized position supply power from the WPN CONTR (f) Contacts D - energized. Contacts D in the
circuit breaker to 19K31 for control of the STBY and energized position connect the SHORT (1 km) position
ARMED lights on the pilot and gunner control panels. on the pilot RANGE switch to the IFCU.
(c) Contacts B - deenergized. Contacts B in m. 19K80 - Gunner Pilot Override Relay.
the deenergized position are open.
(1) Purpose. To allow the gunner to take control
(d) Contacts B - energized. Contacts B in the of the weapons if the pilot is disabled.
energized position provide standby power to the turret
gun control assembly. (2) Function. The override mode allows the
gunner to fire the turret and rocket system from his
(e) Contacts C - deenergized. Contacts C in cyclic grip while flying the helicopter. This is a 10-amp,
the deenergized position are open. 6-pole, socket-mounted relay.
Change 11 9-156.17
TM 55-1520-236-23
(3) Relay contact logic. (3) Relay contact logic.
(a) Contacts A - deenergized. Contacts A in (a) Contacts A - deenargized. Contacts A in
the deenergized position provide weapon control the deenergized position provide voltage to allow the
power to the WPN CONTR switch. pilot helmet sight to control the turret.
(b) Contacts A - energized. Contacts A in the (b) Contacts A - energized. Contacts A in the
energized position provide weapon control power to energized position are open.
the gunner TRIGGER ACTION switch.
(c) Contacts B - deenergized. Contacts B in
(c) Contacts B - deenergized. Contacts B in the deenergized position are in the circuit to the turret
the deenergized position provide arm power to the ground depression limit.
WPN CONTR switch.
(d) Contacts B - energized. Contacts B in the
(d) Contacts B - energized. Contacts B in the energized position open the ground depression limit
energized position provide arm power to the gunner circuit.
TRIGGER ACTION switch.
(e) Contacts C. Contacts C are not used.
(e) Contacts C - deenergized. Contacts C in
the deenergized position provide arm power to the pilot (f) Contacts D - deenergized. Contacts D in
WING ARM FIRE switch. the deenergized position provide voltage to the pilot
TRIGGER TURRET FIRE switch when the WPN CONTR
(f) Contacts C - energized. Contacts C in the switch is in the PILOT position.
energized position provide arm power to the gunner
WING ARM FIRE switch. (g) Contacts D - energized. Contacts D in the
energized position provide voltage to the pilot TRIGGER
(g) Contacts D - deenergized. Contacts D in TURRET FIRE switch when the WPN CONTR switch is
the deenergized position are open. in the FIXED position.
(h) Contacts D - energized. Contacts D in the o. 19K82 - Pilot Trigger Disable Relay.
energized position provide weapon fire voltage to
energize the master arm relay (19K31). (1) Purpose. Relays 19K82 and 19K85 are used
together to provide a controlled interrupt sequence of
(i) Contacts E. Contacts E are not used. the pilot trigger and action circuits during TOW missile
launch.
(j) Contacts F - deenergized. Contacts F in
the deenergized position are open. (2) Function. Relay 19K82 is controlled by the
launcher activate signal from the TOW stabilization
(k) Contacts F - energized. Contacts F in the control amplifier (SCA). This is a 10-amp, 2-pole, time-
energized position provide weapon control voltage to delay-on-dropout relay. The time is fixed at 0.5 second.
the weapon standby relay (19K38).
(3) Relay contact logic.
n . 1 9 K 8 1 - Fixed Forward Relay.
(a) Contacts A - deanergized. Contacts A
(1) Purpose. To switch additional circuits when (pins C and F) in the deenergized position are open.
the WPN CONTR switch is in the FIXED position.
(b) Contacts A - energized. Contacts A (pins
(2) Function. Relay 19K81 switches the pilot F and B) in the energized position provide a ground for
TRIGGER TURRET FIRE switch to the fixed mode and the coil of 19K85.
opens the action and ground depression limit circuits.
This is a 10-amp, 4-pole, socket-mounted relay. (c) Contacts B. Contacts B (pins D, G, and H)
are not used.
9-156.18 Change 11
TM 55-1520-236-23
p. 19K83 - Pilot Action Disable Relay. (e) Contacts C - deenergized. Contacts C in
the deenergized position are open.
(1) Purpose. To detect separation of pilot helmet
sight and control arm. (f) Contacts C - energized. Contacts C in the
energized position provide a ground for the gunner
(2) Function. To open the pilot action circuit and helmet sight reticle.
turn off the sight reticle when the control arm is not
connected to the pilot helmet. This is a 10-amp, 2-pole, (g) Contacts D. Contacts D are not used.
socket-mounted relay.
(3) Relay contact logic. r. 19K85 - Pilot Trigger/Action Disable Relay.
(a) Contacts A - deenergized. Contacts A in (1) Purpose. To disable pilot trigger and action
the deenergized position are open. circuits during TOW missile launch.
(b) Contacts A - energized. Contacts A in the (2) Function. The TOW trigger signal will engage
energized position are in the pilot action circuit to 19K85 if 19K82 is engaged and 19K85 will stay closed
complete the circuit from the pilot TRIGGER ACTION after the trigger is released as long as 19K82 remains
switch to the electronic interface assembly (EIA). closed. This provides controlled interrupt sequence of
the pilot trigger and action circuits of approximately 3
(c) Contacts B - deenergized. Contacts B in seconds during TOW missile launch. This is a 10-amp,
the deenergized position are open. 2-pole, socket-mounted relay.
(d) Contacts B - energized. Contacts B in the
energized position are in the circuit to the pilot helmet (3) Relay contact logic.
sight reticle.
(a) Contacts A - deenergized. Contacts A in
q. 19K84 - Gunner Action Disable Relay. the deenergized position are in the circuit to provide
voltage to the pilot TRIGGER ACTION switch when in
(1) Purpose. To detect separation of gunner the TOW mode.
helmet sight and control arm.
(b) Contacts A - energized. Contacts A in the
(2) Function. To open the gunner TRIGGER energized position are open.
ACTION switch circuit and turn off the helmet sight
reticle when the helmet is not connected to the control (c) Contacts B - deenergized. Contacts B in
arm. This is a 10-amp, 4-pole, socket-mounted relay. the deenergized position are in the circuit to provide
voltage to the pilot TRIGGER TURRET FIRE switch
(3) Relay contact logic. when in the TOW mode.
(a) Contacts A - deenergized. Contacts A in (d) Contacts B - energizad. Contacts B in the
the deenergized position are open. energized position apply voltage to the coil of 19K85
and will remain closed until 19K82 opens.
(b) Contacts A - energized. Contacts A in the
energized position are in the circuit from the gunner
TRIGGER ACTION switch to the turret and are active s. 19K86 - Pilot Trigger/Action Activation Relay.
only in pilot override mode.
(c) Contacts B - deenergized. Contacts B in (1) Purpose. To provide the pilot control of the
the deenergized position send the telescopic sight unit turret when the gunner is in a TOW Mode.
(TSU) left-hand grip (LHG) action signal to the IFCU.
(2) F u n c t i o n . Relay 19K86 is controlled by
(d) Contacts B - energized. Contacts B in the 19K87 to give the pilot control of the turret when in the
energized position send the TSU left-hand grip (LHG) TOW mode. This is a 10-amp, 2-pole, socket-mounted
action signal to the turret. relay.
Change 11 9-156.19
TM 55-1520 -237-23
(3) Relay contact logic. left-hand grip (LHG) TRIGGER switch (first detent) to
the turret.
(a) Contacts A - deenergized. Contacts A in
the deenergized position are open. (h) Contacts D - energized. Contacts D in the
energized position provide a circuit from the TSU left-
(b) Contacts A - energized. Contacts A in the hand grip (LHG) TRIGGER switch (first detent) to the
energized position provide voltage to the pilot TRIGGER TOW system.
ACTION switch through 19K85.
u. 19K88 - Action Interrupt Relay.
(c) Contacts B - deenergized. Contacts B in
the deenergized position are open. (1) Purpose. To open the turret action circuit
during TSU acquisition mode.
(d) Contacts B - energized. Contacts B in the
energized position are used to place the gun in a zero (2) Function. This relay is controlled by the
elevation position through 19K85. gunner ACQ/TRK/STOW and PHS ACQ switches to
open the action circuit to the turret when no sight
t. 19K87 - TOW/Turret Relay. signal is available to the turret. This is a 10-amp,
2-pole, socket-mounted relay.
(1) Purpose. To transfer the gunner left-hand grip
LHG) action and trigger circuits from the turret to the (3) Relay contact logic.
TOW system.
(a) Contacts A - deenergized. Contacts A in
(2) Function. To give the pilot control of the the deenergized position are in the action circuit to the
turret when the gunner takes control of the TOW. This turret.
is a 10-amp, 4-pole, socket-mounted relay.
(b) Contacts A - energized. Contacts A in the
(3) Relay contact logic. energized position open the action circuit to the turret.
(a) Contacts A - deenergized. Contacts A in (c) Contacts B. Contacts B are not used.
the deenergized position are in the circuit from the TSU
left-hand grip (LHG) ACTION switch to the turret.
v. 1 9 K 9 1 - Gunner Armament Light Dimming
Relay.
(b) Contacts A - energized. Contacts A in the
energized position are open. NOTE
(c) Contacts B - deenergized. Contacts B in N V G light dimming system will be
the deenergized position provide a voltage to the pilot deactivated with the incorporation of MWO
TRIGGER ACTION switch to enable the pilot to 55-1520-236-50-4.
interrupt gunner turret fire.
(1) Purpose. To control dimming of the gunner
(d) Contacts B - energized. Contacts B in the PILOT IN CONT, ARMED, and STBY lights when in the
energized position provide a voltage to the pilot night vision goggle (NVG) mode.
TRIGGER ACTION switch for control of the turret.
(2) Function. Relay 19K91 is controlled by the LT
(a) Contacts C - deenergized. Contacts C in switch on the gunner miscellaneous control panel. If
the deenergized position are in the circuit from the TSU the gunner is in the pilot override mode, 19K91 is
left-hand grip (LHG) TRIGGER switch (second detent) controlled by the LTS switch on the gunner cyclic grip.
to the turret burst limit relay (19K8). This is a 10-amp, 4-pole, socket-mounted relay.
(f) Contacts C - energized. Contacts C in the (3) Relay contact logic.
energized position are open.
(a) Contacts A - deenergized. Contacts A in
(g) Contacts D - deenergized. Contacts D in the deenergized position provide full voltage to the
the deenergized position provide a circuit from the TSU gunner STBY light.
9-156.20 Change 11
TM 55-1520-236-23
(b) Contacts A - energized. Contacts A in the (d) Contacts B - energized. Contacts B in the
energized position provide a reduced voltage to the energized position provide reduced voltage to the pilot
gunner STBY light through resistor 19R5. ARMED light through resistor 19R14.
(c) Contacts B - deenergized. Contacts B in x. 19K95 - Track Rate Turret Status Relay.
the deenergized position provide full voltage to the
gunner ARMED light. (1) Purpose. To open the turret status circuit to
the telescopic sight unit (TSU) when in the TOW Mode.
(d) Contacts B - energized. Contacts B in the
energized position provide a reduced voltage to the (2) Function. When a TOW mode is selected by
gunner ARMED light through resistor 19R6. the gunner, 19K95 interrupts the gun flag signal to the
TSU and the stabilization control amplifier (SCA). Relay
(e) Contacts C - deenergized. Contacts C in 19K95 also energizes the fixed forward relay (19K81)
the deenergized position provide full voltage to the to place the turret in a fixed forward position. This is a
gunner PILOT IN CONT light. 10-amp, 2-pole, socket-mounted relay.
(f) Contacts C - energized. Contacts C in the (3) Relay contact logic.
energized position provide a reduced voltage to the
gunner PILOT IN CONT light through resistor 19R15. (a) Contacts A - deenergized. Contacts A in
the deenergized position are in the turret status circuit
(g) Contacts D. Contacts D are not used. to the TSU and the SCA.
w. 19K92 - Pilot Armament Light Dimming Relay. (b) Contacts A - energized. Contacts A in the
energized position are open.
NOTE
(c) Contacts B - deenergized. Contacts B in
NVG light dimming system will be the deenergized position are open.
deactivated with the incorporation of MWO
55-1520-236-50-4. (d) Contacts B - energized. Contacts B in the
energized position energize the fixed forward relay
(1) Purpose. To control the light level for ARMED (19K81) to position the gun to 0 azimuth and 0
and STBY lights. elevation.
(2) Function. If the pilot NVG ENBL switch is y. 19K98 - Pilot Action Enable Relay.
positioned to NVG ENBL, the NVG position of the LTS
switch on the pilot cyclic grip will control 19K92 and (1) Purpose. To apply a voltage to the pilot cyclic
place the pilot armament lights in the night vision TRIGGER TURRET FIRE switch.
mode. This is a 10-amp, 2-pole, socket-mounted relay.
(2) Function. In the TOW mode and pilot-in-
(3) Relay contact logic. control mode, 19K98 is controlled by the pilot
TRIGGER ACTION switch to apply voltage to the pilot
TRIGGER TURRET FIRE switch. This is a 10-amp,
(a) Contacts A - deenergized. Contacts A in
the deenergized position provide full voltage to the pilot 2-pole, socket-mounted relay.
STBY light.
(3) Relay contact logic.
(b) Contacts A - energized. Contacts A in the
energized position provide reduced voltage to the pilot (a) Contacts A - deenergized. Contacts A in
STBY light through resistor 19R13. the deenergized position are open.
(c) Contacts B - deenergized. Contacts B in (b) Contacts A - energized. Contacts A in the
the deenergized position provide full voltage to the pilot energized position provide voltage to the pilot TRIGGER
ARMED light. TURRET FIRE switch to fire the turret gun.
Change 11 9-156.21
TM 55-1520-236-23
(c) Contacts B - deenergized. Contacts B in (3) Relay contact logic.
the deenergized position, when the TOW mode is
selected, energize the fixed forward relay (19K81), to (a) Contacts A - deenergized. Contacts A in
position the gun at 0 azimuth and 0 elevation. the deenergized position ground the super elevation
signal at the IFCU.
(d) Contacts B - energized. Contacts B in the
energized position are open to allow the pilot TRIGGER (b) Contacts A - energized. Contacts A in the
ACTION switch to control the turret. energized position connect the super elevation signal at
the IFCU to the range high circuit in the IFCU.
z. 19K101 - Reticle Flasher Bypass Relay.
(c) Contacts B. Contacts B are not used.
(1) Purpose. To provide a steady reticle in the
helmet sight prior to TRIGGER ACTION switch ab. 19K106 - Wing Stores Enable Relay.
activation.
(1) Purpose. This relay enables the pilot to
interrupt turret fire by the gunner and to fire wing
(2) Function. The sight reticle is controlled by a
circuit in the turret control assembly and is designed to stores.
flash anytime the gun cannot fire. Relay 19K101
provides a steady reticle until the TRIGGER ACTION (2) Function. With the WPN CONTR switch in
switch is pressed to transfer the reticle control to the the GUNNER position, 19K106 will close. This allows
turret control assembly. This is a 10-amp, 2-pole, the pilot TRIGGER ACTION switch to interrupt gunner
socket-mounted relay. turrat fire. When the turret reaches the stow position it
will enable the WING ARM FIRE switch. This is a
(3) Relay contact logic. 10-amp, 2-pole, socket-mounted relay.
(3) Relay contact logic.
(a) Contects A - deenergized. Contacts A in
the deenergized position provide a ground to the IFCU (a) Contacts A - deenergized. Contacts A in
reticle return. the deenergized position allow the pilot TRIGGER
ACTION switch to control the turret.
(b) Contacts A - energized. Contacts A in the
energized position connect the IFCU reticle control to (b) Contacts A - energized. Contacts A in the
the turret control assembly. energized position allow the pilot TRIGGER ACTION
switch to interrupt the gunner action circuit and send
(c) Contacts B - deenergized. Contacts B in the turret to the 0 azimuth position so that rockets can
the deenergized position are open. be fired.
(d) Contacts B - energized. Contacts B in the
(c) Contacts B. Contacts B are not used.
energized position (closed) will keep 19K101 energized
until the pilot releases his TRIGGER ACTION switch. ac. 20K1 - TOW Missile System Interlock Relay.
This allows the gunner reticle to flash when the pilot is
firing rockets.
(1) Purpose. To provide safety switching
function if the TOW electronic power supply (EPS) fails.
aa. 19K102 - Range Enable Relay.
(2) Function. This relay is energized when the
( 1 ) P u r p o s e . To allow range inputs to be TOW power supply has an output. This is a 10-amp,
sccepted by the IFCU. 4-pole, socket-mounted relay.
(2) Function. This relay is controlled by master (3) Relay contact logic.
arm voltage. This relay opens the ground signal into the
iFCU to allow a range signal to be accepted from the (a) Contacts A - deenergized. Contacts A in
piiotor gunner. This is a 10-amp, 2-pole, the deenergized position (closed) will disable the turret
socket-mounted relay. action circuit if TRK is selected and TCP MODE SELECT
switch is in STBY TOW or ARMED position.
9-156.22 Change 11
TM 55-1520-236-23
(b) Contacts A - energized. Contacts A in the voltage to the inboard wing stations for the M-18. This
energized position are open. is a 20-amp, 3-pole, screw-terminal relay.
(c) Contacts B - deenergized. Contacts B in (3) Relay contact logic.
the deenergized position are open.
(a) Contacts A - deenergized. Contacts A in
(d) Contacts B - energized. Contacts B in the the deenergized position are open.
energized position provide control circuit to the TOW
blower thermal switch for the tailboom TOW blower. (b) Contacts A - energized. Contacts A in the
energized position provide voltage from the WING
(e) Contacts C - deenergized. Contacts C in STORE RH GUN circuit breaker to the right inboard
the deenergized position are open. wing M-18 disconnect for battery charging.
(f) Contacts C - energized. Contacts C in the (c) Contacts B - deenergized. Contacts B in
energized position provide a circuit from the SCA to the the deenergized position are open.
TSU gun flags.
(d) Contacts B - energized. Contacts B in the
(g) Contacts D. Contacts D are not used. energized position provide voltage from the WING
STORE LH GUN circuit breaker to the LH inboard wing
ad. 20K84 - TSU Track Rate Select Relay. M-18 disconnect for battery charging.
(1) Purpose. To allow the TSU to slew at a slow (e) Contacts C. Contacts C are not used.
rate in the gun mode, when TSU high magnification is
selected. af. 21K2 - Jettison Control Relay.
(2) Function. This relay is controlled by the (1) Purpose. To prevent jettison of inboard wing
gunner RANGE switch. This is a 10-amp, 2-pole r stores if lower missile launchers are installed outboard.
socket-mounted relay.
(2) Function. Relay 21K2 will open the inboard
(3) Relay contact logic. jettison circuits and route the jettison signal to the
outboard stations if inboard stores are selected for
(a) Contacts A - deenergized. Contacts A in jettison when lower missile launchers are installed.
the deenergized position connect the weapon select When the electrical connector of each lower missile
circuit from the TOW control panel to the SCA. launcher separates, relay 21K2 relay will deenergize
and route the jettison signal to the inboard stations.
(b) Contacts A - energized. Contacts A in the This is a 10-amp, 2-pole, socket-mounted relay.
energized position supply 10 Vdc from the TOW
control panel to the SCA. (3) Relay contact logic.
(c) Contacts B - deenergized. Contacts B in (a) Contacts A - deenergized. Contacts A in
the deenergized position are open. the deenergized position connect the pilot inboard
jettison circuits to the inboard stores stations.
(d) Contacts B - energized. Contacts B in the
energized position connect the TSU gun flag light to the (b) Contacts A - energized. Contacts A in the
turret status circuit in the SCA. energized position open the pilot inboard stores jettison
circuits and send the inboard jettison signal to the
outboard stores stations.
ae. 21K1 - M-18 Power Relay.
(c) Contacts B - deenergized. Contacts B in
(1) Purpose. To allow M-18 battery charging the deenergized position connect the gunner inboard
without arming the system. stores jettison circuits to the inboard stores stations.
(2) Function. This relay is energized anytime (d) Contacts B - energized. Contacts B in the
standby power is on and provides battery charging energized position open the gunner inboard stores
Change 11 9-156.23
TM 55-1520-237-23
jettison circuits and send the inboard jettison signal to (c) Contacts B. Contacts B (pins C, F, and B)
the outboard stores stations. are not used.
ag. 21K3 - Pilot Jettison Switch Relay. ai. 21K5 - Gunner Jettison Control Relay.
(1) Purpose. To ensure the pilot jettison signal is (1) Purpose. To prevent simultaneous jettison of
maintained long enough for jettison sequence inboard and outboard wing stores. Inboard stores are
completion. always delayed for 0.5 second.
( 2 ) F u n c t i o n . When the pilot releases his (2) Function. This relay delays the gunner
JETTISON pushbutton switch, 21K3 will maintain the inboard stores jettison signal for 0.5 second and then
jettison command for one second. This is a 10-amp, sends it to the inboard stations to jettison stores. This
2-pole, time-delay-on-dropout relay. The time delay is is a 10-amp, 2-pole, time-delay-on-pull-in relay. The
1.0 second. time delay is 0.5 second.
(3) Relay contact logic. (3) Relay contact logic.
(a) Contacts A - deenergized. Contacts A in (a) Contacts A - deenergized. Contacts A in
the deenergized position (pins C and F) ground the pilot the deenergized position (pins D and H) ground the left
left and right outboard stores jettison circuits. and right inboard stores jettison circuits.
(b) Contacts A - energized. Contacts A in the (b) Contacts A - energized. Contacts A in the
energized position (pins F and B) remove the ground energized position (pins D and G) open the ground and
from the left and right outboard stores jettison circuits. apply voltage to the inboard stores jettison circuits.
(c) Contacts B - deenergized. Contacts B in (c) Contacts B. Contacts B (pins C, F, and B)
the deenergized position (pins D and H) are open. are not used.
(d) Contacts B - energized. Contacts B in the aj. 21K6 - Wing Stores Disable Relay.
energized position (pins D and H) apply voltage to the
pilot JETTISON SELECT switches. (1) Purpose. To disable rocket fire when the TOW
missile is fired and missile is in flight.
ah. 21K4 - Pilot Jettison Control Relay.
(2) Function. This relay prevents rocket firing
(1) Purpose. To prevent simultaneous jettison of from the time the left-hand grip TRIGGER is pressed
inboard and outboard wing stores. Inboard stores are until after TOW wire cut. This is a 10-amp, 2-pole,
always delayed for 0.5 second. socket-mounted relay.
(2) F u n c t i o n . W h e n t h e p i l o t p r e s s e s t h e (3) Relay contact logic.
JETTISON switch, 21K4 relay will delay for 0.5 second
and then energize and send a signal to the inboard (a) Contacts A. Contacts A are not used.
stations to jettison stores. This is a 10-amp, 2-pole,
time-delay-on-pull-in relay. The time delay is 0.5 (b) Contacts B - deenergized. Contacts B in
second. the deenergized position are in the pilot WING ARM
FIRE switch circuit.
(3) Relay contact logic.
(c) Contacts B - energized. Contacts B in the
(a) Contacts A - deenergized. Contacts A in energized position open the circuit to the pilot WING
the deenergized position (pins D and H) ground the left ARM FIRE switch.
and right inboard stores jettison circuits.
ak. 21K7 - Action Disable Relay.
(b) Contacts A - energized. Contacts A in the
energized position (pins D and G) open the ground and (1) Purpose. To stow turret and stop firing during
apply voltage to the inboard stores jettison circuits. rocket fire.
9-156.24 Change 11
TM 55-1520-236-23
( 2 ) F u n c t i o n . The WING ARM FIRE switch 9-446. q F U N C T I O N A L T E S T -
energizes this relay. It will remain energized for 0.5 UNIVERSAL TURRET SYSTEM CIRCUITRY.
second after the WING ARM FIRE switch is released.
This is a 10-amp, 2-pole, time-delay-on-dropout relay. a. R e q u i r e m e n t s .
The time delay is 0.5 second.
(1) Test equipment.
(3) Relay contact logic.
(a) Auxiliary power. G r o u n d p o w e r u n i t
(a) Contacts A - deenergized. Contacts A (14).
(pins C and F) in the deenergized position are in the
turret action circuit. (b) Hydraulic. Hydraulic ground test cart
(T11).
(b) Contacts A - energized. Contacts A (pins
B and F) in the energized position open the action
circuit to the turret.
(c) Contacts B. Contacts B (pins D, G, and H) All weapons shall be dry fired. Dummy
are not used. ammunition shall not be used.
UNIVERSAL TURRET (2) Special tools.
9-444.
SYSTEM nCIRCUITRY.
(a) Round fire simulator (T5).
9-446. DESCRIPTION - UNIVERSAL
(b) Air speed simulator (T10).
TURRET SYSTEM CIRCUITARY.
b. Preparation for Testing.
The universal turret system interfaces, by means of
auxiliary equipment, with the M136 helmet Sight
(1) General. Q u a l i f i e d a r m a m e n t p e r s o n n e l
subsystem (HSS) and the turret control portion of the
shall be present during all tests specified herein. The
stabilized telescopic sight unit (TSU) of the M65 TOW
following tests shall be accomplished using auxiliary
missile subsystem. The interconnecting airframe
electrical power. (Refer to paragraph 1-51.)
wiring integrates the three subsystem components
through the interface control unit (lFCU), electronic (2) Weapon system preparation.
interface assembly, a n d t h e p i l o t a n d g u n n e r
armament control panels. For additional information (a) Check all system components for proper
pertaining to the universal turret system, refer to TM installation.
9-1090-206 series maintenance manuals. For
additional information pertaining to the M136 helmet (b) Check that the turret weapon and feeder
sight subsystem, refer to TM 9-1270-212-14. For are properly timed.
additional information pertaining to the TSU and M65
TOW missile subsystem, refer to paragraph 9-464 (c) Open (off) all circuit breakers.
and TM 9-1425-473 series maintenance manuals.
Change 11 9-156.25/(9-156.26 blank)
TM 55-1520-236-23
(3) Control switch positions. Position the REF XFMR
following switches as indicated: SECU PWR
WING STORE PWR
(a) Pilot armament control panel. TURRET DRIVE MOTOR
TURRET GUN MOTOR
MASTER ARM OFF TURRET STOW
WPN CONTR GUNNER TMS BLWR
WING STORE RKT PLT JETT
HSS RCTL brightness knob midpoint GNR JETT
RECOIL COMPEN OFF
RANGE SHORT (6) P o w e r s w i t c h p o s i t i o n s . P o s i t i o n t h e
following switches as shown:
(b) Pilot miscellaneous control panel.
ALTNR OFF/RESET
INBD JETTISON SELECT OFF BATTERY RUN
OUTBD JETTISON SELECT OFF NON-ESNTL BUS MANUAL
(7) Gunner miscellaneous panel. Position
(c) Gunner armament control panel. ELEC PWR/EMER OFF switch to ELEC PWR.
PLT ORIDE OFF
WING STORE RKT
RD RMNG 750
SLEW RATE SLOW Before proceeding, clear turret area of
A/S COMPEN OFF any obstructions and warn personnel to
HSS reticle brightness knob midpoint remain on exterior of safety barrier.
TURRET DEPR LIMIT DEPR LIMIT
RANGE SHORT
(d) TOW control panel. c. Testing Procedures.
MODE SELECT OFF (1) Gunner turret control. With test personnel
in the pilot and gunner positions, connect the helmet
(4) Electrical Power. Apply 28-volt dc external sight linkage to the built-in test (BIT) brackets at the
electrical power. (Refer to paragraph 1-51.) forward support points.
(5) Circuit breakers. Engage the following (a) W i t h M A S T E R A R M s w i t c h o n p i l o t
circuit breakers: armament control panel and PLT ORIDE switch on
gunner armament control panel to OFF, check that
(a) DC circuit breaker panel. there is no action or firing of any armament systems
from any triggers. Check that green GUN ELEV
GEN-FIELD STOWED advisory indicator is illuminated in the pilot
DC VM caution panel.
CAUT LT
GEN BUS RESET (b) Position pilot MASTER ARM switch to
INV STBY. Observe that pilot and gunner STBY indicators
are illuminated. Also observe that green GUN ELEV
(b) AC/ARMT circuit breaker panel. STOWED advisory indicator in the pilot caution panel
is not illuminated.
TMS PWR
TURRET CONTR
WPN CONTR (c) P o s i t i o n H S S B I T s w i t c h o n g u n n e r
WPN FIRE armament control panel to BIT and check that a GO
HSS PWR indication appears on the panel indicator.
9-157
TM 55-1520-236-23
NOTE momentarily as turret and HSS LOS are out of
coincidence.
Completion of BIT circuit requires
approximately two seconds. (k) Move turret against upper elevation limit
and slowly through total azimuth sweep. Check that
(d) Check pilot and gunner HSS linkage for reticle flashes while turret is against upper limit in all
freedom of movement in all directions. azimuth positions.
(e) C h e c k t h a t H S S r e t i c l e i l l u m i n a t i o n (1) Move turret against left and right azimuth
controls on pilot and gunner armament control panels limits and slowly through total elevation sweep.
are functioning properly. Turn HSS RETICLE Check that reticle flashes while turret is against
brightness control knob from OFF to BRT and check either azimuth limit in all elevation positions. Total
for corresponding change in light intensity. Move depression at either azimuth shall be checked during
RETICLE TEST switch to TEST and check that HSS flight tests.
retitles are still illuminated.
(m) Release ACTION switch on the LHG and
(f) While holding gunner helmet sight line-
check that the turret returns to stowed (upper
of-sight (LOS) at 0 degrees elevation and 0 degrees
forward) position.
azimuth; press left hand grip (LHG) ACTION switch on
TSU and slowly rotate LOS downward. The weapon
(n) Return TURRET DEPR LIMIT switch to ON.
should reach lower depression limit at approximately
-5 degrees. Then rotate LOS upward; the weapon
(o) Hold the sight in approximately the 0-0
should drive to the upper limit. The reticle should
position and depress ACTION switch on LHG. Attempt
flash when helmet LOS is out of coincidence with the
to fire the weapon with the gunner and pilot triggers.
commanded gun line and when weapon reaches
The weapon should not fire.
upper EL limit or below zero degrees elevation.
Release ACTION switch.
(p) Position pilot MASTER ARM switch to
ARM. Check that pilot and gunner red ARMED
(g) Position TURRET DEPR LIMIT switch to
indicators are illuminated and that pilot and gunner
OFF.
STBY indicators are extinguished.
(q) P r e s s A C T I O N s w i t c h w h i l e h o l d i n g
In the following steps, excessive helmet LOS at 0 degree azimuth and 0 degree
downward movement of LOS can cause elevation and move RANGE switch to MED and
barrels to strike ground. Remove barrels LONG. Check that turret elevation increases with
or elevate helicopter 30 inches if increased range settings. Check that helmet sight
maximum depression cannot be checked reticle does not flash at SHORT, MED OR LONG range
during flight test. settings. Release ACTION switch. Return RANGE
switch to SHORT. (Angular displacements will be
(h) While holding gunner helmet sight LOS at measured as described in subparagraph (6) below.)
0 degrees elevation and 0 degrees azimuth, press
LHG ACTION switch on TSU and slowly rotate helmet (r) Press ACTION switch and move LHG
LOS downward. Confirm that gun barrels move past trigger on gunner TSU to the first detent, then the
the 5-degree depression limit position. Rotate LOS second. Check that turret weapon fires a short burst
upward and confirm that gun barrels move to upper (approximately 1.3 seconds) at first detent and
elevation limit. Release ACTION switch. continuously at second detent.
(i) M o v e t u r r e t t h r o u g h t o t a l e l e v a t i o n , (s) Release ACTION switch and press the
depression, and azimuth limits. Check that no binding trigger. The turret weapon should not fire. Press pilot
or interference occurs. ACTION switch and trigger. Check that weapon does
not move or fire. Press gunner cyclic ACTION switch
(j) Rotate sight rapidly both in azimuth and and trigger. Check that turret weapon does not move
elevation. Check that sight reticle flashes or fire.
9-198
TM 55-1520-236-23
(2) Pilot turret control. Proceed as follows to
(e) Press pilot cyclic stick action switch and
check out and test turret weapon and HSS system
trigger. Check that pilot helmet sight will not control
while under the pilot control:
the turret weapon and that gun does not fire.
(a) Position MASTER ARM switch to STBY.
(f) Position pilot MASTER ARM switch to OFF
and check that both pilot and gunner red ARMED
(b) Position pilot WPN CONTR switch to
indicator lights remain on. Check that only gunner
PILOT. Check that PILOT IN CONT green indicator on
cyclic stick trigger will fire turret weapon.
gunner armament control panel illuminates.
(g) Position pilot WPN CONTR switch to
(c) Press TSU LHG ACTION switch. Check
GUNNER. Check that only gunner cyclic stick trigger
that gunner helmet sight has no control of the turret.
will fire turret weapon.
(d) Press gunner cyclic grip ACTION switch. (h) If ammunition box booster is connected
Check that gunner helmet sight has no control of the during the preceding checks, counter should show
turret weapon. less than 250 rounds (corresponding to the number of
rounds fired).
(e) Press ACTION switch on pilot cyclic grip
and check that turret weapon follows pilot helmet (i) Return PLT ORIDE switch to OFF.
sight LOS in the same manner as that described for
the gunner in subparagraph (1), steps (f) through (n) (4) Turret airspeed compensation. Check out
above. and adjust if necessary the turret airspeed
compensation operation as follows:
(f) Position MASTER ARM switch to ARM.
(a) Position MASTER ARM switch to STBY.
(g) Repeat steps (q) and (r) of subparagraph
(1) above, except use pilot cyclic stick ACTION switch. (b) Position MODE SELECT switch on TCP to
TSU/GUN.
(h) Check that pilot cyclic stick trigger fires
turret weapon: a short burst (approximately 1.3 (c) Apply air pressure to the pitot system to
seconds) at first detent and continuously at second simulate 100 *5 knots airspeed. (Refer to TM 55-
detent. 1500-204-25/1.)
(d) Remove the right hand fixed fairing above
(3) P i l o t o v e r r i d e b y g u n n e r . P r o c e e d a s the turret.
follows to check out function of gunner overriding
pilot control of weapon: (e) Press LHG action switch on TSU and
rotate LOS of TSU to the left 90 degrees. Turret
(a) Position pilot override switch to PLT weapon must also move to the left until OUT mark on
ORIDE. the turret decal aligns.
(b) C h e c k t h a t P L T I N C O N T i n d i c a t o r (f) P o s i t i o n A \ S C O M P E N s w i t c h t o A / S
extinguishes and that gunner red ARMED indicator COMPEN and observe that IN line on the turret decals
illuminates. align.
(g) Return TSU/GUN LOS to forward (0-
(c) Press gunner cyclic stick ACTION switch degree) position.
and check that gunner cyclic stick trigger will fire the
turret weapon. The gunner HSS should control turret (h) Release LHG ACTION switch.
weapon.
(i) Position MASTER ARM switch to OFF.
(d) Press LHG ACTION switch and trigger.
Check that turret weapon does not respond to helmet (j) position TCP MODE SELECT switch to
sight and gun does not fire. OFF.
9-159
TM 55-1520-236-23
(k) Position A/S COMPEN switch to OFF. (f) Return RANGE switch to SHORT. Release
Release air pressure from the pitot system. ACTION switch. Position MASTER ARM switch to
OFF.
(5) Fixed mode firing. Check out fixed mode
firing as follows: (7) Recoil compensation.
(a) Position pilot WPN CONTR switch to
FIXED and MASTER ARM switch to STBY.
(b) Check that turret weapon moves to 0-
Do not apply hydraulic power to system
degree elevation and 0-degree azimuth position.
unless electrical power is applied.
(c) Press pilot cyclic grip ACTION switch.
(a) Apply 1500 *25 psig hydraulic power to
Check that turret weapon does not follow pilot helmet
both systems.
sight.
(d) Press ACTION switch on TSU LHG and (b) Connect Round Fire Simulator to FIRE
cyclic grip ACTION switch. Check that turret weapon VOLT CONNECTOR.
does not follow gunner helmet sight or TSU
commands. (c) Position RECOIL COMPEN switch to
RECOIL COMPEN and power switch on SCAS control
(e) Position MASTER ARM switch to ARM. panel to ON. Engage PITCH, ROLL and YAW ENGAGE
switches.
(f) Press pilot cyclic grip ACTION switch and
trigger. Check that turret weapon fires. (d) Position WPN CONTR switch to GUNNER.
Position MASTER ARM switch to ARM. Depress LHG
ACTION switch. Rotate sight 90 degrees left. Observe
(6) Range compensation. Check out range turret is 90 degrees left and level. Press LHG trigger.
compensation operation as follows: Observe SCAS inputs to tail rotor and swashplate.
Tail rotor response shall be the same as for left pedal
(a) Position MASTER ARM switch to STBY; inputs. Swashplate inputs shall be the same as for
MODE SELECT switch on TOW Control PaneI (TCP) to right cyclic stick (right roll swashplate).
TSU/GUN; HI/LO MAG switch to Hl; and WPN
CONTR to GUNNER. (e) Repeat for 90 degrees right and level. Tail
rotor response shall be the same as for right pedal
(b) Position STOW/TRK/ACQ switch on SHC inputs. Swashplate inputs shall be the same as for left
to TRK and hoId TSU LOS on a fixed distant target. cyclic stick (left roll swashplate).
(c) Press ACTION switch on LHG. Position (f) Repeat for 0 degrees and up elevation.
RANGE switch to SHORT. Position MASTER ARM Swashplate inputs shall be the same as for aft stick.
switch to ARM. Check that turret weapon elevation
increases by approximately 9.2 milliradians. (g) Repeat for 0 degrees and down elevation.
Swashplate inputs shall be the same as for forward
stick.
(d) Position MASTER ARM switch to STBY.
Position RANGE switch to MED. Position MASTER (h) Open all armament switches and
ARM switch to ARM. Check that turret weapon disengage circuit breakers. Disconnect hydraulic
elevation increases by approximately 2 4 . 4 power cart and Round Fire Simulator.
milliradians.
9-447. m T R O U B L E S H O O T I N G -
(e) Position MASTER ARM switch to STBY. TURRET SYSTEM CIRCUITRY.
Position RANGE switch to LONG. Position MASTER
ARM switch to ARM. Check that turret weapon a. Airframe Circuitry and Components. Refer to
elevation increases by approximately 4 2 . 8 paragraph F-9 in Appendix F for wiring diagram and
milliradians. trace malfunctioning circuit loop, using standard
9-160
TM 55-1520-236-23
electronic troubleshooting procedures, and standard TOW system, the computing resolver chain contained
test equipment. Localize malfunctioning components within the turret system is connected to similar
and repair or replace as required. resolvers located in the TSU. Elevation and azimuth
commands and a range compensation function are
b. Turret System. R e f e r t o T M 9 - 1 0 9 0 - 2 0 6 then developed in the TSU which are returned by the
series maintenance manuals for troubleshooting IFCU to the turret system as positioning signals for
procedures pertaining to the universal turret system. the turret assembly. In this manner, as the TSU tracks
the target, the turret assembly is commanded to
c. Helmet Sight Subsystem. Refer to TM 9- follow the TSU line-of-sight. Operation with either
1270-212-14 for troubleshooting procedures the pilot or gunner helmet sight is accomplished in a
pertaining to the M136 helmet sight subsystem. like manner. The function of the IFCU is to receive
signals from all three sighting units and to select the
d. Telescopic Sight Unit. Refer to TM 9-1425- appropriate one, depending upon the mode activated
473 series maintenance manuals for troubleshooting by the system operator. This interchange of signals is
procedures pertaining to the telescopic sight unit accomplished in the IFCU with the use of relay logic.
portion of the M65 TOW missile subsystem. Once the sighting unit is selected, turret positioning
signals are routed from the sight back through the
9-448. q M 1 3 6 ELECTRONIC IFCU to integrated circuit buffer amplifiers. The
INTERFACE ASSEMBLY. amplifiers are incorporated to ensure that computing
accuracy in the resolver chain is maintained. In
9-449. q DESCRIPTION M136 addition to the gun mode, an acquisition mode is
ELECTRONIC INTERFACE ASSEMBLY. provided in which either helmet sight positions the
TSU. The acquisition mode thus allows either the pilot
The electronic interface assembly is a component of or the gunner to acquire a target for the TOW missile
the M136 helmet sight subsystem that provides by utilizing the helmet sight. The relay logic in the
regulated 28 Vdc power and contains the electronic IFCU also provides a dual mode capability. If the
components necessary for the operation of the HSS. gunner has selected the TOW mode, the pilot has the
The electronic interface assembly is the point of capability of directing the turret assembly with the
integration with the interface control unit (IFCU) helmet sight. In addition, either helmet sight may be
which interfaces the HSS and TSU sighting systems directing the turret assembly while the other helmet
with the universal turret system. The electronic sight is used to acquire a target for the TOW missile.
interface assembly is mounted to the rear cockpit Pitch and roll trim resolvers within the IFCU resolve
bulkhead (see figure 9-23). The electronic interface any installation misalignment existing between the
assembly contains buffer amplifiers and circuitry TSU and the turret assembly. These resolvers are
required by the linkage resolvers, azimuth and aligned during system boresighting and then locked
elevation alignment controls and associated circuitry in the corrected position. Other IFCU inputs and
for boresighting each linkage assembly, and the BITE outputs include airspeed data for turret
circuits and controls necessary to provide the HSS compensation, helmet sight reticle voltage, and a
self-test capability. For additional information and turret coincidence signal which provides an
maintenance procedures pertaining to the electronic indication as to turret/sight alignment. The turret
interface assembly, refer to TM 9-1270-212-14. depression limit circuitry in the IFCU limits the down
elevation of the turret to 5 degrees maximum to
9-450. q I N T E R F A C E CONTROL prevent damage which could result if gun strikes the
UNIT (IFCU). ground. Depression limits is activated when gunner
positions TURRET DEPR LIMIT switch from OFF to
9-451. q DESCRIPTION - INTERFACE TURRET DEPR LIMIT.
CONTROL UNIT (IFCU).
The interface control unit (IFCU) contains the signal
switching, resolver, logic, and buffering circuitry
necessary to interface the helmet-sight subsystem 9-452. CLEANING - INTERFACE
(HSS) and stabilized telescopic sight unit (TSU) with CONTRP L UNIT (IFCU).
the universal turret system. The IFCU is located in the
right access compartment below the wing (see figure a. Remove moisture and loose dirt with a clean,
9-23). When the gunner selects the gun mode in the SOft cloth.
9-161
TM 55-1520-236-23
9-456. INSTALLATION - INTERFACE
CONTR @ UNIT (IFCU).
a. Position IFCU in place on wall and install
mounting screws and washers.
Cleaning solvent is flammable and toxic.
Provide adequate ventilation. Avoid b. Remove protective caps or electrical tape from
prolonged breathing of solvent vapors three electrical connectors and install on IFCU.
and contact with skin or eyes.
9-457. m LOGIC CONTROL UNIT.
b. Remove grease, fungus, and dirt with a clean,
lint-free cloth dampened with dry cleaning solvent 9-458. ~ DESCRIPTION - LOGIC
(C112). CONTROL UNIT.
c. Remove dirt from electrical connectors with a The logic control unit (LCU) is an interface unit and a
bristle brush. component of the universal turret system. It
interfaces with the turret control unit, gun control
unit, SCAS armament compensation unit, and the
interface control unit. The LCU is located aft of the
9-453.
INSPECTION - INTERFACE ammunition compartment. Access to the unit is
CONTROL UNIT (IFCU). gained through the access panel located on the left
side of the helicopter above the forward crosstube.
a. Inspect IFCU case for cracks or damage. SCAS compensation signals are provided by a
program switch on the LCU. The program switch
b. Inspect electrical connectors for broken pins or
selects various circuit configurations in the LCU to
cracked connector inserts.
provide for the difference in movement associated
with the individual weapon that is installed (20 or
c. Inspect IFCU for secure mounting.
30MM). Logic command circuits in the LCU provide a
torque enable signal to indicate use of the pitch, roll,
9-454. ~ REMOVAL - INTERFACE and yaw signals by the SCAS system. Two 1.5 degree
CONTROL UNIT (IFCU). error detection circuits, one for azimuth and one for
elevation, are provided to prevent the weapon from
a. Ensure all electrical power is OFF. firing if the turret returns to normal stow while still
clearing. Also, a 180 degree interlock circuit is
b. Remove IFCU access panel (right side, below provided to prevent or interrupt weapon firing when
wing). the turret and sight are not in normal azimuth
alignment. Depression limiting circuitry is provided to
c. Disconnect three electrical connectors from prevent the turret from depressing further than a 5
IFCU. Protect receptacles and plugs with caps or degree down angle. When the turret elevation angle
electrical tape (C121). is changed, a resolver generates a voltage which is
proportional to the sine function of that angular
d. Remove mounting screws and washers, and displacement. This signal is demodulated into a
remove IFCU from wall. proportional linear dc voltage. The demodulation
circuitry is identical to that used in the turret control
assembly. The second functional section of the circuit
detects the phase (direction) and amplitude (angle) of
9-455. ~ REPAIR - INTERFACE the demodulators output. When the turret direction is
CONTROL UNIT (IFCU). down and equal to or greater than 5 degrees, a
transistor is energized providing a ground return for a
a. Repair connectors, and tighten or replace loose relay coil which is powered by the helicopter
or missing mounting screws. electrical circuitry. This accomplishes elevation error
cancellation and prevents the turret from depressing
b. Replace IFCU if case is damaged or defective. further than the 5 degree down angle. A burst length
Evacuate removed IFCU to higher maintenance level limiting circuit with burst limit overide logic
for disposition. interfaces with the gun control unit. The program
9-162
TM 55-1520-236-23
switch on the LCU selects the proper time delay for c. Disconnect electrical connectors from LCU.
the weapon installed. The burst limit overide disables Protect receptacles and plugs with caps or electrical
the time delay function by disconnecting the trigger tape (C121).
signal from the timing circuit. A four input OR circuit
is provided to interface the 180 degree, 1.5 degree d. R e m o v e m o u n t i n g s c r e w s a n d w a s h e r s .
azimuth, and turret electrical interlocks to the gun Remove LCU from helicopter.
control unit. A 180 degree false coincidence circuit is
provided to prevent turret latch-up when the selected
9-462. ~ REPAIR - LOGIC CONTROL
sight position differs from the weapon boreline by
UNIT (LCU).
more than 180 degrees due to rapid rotation of the
helmet sight or mode switching. Other LCU circuits a. Repair connectors and tighten or replace loose
include a transistor inverter for the reticle, and an or missing mounting screws.
elapsed time indicator.
b. Replace LCU if case is damaged or defective.
9-459. CLEANING - LOGIC CONTROL Evacuate removed LCU to higher maintenance level
UNIT (LCU). for disposition.
a. Remove moisture and loose dirt with a clean,
soft cloth. 9-463. ~ INSTALLATION - LOGIC
CONTROL UNIT (LCU).
a. Position LCU in place and install with mounting
screws and washers.
Cleaning solvent is flammable and toxic. b. Remove protective caps or electrical tape and
Provide adequate ventilation. Avoid connect electrical connectors to LCU.
prolonged breathing of solvent vapors
and contact with skin or eyes.
9-464. g M 6 5 TOW MISSILE
b. Remove grease, fungus, and dirt with a clean, SUBSYSTEM CIRCUITRY.
lint-free cloth dampened with dry cleaning solvent
(C112).
9-465. ~ DESCRIPTION - M65 TOW
c. Remove dirt from electrical connectors with a
MISSILE SUBSYSTEM CIRCUITRY.
bristle brush.
9-460. ~ INSPECTION - LOGIC The M65 TOW missile subsystem circuitry provides
CONTROL UNIT (LCU). the capabilities to acquire and track a target,
compensate for effects of helicopter motion, launch a
a. Inspect LCU case for cracks or damage. TOW missile, and guide the missile to the target. The
telescopic sight unit (TSU) portion of the TOW missile
b. Inspect electrical connectors for broken pins or subsystem interfaces with the universal turret
cracked connector inserts. system circuitry, serving as a flexible sighting unit,
and also interfaces with the helmet sight subsystem
c. Inspect LCU for secure mounting. for use during target acquisition. For description and
additional information pertaining to M65 TOW
9-461. q REMOVAL - LOGIC CONTROL missile subsystem components, refer to TM 55-
UNIT (LCU). 1520-236-10 and TM 9-1425-473 series
maintenance manuals. For maintenance information
a. Ensure all electrical power is off. and procedures pertaining to M65 TOW missile
subsystem components, refer to TM 9-1425-473
b. R e m o v e a c c e s s p a n e l a f t o f a m m u n i t i o n series maintenance manuals. For information and
compartment above forward crosstube on left side of maintenance procedures pertaining to the interface
helicopter. control unit (IFCU), refer to paragraph 9-450.
9-163
TM 55-1520-236-23
9-466. ~ F U N C T I O N A L T E S T - M 6 5 (2) Configuration. For the purpose of this test,
TOW MISSILE SUBSYSTEM CIRCUITRY. the universal turret will be assumed to have a 20MM
weapon.
a. Requirements. NOTE
For functional test of M65 TOW missile
(1) Test equipment.
launcher system refer to TM 9-1425-
473 series maintenance manuals.
(a) Auxiliary power. Auxiliary power unit
(T14).
(3) Weapon system preparation.
(b) Hydraulic. Hydraulic ground test cart
(a) Check all systems components for proper
(T11).
installation.
(b) Verify that the launchers are properly
connected, four launchers installed, and the TSEM
installed in No. 1 missile position. (See figure 9-24.)
All weapons shall be dry fired. Only
(c) Open (off) all circuit breakers.
dummy ammunition with smooth cases
like live ammunition shall be used.
(4) C o n t r o l s w i t c h p o s i t i o n s . P o s i t i o n t h e
(2) Special tools. TOW simulator evaluation following switches as indicated:
missile (TSEM) (T70).
(a) Pilot armament control panel.
b. Preparation for Testing.
MASTER ARM OFF
(1) General. Qualified armament personnel WPN CONTR GUNNER
shall be present during all tests specified herein. WING STORE RKT
Figure 9-24. TOW Missile Launcher Positions
9-164
TM 55-1520-236-23
(b) Pilot rocket control panel. (7) Power switch positions. Position the
following switches as shown:
WG ST ARM OFF
ALTNR OFF RESET
(c) Gunner armament control panel. BATTERY RUN
NON-ESNTL BUS MANUAL
WING STORE RKT ELEC PWR/EMER OFF ELEC PWR
TURRET DEPR LIMIT DEPR LIMIT
PLT ORIDE OFF
SLEW RATE NORM
A/S COMPEN A\S COMP
RANGE SHORT Before proceeding, clear turret area of
RD RMNG 750 any obstructions and warn personnel to
remain on exterior of safety barrier.
(d) TOW control panel (TCP).
MODE SELECT OFF
CAMERA OFF To ensure immediate control of the
MISSILE SELECT 1
system, do not apply hydraulic power to
EXPOSURE BRT
system unless electrical power is applied.
(e) Sight hand control (SHC).
(8) Hydraulic power. Apply 1500 * 25 psi
STOW/TRK/ACQ hydraulic power to system No. 2.
STOW
(f) Telescopic sight unit (TSU). (9) S p e c i a l t e s t e q u i p m e n t . P o s i t i o n t h e
following test equipment switches or controls as
FILTER SELECT LEVER indicated:
CLEAR
TOW system evaluator missile (TSEM).
(5) Electrical power. Check that the aircraft
battery is connected, then apply 28-volt dc external POWER OFF
electrical power. FUNCTION LAMP TEST
(6) Circuit breakers. E n g a g e t h e f o l l o w i n g c. Testing Procedures.
circuit breakers:
(1) Initial system tests. Perform the following
(a) Dc circuit breaker panel. steps for initial system tests:
GEN FIELD NOTE
DC VM
CAUT LT For this test, one technician will be
INV required in the gunners position, one
GEN BUS RESET technician in the pilot position, and one
technician outside the helicopter.
(b) Ac circuit breaker panel.
(a) Position the pilot MASTER ARM switch to
TURRET CONTR STBY and WPN CONTR to GUNNER.
TMS PWR
WPN CONTR (b) Position the TCP MODE SELECT switch to
WPN FIRE TSU/GUN.
HSS PWR
REF XFMR (c) Verify that system status indicator on TCP
SECU PWR moves from OFF to TEST after approximately 10
WING STORE PWR seconds.
9-165
TM 55-1520-236-23
(d) Verify that within 120 seconds after TCP (n) Release ACTION switch and position
system status indicator reads TEST in step(c), the TCP MASTER ARM switch on pilot armament control
system status indicator moves to PWR ON. panel to STBY.
(e) Verify that all BIT indicators on the TCP (o) Return STOW/TRK/ACQ switch to
are in go condition (black on black). STOW.
(f) Move HI/LO MAG switch on LHG to LO (p) Return TURRET DEPR LIMIT switch to
MAG. DEPR LIMIT.
(g) Move STOW/TRK/ACQ switch to TRK. (2) Telescopic sight controls. Perform the
Observe that TSU turret follows the inputs from SHC following steps for initial system turn-on:
transducer stick and that status flag in TSU shows (a) Position MODE SELECT switch to STBY
GUNS. Verify that gun does not follow the sight. TOW on TOW control panel (TCP). Verify that TCP
system status indicator remains at PWR ON.
(h) Position TURRET DEPR LIMIT switch to
OFF.
(b) Position STOW/TRK/ACQ switch to TRK
and press LHG ACTION switch. Observe that turret
weapon will not follow inputs from SHC transducer
stick.
Do not depress TSU or gun barrels during (c) Release LHG ACTION switch and return
the following check if gun barrels are STOW/TRK/ACQ switch to STOW.
installed. Barrels could strike the ground
with sufficient force to cause system (d) Position TCP MODE SELECT switch from
damage. STBY TOW to ARMED MAN. Verify that TCP system
status indicator remains at PWR ON.
(i) Press ACTION switch on LHG. Observe
that turret weapon follows TSU when moved through (e) Position MASTER ARM switch on pilot
the limits with SHC transducer stick. Observe that armament control panel from STBY to ARM to STBY.
GUNS flag in TSU sight flashes when at limit stops of Verify that system status indicator on TCP moves
the turret weapon. from PWR ON to ARMD to PWR ON during this
sequence.
NOTE (f) Position WPN CONTR switch on pilot
armament control panel to PILOT.
Guns flag may not flash if gun turret
exceeds TSU in azimuth, due to tolerance (g) Position MASTER ARM switch from STBY
in stop location. to ARM to STBY. Verify that system status indicator
on TCP remains at PWR ON during this sequence.
(j) Release ACTION switch. Observe that
turret weapon returns to STOW. (h) Position WPN CONTR switch on pilot
armament control panel to FIXED and repeat step (g).
(k) Move LOS of TSU to approximately 0 Return WPN CONTR switch to GUNNER.
degrees azimuth and elevation and press LHG
ACTION switch and trigger. Observe that turret (i) Position STOW/TRK/ACQ switch on SHC
weapon will not fire. to TRK and return to STOW. Verify that system status
indicator remains in the PWR ON position during this
(l) Release ACTION switch. Position pilot sequence.
MASTER ARM switch to ARM. NOTE
(m) Move LOS on TSU to approximately 0 Steps (j), (k), (l), and (m) should be done
degrees azimuth and elevation and press LHG in rapid succession in order to maintain
ACTION switch and trigger. Observe that turret the TEST indication. Read these steps
weapon fires. before their initiation.
9-166
TM 55-1520-236-23
(j) Press and hold BIT pushbutton on TCP. (t) Use SHC stick to drive TSU from stop to
Verify that ATTK, RDY, and GUNS flags are visible in stop horizontally and vertically. Verify that TSU can be
TSU eyepiece. Verify that ascend and descend driven stop to stop horizontally in 8 seconds and
pointers and ATTK, RDY, and FIRE flags are visible on vertically in 4 seconds.
pilot steering indicator. Release BIT SWITCH after
verifying the above and check that system status (u) R e t u r n STOW/TRK/ACQ switch to
indicator on TCP reads TEST. STOW.
(k) Position TCP MODE SELECT switch from (3) Helmet sight tracking.
ARMED MAN to OFF to ARMED MAN in less than 5
seconds. Verify that system status indicator on TCP (a) Position MASTER ARM switch on pilot
moves from TEST to OFF to TEST. There should be no panel to STBY.
10-second delay from OFF to TEST on TCP system
status indicator. (b) Connect helmet sight linkages to the
BUILT-IN TEST (BIT) brackets.
(l) With system status indicator reading TEST
from step (k), position STOW/TRK/ACQ switch on (c) P o s i t i o n H S S B I T s w i t c h o n g u n n e r
sight hand control to TRK and return it to STOW. control panel to BIT and release. Check that a GO
Verify that system status indicator cycles from TEST indication appears on HSS test indicator.
to PWR ON to TEST during this sequence.
NOTE
(m) With system status indicator reading
TEST from step (l), position MASTER ARM switch on Completion of BIT circuit requires
pilot armament control panel from STBY to ARM to approximately two seconds.
OFF. Verify that system status indicator on TCP
moves from TEST to ARMD to OFF during this
sequence. (d) Connect pilot and gunner linkages to their
respective helmets and check for freedom of
(n) Position pilot MASTER ARM switch to movement in all directions. Adjust helmet sight
ARM, the STOW/TRK/ACQ switch on SHC to TRK reticle on helmet until full reticle pattern can be seen.
and position TCP MODE SELECT switch to STBY
TOW. (e) Position STOW/TRK/ACQ switch to TRK.
Press and hold PHS ACQ and check that gunner
(o) Position TSU optics to HI MAG using helmet sight reticle retracts automatically. Check that
HI/LO MAG switch on TSU LHG grip. Observe that TSU follows pilot helmet sight as it is aimed to left,
TSU is now in HI MAG mode. right, up, and down. Release PHS ACQ switch.
(p) While holding ACTION switch, use SHC (f) If installed, return gunner helmet sight
stick to drive TSU from stop to stop horizontally and reticle to the down position.
vertically. Verify that TSU can be driven stop to stop
horizontally in less than 50 seconds and vertically in (g) H o l d S T O W / T R K / A C Q s w i t c h i n A C Q
less than 30 seconds. position. Verify that TSU follows gun helmet sight as
it is aimed to left, right, up, and down. Release
(q) Position TSU optics to LO MAG using STOW/TRK/ACQ switch and check that gunner
HI/MAG switch on TSU LHG grip. helmet sight reticle retracts.
(r) Use SHC stick to drive TSU to stop, (h) P o s i t i o n S T O W / T R K / A C Q s w i t c h t o
horizontally and vertically. Verify that TSU can be STOW.
driven from stop to stop horizontally in less than 3
seconds and vertically in less than 2 seconds. (4) Pilot steering indicator commands and
Release ACTION switch. constraints test. Pilot steering commands on the PSI
are a function of TSU AZ and EL gimbal angles. PSI
(s) Position TSU OPTICS to HI MAG using azimuth steering is biased plus 0.75 degree left for
HI/LO MAG switch and position TCP MODE SELECT right missiles. Logic prevents prefiring a TOW missile
switch to TSU GUN. until LOS rate, gimbal angle, attack logic, launcher
9-167
TM 55-1520-236-23
position status, and roll constraint requirements are (d) Depress and hold ACTION switch on LHG.
satisfied. Verify that left launcher is slaving to TSU LOS in
elevation.
(a) Position the pilot MASTER ARM switch to
ARM. (e) Drive TSU up slowly in elevation until
elevation needle on PSI falls outside the inner
(b) Position the TCP MODE SELECT switch to rectangle. Verify that PSI RDY flag disappears.
ARMED MAN.
(f) Recenter the elevation needle and verify
(c) Position SHC STOW/TRQ/ACQ switch to reappearance of the RDY flag. Drive TSU down until
TRK and HI/LO MAG switch to HI. Select missile the elevation needle falls below the inner rectangle
number 1. and verify that RDY flag disappears.
(d) Depress LHG ACTION switch. (g) Press and hold ACTION switch on LHG
and drive TSU with SHC stick vertically from stop-to-
(e) Using the SHC, adjust TSU position for stop. Verify that right launcher does not move and
azimuth and elevation LOS to be zero. that left launcher follows vertical motion of TSU
within the limits of the launchers mechanical stops.
(f) V e r i f y t h e P S I a z i m u t h n e e d l e i s
approximately one-third from center to right when AZ (h) With TSU at the lower stop, release LHG
and EL LOS is zero. ACTION switch and verify that after a short delay (0.5
second), the launcher moves back to its stowed
(9) Select missile number 2. position.
(h) Adjust TSU position for azimuth and (i) Select missile number 2 and repeat steps
elevation LOS to be zero and depress LHG ACTION (a) through (h), verifying action of the right launcher.
switch.
(i) V e r i f y t h e P S I a z i m u t h n e e d l e i s (6) Armament control tests. Operation during
approximately one-third from center to the left when the preparation for launch and guidance of a missile
the AZ and EL LOS is zero. shall be verified as follows:
(j) M o v e T S U L O S t h r o u g h a z i m u t h a n d (a) Pilot turret control and firing while in the
elevation; observe that PSI indicates the movement of TOW mode.
TSU LOS.
1 Position WPN CONTR switch on pilot
(k) Release LHG ACTION switch. armament control panel to PILOT and MASTER ARM
switch to ARM.
(l) Return STOW/TRK/ACQ switch to STOW.
2 With MODE SELECT switch on TCP in
(5) Launcher/TSU alignment and slaving any of the TOW modes (STBY TOW, ARMED MAN, or
test. ARMED AUTO) and STOW/TRK/ACQ switch on SHC
(a) A p p l y h y d r a u l i c p o w e r t o h e l i c o p t e r . in either TRK or STOW, check that gunner PILOT
Position TCP MODE SELECT switch to ARMED MAN INCONT green indicator is illuminated and that pilot
and MASTER ARM switch to ARM on pilot armament can fire the turret weapon while using his helmet
control panel. Position TSU HI/LO MAG switch to HI. sight.
(b) Select missile number 1 on TCP. Verify 3 Position the WPN CONTR switch to
that missile status indicator on TCP for missile GUNNER and repeat step 2.
number 1 reads MSL.
(b) TSEM operating procedure. Installation
(c) Set STOW/TRK/ACQ switch on SHC to and operation of the TSEM shall be as follows:
TRK and track TSU to 0 degrees azimuth and 0
degrees elevation. Verify pilot L/R TOW indicator 1 After loading the TSEM into launcher
indicates left side. and Iowering the arming lever, position POWER
9-168
TM 55-1520-236-23
switch to ON. Check that POWER light and SHEAR 2 Turn TSEM to ON and press reset button.
PIN light illuminate.
3 Connect TSEM power cable to TSEM and
2 Position SELF TEST switch to AUTO and to DC power connector located in the ammunition
press RESET button. bay.
3 When TSEM is fired in a normal 4 Position TSEM mode select switch to
equence, the following will be observed on rear AUTO and power switch to ON.
panel of the TSEM:
5 Press TSEM RESET switch and verify
a The START and WIRE SIGNAL AMPL that power lamp is illuminated.
lights illuminate simultaneously, then PREFIRE and
-12 lights illuminate in sequence. 6 Rotate mode select switch to LAMP TEST
and verify that all TSEM lamps illuminate.
b The YAW, PITCH, FIRE, MSL GONE,
and ZERO lights illuminate in sequence. 7 Rotate mode select switch to SP GO
and verify that shearpin lamp illuminates.
c The WIRE CUT and SQUIB DISC lights
then illuminate and WIRE SIGNAL AMPL light 8 Rotate launcher armament control
extinguishes. handle to ARMED position and secure it with the
captive locking pin. Verify that shearpin lamp goes
d The previously mentioned lights will out.
remain illuminated until RESET button is depressed.
Exception: the SHEAR PIN light will remain 9 Rotate TSEM mode select switch to SP
illuminated until launcher arming lever is raised. GO and verify that shearpin lamp illuminates. If
shearpin lamp does not illuminate, this launcher
NOTE position should not be used until readjustment and
verification of shearpin depression is accomplished.
In the first simulated firing following
TSM turn on, or following a BIT
sequence, the PITCH and YAW balance 1 0 Push RESET button.
lights may not illuminate. This should not
be interpreted as an abnormal firing 1 1 Position MASTER ARM switch on pilot
sequence unless the PITCH and YAW armament control panel to ARM.
lights fail to illuminate on successive
firings. 1 2 Position MODE SELECT switch on TCP
to ARMED MAN. Verify that MISSILE SELECT switch
is on missile position No. 1.
4 At the end of test, or when use of TSEM is
not called for in a test, or when TSEM is to be down
1 3 Verify that missile status indicator on
loaded, position POWER switch to OFF. (An
TCP for missile No. 1 indicates MSL.
unpowered TSEM loaded into a launcher will not
affect the outcome of tests not requiring the TSEM.)
1 4 Set STOW/TRK/ACQ switch on SHC to
TRK.
(c) Manual missile selection and firing.
NOTE 1 5 Set HI/LO MAG switch on LHG to HI.
Shearpin depression limits must be 1 6 Verify the appearance of ATTK flag in
within tolerance for the launcher to be
the eyepiece of TSU and on PSI.
acceptable for firing. Both pods of all
launchers must be verified. To avoid a
NOTE
double effort, check the upper outboard
position last. Within constraint limitations means that
the elevation and azimuth needles are
1 Move launcher armament control handle within the inner rectangle and the ascend
to up position. and descend pointers are not visible.
9-169
TM 55-1520-236-23
1 7 While observing PSI, maintain 2 8 Momentarily press trigger on LHG. The
maneuver indicators within constraint limitations ACTION switch may be released with the trigger
using SHC tracking stick. Verify that RDY flags are switch.
visible on PSI and in the eyepiece of TSU.
2 9 Reset TSEM and with TSU LOS in
1 8 Position TSEM mode select switch to constraints, pull ACTION switch and trigger switch on
MSL GONE. Verify that RDY flags disappear on PSI LHG. Push gunner wire cut switch and observe wire
and in the eyepiece of TSU. Position TSEM mode cut indicator on TSEM.
select switch to AUTO.
3 0 Repeat step 29 using pilot wire cut
button.
NOTE
3 1 Remove TSEM from missile position
The ACTION and trigger switch on the No. 1, cycle (install) the TSEM through the remaining
pilot cyclic grip will be depressed and missile positions, and repeat steps 3 through 31 for
held through steps 19 through 21. Read each position selected.
all of these steps before depression of the
trigger. (d) Automatic selection and firing.
1 Install TSEM in missile position No. 1.
1 9 Hold pilot helmet sight at 0 degree
elevation and 0 degree azimuth and press pilot cyclic 2 Set mode select switch on TSEM to
stick ACTION and trigger switch. Verify that turret AUTO.
weapon fires.
3 Set MASTER ARM switch on pilot
2 0 Press the trigger and ACTION switch on armament control panel to ARM. Set MODE SELECT
LHG. Verify that turret weapon firing is interrupted. switch on TCP to ARMED AUTO.
2 1 Verify that turret weapon resumes 4 Set STOW/TRK/ACQ switch on SHC to
firing after a time delay of 2.8 TO 3 . 2 s e c o n d s . T R K .
Release pilot cyclic grip trigger and ACTION switch.
5 Set HI/LO MAG select switch on LHG to
2 2 Verify the appearance of FIRE flag on HI.
PSI. The FIRE flag will disappear at completion of
firing sequence, approximately 23 seconds. 6 Press LHG ACTION switch and, by
observing PSI, maintain indications within maneuver
2 3 Using the TSEM, verify that a proper constraints.
firing sequence takes place. Lights on TSEM will
show proper sequence according to subparagraph (b) 7 Momentarily press the trigger on LHG.
3 above. Note completion of firing sequence by observing a
loss of the FIRE flag on PSI. Verify that TSEM firing
2 4 Verify that indicator for missile No. 1 on sequence is in accordance with subparagraph (b)3
TCP switches from MSL to barber pole pattern. above.
25 When FIRE flag disappears, press 8 Return STOW/TRK/ACQ switch to
RESET button on TSEM and verify that indicator for STOW.
missile No. 1 on TCP again indicates MSL.
9 Check that MISSILE SELECT switch on
2 6 Press and hold ACTION switch on LHG TCP has automatically selected missile No. 2 or the
and drive TSU LOS out of constraints in elevation. Pull next available missile. Check pilot L-R TOW indicator.
trigger to confirm missile will not fire.
1 0 Repeat steps 5 through 9 for all
2 7 Press CONST OVRD switch on SHC. remaining missile positions. Verify that PSI and TCP
Verify appearance of ATTK flag in the eyepiece of TSU indications are normal and verify TSEM firing
and on PSI. RDY flag should not appear. sequence.
9-170
TM 55-1520-236-23
1 1 For missile position No 8, set TCP TSU. The TOW missile can be guided to target only if
CAMERA switch to AUTO. Verify that camera the initial launch thrust positions the missile within
operations (if available) start when the LHG trigger is this field of view. During the attack mode, when the
pressed and stop with the loss of fire flag indication gunner selects a missile for firing, the launcher
on PSI. containing the selected missile is activated. Upon
activation, the SECU initial command drives the
1 2 Position gunner PLT ORIDE switch to launcher up. Angular position signals from the TSU
PLT ORID. Observe that TCP system status indicator resolver are routed to the SECU, processed through
moves to OFF. buffer amplifier stages, then applied to the respective
launcher resolver. The launcher resolver output
1 3 Turn TSEM off. provides position feedback to the servo amplifier loop,
and the accelerometer provides launcher
1 4 Place pilot MASTER ARM to OFF, PLT acceleration feedback to the servo amplifier loop. The
ORIDE to OFF, and TCP MODE SELECT switch to OFF. servo amplifier output to the hydraulic actuator servo
coil allows the hydraulic actuator to change the pitch
1 5 Turn CAMERA (if available) switch to angle of the activated launcher when hydraulic
OFF. pressure is provided to the actuator. The SECU also
has a detector circuit which decreases the servo
d. Conclusion of Tests. Upon completion of the amplifier gain when the launcher approaches the
preceding tests, de-energize and disconnect auxiliary mechanical elevation stop at either extreme.
power unit and hydraulic ground test cart. Remove Hydraulic pressure is applied to the activated
TSEM from launcher. launcher through the hydraulic solenoid valve and
the launcher pitches from stow position to the correct
9-467. TROUBLESHOOTING - M65 pitch angle relative to the TSU LOS. When fired, the
missile is launched into the field of view of the
TOW MISSILE SUBSYSTEM CIRCUITRY.
infrared receiver, and wire transmitted command
a. Airframe circuitry and components. Refer to signals from the M65 guidance and command
paragraph F-9 in Appendix F for wiring diagram and functional group steers the missile along the TSU
trace malfunctioning circuit loop, using standard LOS. After launch, the SECU activate signal ceases
electronic troubleshooting procedures and standard and the launcher is returned to stow position. The
test equipment. Localize malfunctioning components hydraulic solenoid is turned off after a delay of 1.5
and repair or replace, as required. 0.75 seconds. The SECU is located just aft of the
ammunition compartment (figure 9-23).
b. M 6 5 T O W m i s s i l e subsystem.
Troubleshooting of the M65 TOW missile subsystem 9-470.
CLEANING - SERVO
is accomplished during BIT (built-in test) procedures ELECTRONIC CONTROL UNIT (SECU).
and also by use of Test Set, Guided Missile System
(TSGMS). Refer to TM 9-1425-473 series a. Remove moisture and loose dirt with a clean,
maintenance manuals for troubleshooting soft cloth.
procedures.
9-468.
SERVO ELECTRONIC
CONTROL UNIT (SECU).
9-469.
DESCRIPTION - SERVO Cleaning solvent is flammable and toxic.
ELECTRONIC CONTROL UNIT (SECU). Provide adequate ventilation. Avoid
prolonged breathing of solvent vapors
The servo electronic control unit (SECU) provides and contact with skin or eyes.
regulated power and contains signal switching, servo
amplifier, logic, and buffering circuitry necessary to b. Remove grease, fungus, and dirt with a clean,
align the pitch angle of the TOW missile launchers lint-free cloth dampened with dry cleaning solvent
with the pitch angle of the line-of-sight (LOS) of the (C112).
telescopic sight unit (TSU). Slaving of the two pitch
angles ensures that the TOW missile will reliably c. Remove dirt from electrical connectors with a
enter the field of view of the infrared receiver of the bristle brush.
9-171
TM 55-1520-236-23
9-471. ~ INSPECTION - SERVO c. Close and secure access panel.
ELECTRONIC CONTROL UNIT (SECU).
d. Close left ammo compartment door.
a. Inspect SECU case for cracks or dents.
e. I n s t a l l p r i n t e d w i r i n g a s s e m b l y i n S E C U
case. Close door and fasten two screw assemblies.
b. Inspect SECU for secure mounting.
c. Inspect electrical connectors for broken pins or 9-475. q W I N G S T O R E S ARMAMENT
cracked inserts. SYSTEMS CIRCUITRY.
d. Inspect printed wiring assemblies for cracked, 9-476. @ DESCRIPTION - WING
broken, loose or missing hardware and components; S T O R E S A R M A M E N T S Y S T E M
burned components and wiring; cracked, chipped, or CIRCUITRY
broken wiring board. The wing stores armament systems consist of the
9-472. m REMOVAL - SERVO XM138 rocket management subsystem circuitry,
ELECTRONIC CONTROL UNIT (SECU). XM18 minigun circuitry, and wing stores jettison
circuitry.
a. Ensure all electrical power is OFF.
9 - 4 7 7 . ~ X M 1 3 8 ROCKET
b. Open left ammo compartment door just MANAGEMENT - S U B S Y S T E M
forward of wing. CIRCUITRY.
c. R e m o v e a c c e s s p a n e l o n a f t a m m o 9-478. ~ DESCRIPTION - ROCKET
compartment bulkhead. MANAGEMENT SUBSYSTEM CIRCUITRY.
d. Disconnect electrical connectors from SECU. The rocket management subsystem circuitry enables
Protect receptacles and plugs with caps or electrical the pilot to determine the number of rockets-on-board
tape (C121). before and after firing, select the warhead and fuze
type, set the fuze to compensate for forest canopy or
e. Remove mounting screws and washers bunker cover thickness to be penetrated, select the
securing SECU to structure and remove SECU. rate at which the rockets will be fired, select singles,
pairs, or quads, select the total number of rockets to
f. L o o s e n t w o s c r e w a s s e m b l i e s o n f r o n t o f be fired, select the range in meters, and to Iaunch the
SECU. Open door assembly and slide printed wiring
rockets from rocket launchers mounted on any or all
assemblies out, if required. of the four wing stations. With the systems armed,
rockets may be launched by pressing either the pilot
9-473. ~ R E P A I R SERVO WING ARM FIRE switch or gunner WING ARM FIRE
ELECTRONIC CONTROL UNlT (SECU). switch (when in PLT ORIDE mode).
a. Repair connectors, and tighten or replace loose
9-479. Q FUNCTIONAL TEST-ROCKET
or missing mounting screws.
MANAGEMENT SUBSYSTEM CIRCUITRY.
b. Replace SECU if case is damaged or defective.
The following functional test of the XM138 rocket
Evacuate removed SECU to higher maintenance level
management system (RMS) is designed to be
for disposition.
performed using the RMS on-board built-in test (BIT)
c. Replace printed wiring assemblies as required. (figures 9-25 and 9-26).
9-474. ~ I N S T A L L A T I O N - S E R V O
ELECTRONIC CONTROL UNIT (SECU).
a. Position SECU in place and secure with Ensure no live ammunition is present in
mounting screws and washers. any of the armament systems.
b. Remove protective caps or electrical tape from a. Open all circuit breakers and place all switches
connectors and connect to respective receptacles on to their OFF or de-energized positions.
SECU.
9-172 Change 12
TM 55-1520-236-23
b. Connect a 28 Vdc external power source to
helicopter external power receptacle and energize
power source.
c. Place pilot MASTER ARM switch in STBY
position.
Change 12 9172.1/(9.172.2 blank)
TM 55-1520-236-23
d. Press the pilot RMS display unit TEST switch.
The RMS BIT test will perform two routines when the
TEST switch is pressed.
(1) The first routine is a digital display test and
checks the display segments by lighting all segments
and displaying a lighted eight (8) in all eight positions
of the RND REM Panel on the pilot display unit (DU).
The RMS BIT will identify a fault during the first
routine by displaying a number less than eight (8) in
the position containing the fault (figure 9-25).
(2) The second routine is a line replaceable unit
(LRU) fault identification and location test which
automatically follows the first routine. This test
provides for the detection and isolation of any LRU
(DU and four operations units) malfunction and non-
compliant verification of LRU functions. Test results
are visually displayed on the RND REM panel of the
pilot display panel. If all LRUs are functioning properly
as determined by the test routine the number seven
(7) will be displayed for each of the five LRUs (figure 9-
26). A malfunction or non-complaint of any LRU will Figure 9-26. LRU Fault Identification
cause the associated digital display to be blanked and Location Test
indicating the LRU should be replaced.
c. The BIT test may be performed at any time but (1) The equipment status indicator flags permit
ONLY if the MASTER ARM switch is in the STBY the last LRU status to be displayed after primary
position. Switching to the ARM position will override power outages or after primary power has been
the TEST switch and terminate any test in progress, removed.
returning the system to normal operation.
(2) The equipment status indicators are
f. An additional verification of the defective LRU magnetic-latching and mechanically resettable.
will be the activation of the equipment status
indicator flag on the malfunction LRU.
9-480. ~ TROUBLESHOOTING - XM138
ROCKET MANAGEMENT SUBSYSTEM
CIRCUITRY.
NOTE
A filter (21A12) is installed between
airframe wiring and display unit to
prevent excessive noise in fm radio
system. If a noise problem exists in fm
radio system, turn RMS off to determine
if filter is defective. Replace filter if
required.
a. Airframe Circuitry and Components. Refer to
paragraph F-9 in Appendix F for wiring diagram and
trace malfunctioning circuit loop using standard
209075-408 electronic troubleshooting procedures and standard
test equipment. Localize malfunctioning components
Figure 9-25. ~ DU Digital Display Test and repair or replace, as required.
Change 2 9-173
TM 55-1520-236-23
b. XM138 Rocket Management Subsystem. c. Disconnect two electrical connectors from
Troubleshooting of the XM 138 rocket management each OU. Protect receptacles and plugs with caps or
subsystem is accomplished during BIT (built-in-test) electrical tape (C121).
procedure.
d. Remove four mounting bolts and washers to
9-481. ~ OPERATIONS UNITS (OU). remove the OU from the wing leading edge bulkhead.
9-482. DESCRIPTION - OPERATIONS 9-486.
(OU).
REPAIR - OPERATIONS UNITS
UNITS (OU).
The operations units receive electrical command a. Repair connectors, and tighten or replace loose
signals from the integrated control and display unit. or missing mounting or assembly screws or bolts.
The operations unit evaluates the information and
provides the proper signals to set the fuzes on the b. Replace OU if case is damaged or defective.
rockets for desired running time and to provide power Evacuate removed OU to next higher echelon for
for the electronic circuitry. repair or disposition (TM 9-1270-217-13 & P).
9-483. CLEANING - OPERATIONS 9-487. m INSTALLATION
OPERATIONS UNITS (OU).
-
UNITS (OU).
a. Position OU on the wing leading edge bulkhead
a. Remove moisture and loose dirt with a clean, and install mounting bolts and washers.
soft cloth.
b. Remove protective caps or electrical tape from
two electrical connectors and install on OU.
Cleaning solvent is flammable and toxic, 9-488. ~ X M 1 8 MINIGUN
Provide adequate ventilation. Avoid CIRCUITRY.
prolonged breathing of solvent vapors
and contact with skin or eyes. 9-489.
DESCRIPTION - XM18
MINIGUN CIRCUITRY.
b. Remove grease, fungus, and dirt with a clean,
lint-free cloth dampened with dry cleaning solvent The XM-18 minigun circuitry enables the pilot or
(C112). gunner (when in PLT ORIDE mode) to select and fire
either or both XM-18 miniguns mounted on inboard
c. Remove dirt from electrical connectors with a wing stations. With the system armed, either or both
bristle brush. miniguns may be fired by pressing either the pilot
WING ARM FIRE switch or gunner WING ARM FIRE
9-484. ~ INSPECTION - O P E R A T I O N S switch (when in PLT ORIDE mode).
UNITS (OU).
9-490. ~ FUNCTIONAL TEST - XM18
a. Inspect OU case for cracks or damage. MINIGUN CIRCUITRY.
b. Inspect electrical connector for damaged pins The following functional test of the XM18 minigun
and cracked connector inserts or hood. circuitry is designed to be performed using a test set
as indicated in figure 9-27, or a suitable equivalent.
c. Inspect OU for secure mounting.
9-485. ~ REMOVAL - OPERATIONS
UNITS (OU).
a. Insure all electrical power is o f f . Ensure no live ammunition is present in
any of the armament systems.
b. Remove OU access panel(s) (Outboard and
inboard leading edge access panels on the left and a. Open all circuit breakers and place all switches
right wing). to their OFF or de-energized positions.
9-174
TM 55-1520-236-23
209475-510
Figure 9-27. ~ XM18 Minigun Circuitry Test Panel
9-175
TM 55-1520-236-23
b. Connect the two XM18 test set cables to g. Place WPN CONTR switch on pilot ARMT panel
connectors (21A10P1 and 21A11P1) at inboard wing in GUNNER position.
stores disconnect area in wings on the helicopter.
h. Perform steps 1 through 15 in the XM18
c. Connect a 28 Vdc external power source to minigun checkout chart, table 9-37.
helicopter external power receptacle and energize
power source.
i. With the turret gun installed and operational,
d. Close WPN CONT, RH MINIGUN, and LH position turret full left and perform steps 7, 8, 11, 12,
MINIGUN circuit breakers. 13, and 15 in the XM18 minigun checkout chart, table
9-37. No FIRED light shall illuminate.
e. Place WPN CONTR switch on pilot ARMT panel
in PILOT position. Check that no lights are illuminated
on the test set. j. With the turret gun installed and operational,
position turret full right and perform steps 7, 8, 11,
f. P e r f o r m s t e p s 1 t h r o u g h 1 5 i n t h e X M 1 8 12, 13, and 15 in the XM18 minigun checkout chart,
minigun checkout chart, table 9-37. table 9-37. No FIRED light shall illuminate.
Table 9-37. XM18 Minigun Checkout Chart
Pilot Gunner Pilot Gunner
WING WING WING WING Pilot MASTER Test Set Test Set
STORE STORE ARM FIRE ARM FIRE ORIDE ARM BAT CHG FIRED
Step Switch Switch Switch Switch Switch Switch Lights Lights
1 GUN either OFF STBY on off
2 GUN GUN fire OFF STBY on off
3 GUN GUN fire OFF STBY on off
4 GUN GUN fire OFF OFF on off
5 GUN GUN fire OFF OFF off off
6 GUN RKT fire OFF ON off on
release off
7 GUN GUN fire OFF ON off on
release off
8 RKT GUN fire OFF ON off off
9 GUN GUN fire ON ON off off
10 GUN RKT fire ON ON off off
11 RKT GUN fire ON ON off on
release off
12 GUN GUN fire ON ON off on
release off
9-176
TM 55-1520-236-23
Table 9-37. XM18 Minigun Checkout Chart (Cont)
Pilot Gunner Pilot Gunner
WING WING WING WING Pilot MASTER Test Set Test Set
STORE STORE ARM FIRE ARM FIRE ORIDE ARM BAT CHG FIRED
Step Switch Switch Switch Switch Switch Switch Lights Lights
13 GUN GUN fire OFF ON off on
release off
14 GUN RKT fire ON ON off off
15 RKT GUN fire OFF ON off on
release off
9-491. TROUBLESHOOTING - XM18 tripped circuit breakers are omitted from indications
MINIGUN CIRCUITRY. of trouble. Such trouble is usually easily detected and
corrected. Broken wiring is always a probable cause
Refer to paragraph F-9 in Appendix F for wiring of circuit malfunction or failure and has not been
diagram. Use Table 9-38 and perform checks as included.
necessary to isolate trouble. In the following table,
NOTE
Before you use this table, be sure you
have performed all normal operational
checks. If you have a malfunction which
is not listed in this table, notify the next
higher level of maintenance.
Table 9-38. ~ Troubleshooting XM-18 Minigun Circuitry.
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. With switch breakers on AC/ARMT circuit breaker panel in WPN FIRE, LH GUN, and RH GUN positions,
MASTER ARM switch in ARM, and WING STORE switch in GUN, XM18 miniguns do not fire when pilot
WING ARM FIRE switch is pressed.
STEP 1. Check for defective wiring.
If defective, repair wiring.
STEP 2. Check for defective master arm relay (19K31).
If defective, replace relay (paragraph 9-16).
9-177
TM 55-1520-236-23
Table 9-38. Troubleshooting XM-18 Minigun Circuitry (Cont)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
STEP 3. Check for defective WING STORE switch.
If defective, replace switch (paragraph 9-16).
STEP 4. Check for defective WING ARM FIRE switch on pilots cylic stick.
Handle in accordance with instructions pertinent to the cyclic stick (paragraph 11-40).
With switch breakers on AC/ARMTcircuit breaker panel in WPN FIRE, LH GUN, and RH GUN, MASTER ARM
switch in ARM, and WING STORE switch in GUN, one XM18 minigun fires, but the other does not fire.
STEP 1. Check for defective ground connection to airframe on the side which does not fire.
If defective, repair ground connection.
STEP 2. Check for defective wiring.
If defective, repair wiring.
STEP 3. Check for defective wing disconnect connector (21J1-21P1 or 21J2-21P2) on the side which does
not fire.
If defective, replace connector (paragraph 9-16).
STEP 4. Check for defective LH GUN or RH GUN switch breaker which controls the side that does not fire.
If defective, replace circuit breaker (paragraph 9-23).
With switch breakers on AC/ARMT circuit breaker panel in LH GUN and RH GUN, TURRET PWR circuit
breaker closed, PILOT ORIDE switch in PILOT ORIDE, and WING STORE switch in GUN, neither XM18
minigun fires when WING ARM FIRE switch on gunners cyclic stick is pressed.
STEP 1. Check for defective wiring.
If defective, repair wiring.
STEP 2. Check for defective TURRET CONTR circuit breaker.
If defective, replace circuit breaker (paragraph 9-23).
STEP 3. Check for defective WING ARM FIRE switch on gunners cyclic stick.
Handle in accordance with instructions pertinent to the cyclic stick (paragraph 11-40).
9-178
TM 55-1520-236-23
Table 9-38. Troubleshooting XM-18 Minigun Circuitry (Cont)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
STEP 4. Check for defective connector (21A9P1), (21A8P1), (21J1-21P1), (21J2-21P2).
If defective, replace connector (paragraph 9-16).
STEP 5. Check for defective turret system circuitry.
Refer to TM9-1090-206 series maintenance manuals.
4. With TURRET CONTR circuit breaker and minigun switch breakers in LH GUN and RH GUN positions, PILOT
ORIDE switch positioned to PILOT ORIDE, and WING STORE switch in GUN position, one XM18 minigun
fires, but the other does not fire when gunners WING ARM FIRE switch is pressed.
STEP 1. Check for defective wiring.
If defective, repair wiring.
STEP 2. Check for defective TURRET CONTR circuit breaker.
If defective, replace circuit breaker (paragraph 9-23).
STEP 3. Check for defective WING ARM FIRE switch on gunners cyclic stick.
Handle in accordance with instructions pertinent to the cyclic stick (paragraph 11-40).
STEP 4. Check for defective connector (21A10P1), (21A11P1), (21J1-21P1), (21J2-21P2).
If defective, replace connector (paragraph 9-16).
STEP 5. Check for defective turret system circuitry.
Refer to TM 9-1090-206 series maintenance manuals.
9-492.
WING STORES JETTISON 9-494.
FUNCTIONAL TEST-WING
CIRCUITRY. STORES JETTISON CIRCUITRY.
9-493.
DESCRIPTION - WING
The functional test of the wing stores jettison circuitry
STORES JETTISON CIRCUITRY.
is designed to be performed using a test set as
The wing stores jettison circuitry enables the pilot to indicated in figure 9-28, or equivalent.
select wing station weapons (inboard or outboard) to
be jettisoned in an emergency situation. Selected
wing station weapons are jettisoned by pressing the a. Open all circuit breakers and place all switches
pilot or gunner WING STORES JETTISON switch. to their OFF or de-energized positions.
9-179
TM 55-1520-236-23
209475-509
Figure 9-28. ~ Wing Stores Circuitry Test Panel
9-180
TM 55-1520-236-23
b. Connect wing stores jettison test set cables to e. Ensure that WING STORE JETTISON switch on
respective helicopter receptacles (21SQ1J1, gunner instrument panel is in the down position and
21SQ2J1, 21SQ3J1, and 21SQ4J1). that metal guard is in place over the switch toggle.
c. Connect a 28 Vdc external power source to
helicopter external power receptacle and energize f. P l a c e W I N G S T O R E S s w i t c h b r e a k e r s o n
power source. AC/ARMT circuit breaker panel to PLT JETT and GNR
JETT. Check that no JETTISON lights on test set are
d. Ensure that JETTISON SELECT switches on illuminated and perform the checkout procedures, in
pilot miscellaneous panel are in OFF position. wing stores jettison checkout chart, table 9-39.
Table 9-39. Wing Stores Jettison Checkout Chart
Pilot OUTBD Pilot INBD Gunner
JETTISON JETTISON JETTISON Pilot CLTV Gunner CLTV
SELECT SELECT SELECT JETTISON JETTISON Results
Switch Switch Switch Switch Switch Test Set
Step (21S5) (21S4) (21S2) (21S3) (21S1) Jettison Lights
1 Close PLT JTSN circuit breaker. No test set
jettison lights
2 OFF OFF BOTH Depress & OFF No test set
Release jettison lights
3 OFF OFF INBD Depress & OFF No test set
Release jettison lights
4 OFF OFF OUTBD Depress & OFF No test set
Release jettison lights
5 OUTBD OFF BOTH Depress & OFF Outboard lights
Release illuminate&extinguish
approximately
0.5 seconds later
6 OFF INBD BOTH Depress & OFF Inboard lights
Release illuminate and
extinguish approx.
0.5 seconds later
7 OUTBD INBD BOTH Depress & OFF Outboard and inboard
Release lights illuminate
and extinguish
approx. 0.5
seconds later
8 OUTBD INBD BOTH Released JTSN No test set
jettison lights
9 OUTBD OFF BOTH Released JTSN No test set
jettison lights
9-181
TM 55-1520-236-23
Table 9-39. ~Wing Stores Jettison Checkout Chart (Cont)
Pilot OUTBD Pilot INBD Gunner
JETTISON JETTISON JETTISON Pilot Gunner
SELECT SELECT SELECT JETTISON JETTISON Results
Switch Switch Switch Switch Switch Test Set
Step (21S5) (21S4) (21S2) (21S3) (21S1) Jettison Lights
10 OFF INBD both Released JTSN No test set
jettison lights
11 OFF OFF BOTH Released OFF No test set
jettison lights
12 Close GNR JTSN circuit breaker. No test set
jettison lights
13 OFF OFF INBD Released JTSN Inboard lights
illuminate
14 OFF OFF OUTBD Released JTSN Outboard lights
illuminate
15 OFF OFF BOTH Released JTSN Outboard &
inboard lights
illuminate
16 Insert jumber wires between pins A & C for both connectors 20P8J01 & 20S8J01
17 OFF INBD BOTH Depress & OFF Outboard lights
Release illuminate and
extinguish approx.
0.5 seconds later
18 OFF OFF INBD Released JTSN Outboard lights
illuminate and
remain illuminated
19 Repeat Set 13
20 Open GNR JETT circuit breaker
21 Repeat Steps 1, 2, 3, 4, 7, 8, 9, & 10
22 Repeat Step 5 No test set
jettison lights
23 Repeat Step 6 Only outboard
lights illuminate
and extinguish
approximately 0.5
seconds later
24 Remove jumper wires from connectors 20P8J01 & 20S8J01
25 Remove test set. Restore Wing stores wiring to normal configuration
9-182
TM 55-1520-236-23
9-495.
TROUBLESHOOTING - WING of circuit malfunction or failure and has not been
STORES JETTISON CIRCUITRY. included.
NOTE
Refer to paragraph F-9 in Appendix F for wiring
diagram. Use Table 9-40 and perform checks as Before you use this table, be sure you
necessary to isolate trouble. In the following table, have performed all normal operational
tripped circuit breakers are omitted from indications checks. If you have a malfunction which
of trouble. Such trouble is usually easily detected and is not listed in this table, notify the next
corrected. Broken wiring is always a probable cause higher level of maintenance.
Table 9-40. 9 Troubleshooting Wing Stores Jettison Circuitry
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. WING STORES JTSN and PLT JTSN circuit breakers are closed. Pilot JETTISON SELECT switches are
positioned as required to jettison appropriate wing stores. Gunner JTSN SEL switch is in BOTH position and
gunner JETTISON switch is in OFF position. The appropriate (outboard, inboard, or both) wing stores do not
jettison when pilot collective JETTISON switch is depressed.
STEP 1. Check for defective wiring.
Replace or repair wiring.
STEP 2. Check for defective PLT JTSN or WING STORES JTSN circuit breakers. (21CB1 and/or 21CB2).
Replace defective circuit breaker(s) (paragraph 9-23).
STEP 3. Check for defective pilot collective JETTISON switch (21S3).
Replace defective switch (paragraph 9-16).
STEP 4. Check for defective pilot JETTISON SELECT switches (21S4 and/or 21S5).
Replace defective switch(es) (paragraph 9-16).
STEP 5. Check for defective or incorrectly installed diodes (21CR3, 21CR4).
Replace defective diodes (paragraph 9-16).
STEP 6. Check for defective pilot jettison switch relay (21K3).
Replace defective relay (paragraph 9-16).
STEP 7. Check for defective jettison control relay (21K2) or pilot jettison control relay (21K4).
Replace defective relay (paragraph 9-16).
9-183
TM 55-1520-236-23
Table 9-40. Troubleshooting Wing Stores Jettison Circuitry (Cont)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
2. With conditions same as condition 1, appropriate wing stores are jettisoned on one side, but not on the other
side when pilot collective JETTISON switch is depressed.
STEP 1. Check for defective wiring.
Repair wiring, if defective (paragraph 9-16).
STEP 2. Check for defective wing disconnect connectors (21J1/21P1, 21J3/21P3 or 21J2/21P2,
21J4/21P4) on side that does not jettison properly.
Replace defective connector (paragraph 9-16).
3. WING STORES JTSN, PLT JTSN, and GNR JTSN circuit breakers are closed. Pilot JETTISON SELECT
switches are both positioned to OFF. Gunner JTSN SEL switch is positioned as required to jettison
appropriate wing stores. Pilot collective JETTISON switch is released. The appropriate (outboard, inboard, or
both) wing stores do not jettison when gunner JETTISON switch is positioned to JTSN.
STEP 1. Check for defective wiring.
Replace or repair wiring.
STEP 2. Check for defective GNR JTSN circuit breaker (21CB5).
Replace circuit breaker (paragraph 9-23).
STEP 3. Check for defective gunner JETTISON switch (21S1).
Replace defective switch (pararaph 9-16).
STEP 4. Check for defective gunner JTSN SEL switch (21S2).
Replace defective switch (paragraph 9-16).
STEP 5. Check for defective or incorrectly installed diodes (21CR5, 21CR6).
Replace defective diodes (paragraph 9-16).
STEP 6. Check for defective gunner jettison control relay (21K5).
Replace defective relay (paragraph 9-16).
STEP 7. Check for defective jettison control relay (21K2).
Replace defective relay (paragraph 9-16).
4. With conditions same as condition 3, appropriate wing stores are properly jettisoned on one side but not on
the other side when gunner JETTISON switch is positioned to JTSN.
9-184
TM 55-1520-236-23
Table 9-40. Troubleshooting Wing Stores Jettison Circuitry (Cont)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
STEP 1. Check for defective wiring.
Repair wiring, if defective.
STEP 2. Check for defective wing disconnect connectors (21J1/21P1, 21J3/21P3 or 21J2/21P2,
21J4/21P4) on side that does not jettison properly.
Replace defective connector (paragraph 9-16).
SECTION X. ~ ARMAMENT AND FIRE CONTROL SYSTEMS CIRCUITRY
9-496. q ARMAMENT AND FIRE subsystem (HSS) and the turret control portion of the
CONTROL SYSTEMS CIRCUITRY. stabilized telescopic sight unit (TSU) of the M65 TOW
missile subsystem. The interconnecting airframe
9-497. m DESCRIPTION - ARMAMENT wiring integrates the three subsystem components
AND FIRE CONTROL SYSTEMS through the interface control unit (IFCU), electronic
CIRCUITRY. interface assembly, and the pilot and gunner
armament control panels. For additional information
The armament systems consist of the universal turret pertaining to the universal turret subsystem, refer to
subsystem, wing stores armament subsystem, XM- TM 9-1090-206 series maintenance manuals. For
138 rocket management subsystem, M-136 helmet additional information pertaining to the Ml 36 helmet
sight subsystem, and M65 TOW missile subsystem. sight subsystem, refer to TM 9-1270-212-14. For
The fire control system (FCS) consists of the XM22 additional information pertaining to the TSU and M65
fire control computer (FCC), XM76 head up display TOW missile subsystem, refer to paragraph 9-518
subsystem (HUD), XM143 Fire and flight air data and TM 9-1425-473 series maintenance manuals.
subsystem (ADS), and airborne laser tracker (ALT).
Functional test and troubleshooting procedures are
presented for each armament subsystem circuitry. 9-500. ~ FUNCTIONAL TEST -
References are made to appropriate maintenance UNIVERSAL TURRET SUBSYSTEM
manuals and/or chapters within this maintenance CIRCUITRY.
manual, where applicable. Refer to paragraph F-9 in
Appendix F for equipment location charts and wiring
a. Requirements.
diagrams.
(1) Test equipment.
9-498. UNIVERSAL TURRET
SUBSYSTEM CIRCUITRY.
(a) Auxiliary power. Ground power unit
9-499. m DESCRIPTION - UNIVERSAL (T14).
TURRET SUBSYSTEM CIRCUITRY.
The universal turret subsystem interfaces, by means (b) Hydraulic. Hydraulic ground test cart
of auxiliary equipment, with the M136 helmet sight (T11).
9-185
TM 55-1520-236-23
HSS reticle brightness knob midpoint
LASER SAFE/
TURRET DEPR LIMIT DEPR LIMIT
RANGE SHORT
All weapons shall be dry fired. Only
dummy ammunition with smooth cases
(d) TOW control panel.
like live ammuntion shall be used.
(2) Special tools. MODE SELECT OFF
LASER ARM OFF
(a) Round fire simulator (T5).
(b) Airspeed simulator (T10). (e) Pilot instrument panel.
(c) Ground safety pins (2 required) (T66.1). MED
RECOIL COMP
b. Preparation for Testing. (4) Electrical Power. Apply 28-volt dc external
electrical power. (Refer to paragraph 1 -51.)
(1) General. Qualified armament personnel
shall be present during all tests specified herein. The (5) Circuit breakers. Engage the following
following tests shall be accomplished using auxiliary circuit breakers:
electrical power. (Refer to paragraph 1-54.)
(2) Weapon system preparation. (a) DC circuit breaker panel.
(a) Check all system components for proper GEN-FIELD
installation. DC VM
(b) Install ground safety pin in each ejector CAUT LT
rack. GEN BUS RESET
INV
(c) Check that the turret weapon and feeder
DPLR NAV
are properly timed.
(d) Open (off) all circuit breakers.
(b) AC/AR MT circuit breaker panel,
(3) Control switch positions. Position the
following switches as indicated: ADS POWER
TMS PWR
(a) Pilot armament control panel. ARMT CONTR
WPN CONTR
MASTER ARM OFF WPN FIRE
WPN CONTR GUNNER HSS PWR
WING STORE RKT REF XFMR
HSS RCTL brightness knob midpoint SECU PWR
RECOIL COMPEN OFF WING STORE PWR
RANGE SHORT TURRET DRIVE MOTOR
TURRET GUN MOTOR
(b) Pilot miscellaneous control panel, TURRET STOW
TMS BLWR
INBD JETTISON SELECT OFF PLT JETT
OUTED JETTISON SELECT OFF GNR JETT
FCC
(c) Gunner armament control panel.
(6) Power switch positions. Position the
PLT ORIDE OFF following switches as shown:
WING STORE RKT
RD RMNG 750 ALTNR OFF/RESET
TSU/GUN SLEW RATE LOW BATTERY RUN
TUR SLEW GND TEST NON-ESNTL BUS MANUAL
9-186
TM 55-1520-236-23
(7) Gunners miscellaneous panel. Position TSU and slowly rotate LOS downward. The weapon
ELEC PWR/EMER OFF switch to ELEC PWR. should reach lower depression limit at approximately
-5 degrees. Then rotate LOS upward; the weapon
should drive to the upper limit. The reticle should
flash when helmet LOS is out of coincidence with the
commanded gun line and when weapon reaches
upper elevation limit or below zero degrees elevation.
Before proceeding, clear turret area of Release ACTION switch.
any obstructions and warn personnel to
remain on exterior of safety barrier. (g) Position LASER SAFE/TURRET DEPR
LIMIT switch to OFF.
c. Testing Procedures.
(1) Gunner turret control. With test personnel
in the pilot and gunner positions, connect the helmet
sight linkage to the built-in test (BIT) brackets at the In the following steps, excessive
forward support points. downward movement of LOS can cause
barrels to strike ground. Remove barrels
(a) W i t h M A S T E R A R M s w i t c h o n p i l o t or elevate helicopter 30 inches if
armament control panel and PLT OR IDE switch on maximum depression cannot be checked
gunner armament control panel to OFF, check that during flight test.
there is no action or firing of any armament systems
from any triggers. Check that green GUN ELEV
STOWED caution light is illuminated in the pilot (h) While holding gunner helmet sight LOS at
caution panel. 0 degrees elevation and 0 degrees azimuth, press
LHG ACTION switch on TSU and slowly rotate helmet
(b) Position pilot MASTER ARM switch to LOS downward. Confirm that gun barrels move past
STBY. Observe that pilot and gunner STBY indicators the 5 degree depression limit position. Rotate LOS
are illuminated. Also observe that green GUN ELEV upward and confirm that gun barrels move to upper
STOWED advisory light in the pilot caution panel is elevation limit. Release ACTION switch.
illuminated.
(i) M o v e t u r r e t t h r o u g h t o t a l e l e v a t i o n ,
(c) P o s i t i o n H S S B I T s w i t c h o n g u n n e r depression, and azimuth limits. Check that no binding
armament control panel to BIT and check that a GO or interference occurs.
indication appears on the panel indicator.
(j) Rotate sight rapidly both in azimuth and
NOTE elevation. Check that sight reticle flashes
momentarily as turret and HSS LOS are out of
Completion of BIT circuit requires coincidence.
approximately two seconds.
(k) Move turret against upper elevation limit
(d) Check pilot and gunner HSS linkage for and slowly through total azimuth sweep. Check that
freedom of movement in all directions. reticle flashes while turret is against upper limit in all
azimuth positions.
(e) C h e c k t h a t H S S r e t i c l e i l l u m i n a t i o n
controls on pilot and gunner armament control panels (l) Move turret against left and right azimuth
are functioning properly. Turn HSS RETICLE limits and slowly through total elevation sweep.
brightness control knob from OFF to BRT and check Check that reticle flashes while turret is against
for corresponding change in light intensity. Move either azimuth limit in all elevation positions. Total
RETICLE TEST switch to TEST and check that HSS depression at either azimuth shall be checked during
retitles are still illuminated. flight tests.
(f) While holding gunner helmet sight line- (m) Release ACTION switch on the LHG and
of-sight (LOS) at 0 degrees elevation and 0 degrees check that the turret returns to stowed (upper
azimuth; press left hand grip (LHG) ACTION switch on forward) position.
9-187
TM 55-1520-236-23
(n) Return LASER SAFE/TURRET DEPR sight LOS in the same manner as that described for
LIMIT switch to ON. the gunner in subparagraph (1), steps (f) through (n)
above.
(o) Hold the sight in approximately the 0-0
position and depress ACTION switch on LHG. Attempt (f) Position MASTER ARM switch to ARM.
to fire the weapon with the gunner and pilot cyclic
triggers. The weapon should not fire. (g) Repeat steps (q) and (r) of subparagraph
(1) above, except use pilot cyclic stick ACTION switch.
(p) Position pilot MASTER ARM switch to
ARM, Check that pilot and gunner red ARMED (h) Check that pilot cyclic stick trigger fires
indicators are illuminated and that pilot and gunner turret weapon: a 164 round burst at first detent and
STBY indicators are extinguished. continuously at second detent.
(q) Press ACTION switch while holding (3) Pilot override by gunner. P r o c e e d a s
helmet LOS at 0 degree azimuth and 0 degree follows to check out function of gunner overriding
elevation and move RANGE switch to MED and pilot control of weapon:
LONG. Check that turret elevation increases with
increased range settings. Check that helmet sight (a) Position pilot override switch to PLT
reticle does not flash at SHORT, MED OR LONG range ORIDE.
settings. Release ACTION switch. Return RANGE
switch to SHORT. (b) Check that PLT IN CONT indicator
extinguishes and that pilot and gunner red ARMED
(r) Press ACTION switch and move LHG indicator illuminates.
trigger on gunner TSU to the first detent, then the
second. Check that turret weapon fires a 16 4 round
(c) Press gunner cyclic stick ACTION switch
burst at first detent and continuously at second
and check that gunner cyclic stick trigger will fire the
detent.
turret weapon. The gunner HSS should control turret
weapon.
(s) Release ACTION switch and press the
trigger. The turret weapon should not fire. Press pilot
(d) Press LHG ACTION switch and trigger.
ACTION switch and trigger. Check that weapon does
Check that turret weapon does not respond to helmet
not move or fire. Press gunner cyclic ACTION switch
sight and gun does not fire.
and trigger. Check that turret weapon does not move
or fire.
(2) Pilot turret control. Proceed as follows to (e) Press pilot cyclic stick action switch and
check out and test turret weapon and HSS system trigger. Check that pilot helmet sight will not control
while under pilot control: the turret weapon and that gun does not fire.
(f) Position pilot MASTER ARM switch to OFF
(a) Position MASTER ARM switch to STBY. and check that both pilot and gunner red ARMED
indicator lights remain on. Check that only gunner
(b) Position pilot WPN CONTR switch to cyclic stick trigger will fire turret weapon.
PILOT. Check that PILOT IN CONT indicator on gunner
armament control panel illuminates.
(g) Position pilot WPN CONTR switch to
(c) Press TSU LHG ACTION switch. Check GUNNER. Check that only gunner cyclic stick trigger
that gunner helmet sight has no control of the turret. will fire turret weapon.
(d) Press gunner cyclic grip ACTION switch. (h) If ammunition box booster is connected
Check that gunner helmet sight has no control of the during the preceding checks, counter should show
turret weapon. less than 250 rounds (corresponding to the number of
rounds fired).
(e) Press ACTION switch on pilot cyclic grip
and check that turret weapon follows pilot helmet (i) Return PLT ORIDE switch to OFF.
9-188
TM 55-1520-236-23
(4) Turret airspeed compensation. Check out (d) Press ACTION switch on TSU LHG and
the contribution of airspeed to the fire control solution cyclic grip ACTION switch. Check that turret weapon
as follows: does not follow gunner helmet sight or TSU
commands.
(a) Position MASTER ARM switch to STBY.
(e) Position MASTER ARM switch to ARM.
(b) Position MODE SELECT switch to
TSU/GUN. (f) Press pilot cyclic grip ACTION switch and
trigger. Check that turret weapon fires. Check that
(c) Ascertain that the ADS ANTIICE circuit rocket direct reticle is positioned to 0-0 on HUD.
breaker is OFF and ADS pitot tube is cool enough to
handle. (6) Range compensation. Check out range
compensation operation as follows:
(d) Apply air pressure to the air data
subsystem EPU to simulate 100 5 knots airspeed. (a) Disengage FCC circuit breaker. Position
Position pitot tube to straight ahead. MASTER ARM switch to STBY, MODE SELECT switch
on TOW Control Panel (TCP) to TSU/GUN, Hl/LO
MAG switch to Hl, WPN CONTR to GUNNER, and
(e) Press LHG ACTION switch and using the
LRF/PWR circuit breaker to OFF.
SHC stick rotate the LOS of the TSU to 90 degrees left.
Turret weapon will follow the sight to the left. Switch
(b) Position STOW/TRK/ACQ switch on SHC
the FCC/OFF breaker to OFF. The gun shall move
to TRK and hold TSU LOS on a fixed distant target.
forward, closer to zero degrees azimuth. Reset the
breaker to FCC. The gun shall move farther away from
(c) Press ACTION switch on LHG. Position
zero degrees azimuth.
RANGE switch to SHORT. Position MASTER ARM
switch to ARM. Position FCC/OFF circuit breaker to
(f) Repeat step (e) at 90 degrees right. In both
FCC. Check that turret weapon elevation increases by
cases forward airspeed causes the gun to deflect
approximately 9.2 milliradians above FCC OFF
farther away from zero degrees azimuth.
position.
(g) Repeat step (e) at a depressed elevation
(d) Position RANGE switch to MED. Check
angle. Use caution that barrels do not hit ground. As
t h a t t u r r e t weapon elevation increases by
before, forward airspeed causes the gun to deflect
approximately 24.4 milliradians above FCC OFF
farther from the forward position.
position.
(h) Turn MODE SELECT switch to OFF.
(e) Position RANGE switch to LONG. Check
t h a t t u r r e t weapon elevation increases by
(i) Turn MASTER ARM to OFF.
approximately 42.8 milliradians above FCC OFF
position.
(5) Fixed mode firing. Check out fixed mode
(f) Return RANGE switch to SHORT. Release
firing as follows: ACTION switch. Position MASTER ARM switch to
OFF.
(a) Position pilot WPN CONTR switch to
FIXED, MASTER ARM switch to STBY, HUD PWR
(7) R e c o i l c o m p e n s a t i o n
switch to ON, HUD MODE switch to NORM, HUD
AUTO BAT as desired, and adjust HUD brightness
knob.
(b) Check that turret weapon moves to 0-
degree elevation and 0-degree azimuth position. Do not apply hydraulic power to system
unless electrical power is applied.
(c) Press pilot cyclic grip ACTION switch.
Check that turret weapon does not follow pilot helmet (a) Apply 1500 25 psig hydraulic power to
sight. both systems.
9-189
TM 55-1520-236-23
(b) Connect Round Fire Simulator to FIRE procedures pertaining to the telescopic sight unit
VOLT CONNECTOR. portion of the M65 TOW missile subsystem.
(c) Engage SCAS circuit breakers. Position
9-502. m M136 ELECTRONIC
RECOIL COMP select switch to MED. Position
INTERFACE ASSEMBLY.
RECOIL COMPEN switch to RECOIL COMPEN and
power switch on SCAS control panel to PWR. Engage
9-503. q DESCRIPTION - M136
PITCH, ROLL and YAW ENGAGE switches.
ELECTRONIC INTERFACE ASSEMBLY.
(d) Position WPN CONTR switch to GUNNER.
Position MASTER ARM switch to ARM. Press LHG The electronic interface assembly is a component of
ACTION switch, Rotate sight 90 degrees left. Observe the M 136 helmet sight subsystem that provides
turret is 90 degrees left and level. Press LHG trigger. regulated 28 Vdc power and contains the electronic
Observe SCAS inputs to tail rotor and swashplate. components necessary for the operation of the HSS.
Tail rotor response shall be the same as for left pedal The electronic interface assembly is the point of
inputs. Swashplate inputs shall be the same as for integration with the interface control unit (IFCU)
right cyclic stick (right roll swashplate). which interfaces the HSS and TSU sighting systems
with the universal turret system. The electronic
(e) Repeat for 90 degrees right and level. Tail interface assembly is mounted to the rear cockpit
rotor response shall be the same as for right pedal bulkhead (refer to paragraph F-9 in Appendix F for
inputs. Swashplate inputs shall be the same as for left equipment location charts).
cyclic stick (left roll swashplate).
The electronic interface assembly contains buffer
(f) Repeat for 0 degrees and up elevation.
amplifiers and circuitry required by the linkage
Swashplate inputs shall be the same as for aft stick.
resolvers, azimuth and elevation alignment controls
(g) Repeat for 0 degrees and down elevation. and associated circuitry for boresighting each linkage
Swashplate inputs shall be the same as for forward assembly, and the BITE circuits and controls
stick. necessary to provide the HSS self-test capability. For
additional information and maintenance procedures
(h) Repeat steps (c) through (g) with RECOIL
pertaining to the electronic interface assembly, refer
COMP switch in LOW. Observe smaller inputs to tail
to TM 9-1270-212-14.
rotor and swashplate.
(i) Repeat steps (c) through (g) with RECOIL
COMP switch in HIGH. Observe larger inputs to tail 9-504. m I N T E R F A C E CONTROL
rotor and swashplate. UNIT (IFCU).
(j) O p e n a l l a r m a m e n t s w i t c h e s a n d 9-505. ~ DESCRIPTION - INTERFACE
disengage circuit breakers. disconnect hydraulic CONTROL UNIT (IFCU).
power cart and Round Fire Simulator.
The interface control unit (IFCU) contains the signal
9-501.
TROUBLESHOOTING - switching, signal buffering, reticle lamp and retract
TURRET SUBSYSTEM CIRCUITRY. circuitry, and offset signals from and logic outputs to
a. For troubleshooting procedures, refer to TM the fire control computer (FCC) necessary to interface
55-1520-236-T. the helmet sight subsystem (HSS), stabilized
telescopic sight unit (TSU), airborne laser tracker
b. Turret Subsystem. Refer to TM 9-1090-206 (ALT), and the FCC with the turret subsystem. The
series maintenance manuals for troubleshooting IFCU is located in the right access compartment
procedures pertaining to the universal turret below the wing. See equipment location charts and
subsystem. wiring diagrams in Appendix F. (Refer to paragraph F-
9 for appropriate chart and wiring diagram locations).
c. Helmet Sight Subsystem. Refer to TM 9- When the gunner selects the gun mode of the TOW
1270-212-14 for troubleshooting procedures system, the computing resolver chain contained
pertaining to the M136 helmet sight subsystem. within the turret subsystem is connected to similar
resolvers located in the TSU. Elevation and azimuth
d. Telescopic Sight Unit. Refer to TM 9-1425- commands function are then developed in the TSU
473 series maintenance manuals for troubleshooting which are returned to the turret subsystem as
9-190 Change 3
TM 55-1520-236-23
positioning signals for the turret assembly. The FCC is c. Remove dirt from electrical connectors with a
parallel to the computing resolver chain loop and adds bristle brush.
offset inputs through the IFCU buffer amplifiers for
range and air data compensation and boresight 9-507. ~ I N S P E C T I O N - I N T E R F A C E
corrections using the TSU as a baseline. If the FCC is CONTROL UNIT (IFCU).
not operable, the IFCU eliminates it from the loop and
processes basic line-of-sight information without a. Inspect IFCU case for cracks or damage.
compensation or boresight correction. I n t h i s
manner, as the TSU tracks the target, the turret b. Inspect electrical connectors for broken pins or
assembly is commanded to follow the TSU line-of- cracked connector inserts.
sight. Operation with either the pilot or gunner
helmet sight is accomplished in a like manner. The c. Inspect IFCU for secure mounting.
function of the IFCU is to receive signals from all three
sighting units and to select the appropriate one, 9-508. m REMOVAL - INTERFACE
depending upon the mode activated by the subsystem CONTROL UNIT (IFCU).
operator. This interchange of signals is accomplished
in the IFCU with the use of relay logic. Once the a. Ensure all electrical power is OFF.
sighting unit is selected, turret positioning signals are
routed from the sight back through the IFCU b. Remove IFCU access panel (right side, below
integrated circuit buffer amplifiers to the selected wing).
sight/resolver. The amplifiers are incorporated to
ensure that computing accuracy in the resolver chain c. Disconnect three electrical connectors from
is maintained. In addition to the gun modes, an IFCU. Protect receptacles and plugs with caps or
acquisition mode is provided in which either helmet electrical tape (C121).
sight or the ALT positions the TSU. The acquisition
mode thus allows either the pilot, the gunner, or the d. Remove mounting screws and washers, and
ALT, to acquire a target for the TOW missile or turret remove IFCU from shelf.
gun by utilizing the helmet sight or ALT. The relay
logic in the IFCU also provides a dual mode capability. 9-509.
REPAIR - INTERFACE
If the gunner has selected the TOW mode, the pilot CONTROL UNIT (IFCU).
has the capability of directing the turret assembly
while the other helmet sight is used to acquire a a. Repair connectors, and tighten or replace loose
target for the TOW missile or the turret gun. Relays to or missing mounting screws.
eliminate signals from the FCC when it is in a failed
condition are in the IFCU. The IFCU provides logic b. Replace IFCU if case is damaged or defective.
signals to the FCC to establish the mode that has been Evacuate removed IFCU to higher maintenance level
selected. for disposition.
9-506. m CLEANING - INTERFACE 9-510. m INSTALLATION - INTERFACE
CONTROL UNIT (IFCU). CONTROL UNIT (IFCU).
a. Remove moisture and loose dirt with a clean, a. Position IFCU in place on shelf and install
soft cloth. mounting screws and washers.
b. Remove protective caps or electrical tape from
three electrical connectors and install on IFCU.
Cleaning solvent is flammable and toxic. 9-511. m LOGIC CONTROL UNIT.
Provide adequate ventilation. Avoid
prolonged breathing of solvent vapors 9-512. ~ DESCRIPTION - LOGIC
and contact with skin or eyes. CONTROL UNIT.
b. Remove grease, fungus, and dirt with a clean, The logic control unit (LCU) is an interface unit and a
lint-free cloth dampened with dry cleaning solvent component of t h e u n i v e r s a l t u r r e t s y s t e m . I t
(C112). interfaces with the turret control unit, gun control
9-191
TM 55-1520-236-23
unit, SCAS armament compensation unit, and the a. Remove moisture and loose dirt with a clean,
interface control unit. The LCU is located aft of the soft cloth.
ammunition compartment. Access to the unit is
gained through the access panel located on the left
side of the helicopter above the forward crosstube.
SCAS compensation signals are provided by a
program switch on the LCU. The program switch
selects various circuit configurations in the LCU to
Cleaning solvent is flammable and toxic.
provide for the difference in movement associated
Provide adequate ventilation. Avoid
with the individual weapon that is installed (20MM or
prolonged breathing of solvent vapors
30 MM). Logic command circuits in the LCU provide a
and contact with skin or eyes.
torque enable signal to indicate use of the pitch, roll,
and yaw signals by the SCAS system. Two 1.5 degree
b. Remove grease, fungus, and dirt with a clean,
error detection circuits, one for azimuth and one for
lint-free cloth dampened with dry cleaning solvent
elevation, are provided to prevent the weapon from
(C112).
firing if the turret returns to normal stow while still
clearing. Also, a 180 degree interlock circuit is
c. Remove dirt from electrical connectors with a
provided to prevent or interrupt weapon firing when
bristle brush.
the turret and sight are not in normal azimuth
alignment. Depression limiting circuitry is provided to
prevent the turret from depressing further than a 5
9-514. ~ INSPECTION - LOGIC
degree down angle. When the turret elevation angle
CONTROL UNIT (LCU).
is changed, a resolver generates a voltage which is
a. Inspect LCU case for cracks or damage.
proportional to the sine function of that angular
displacement. This signal is demodulated into a
b. Inspect electrical connectors for broken pins or
proportional linear dc voltage. The demodulation
cracked connector inserts.
circuitry is identical to that used in the turret control
assembly. The second functional section of the circuit
c. Inspect LCU for secure mounting.
detects the phase (direction) and amplitude (angle) of
the demodulators output. When the turret direction is
down and equal to or greater than 5 degrees, a
9-515. ~ REMOVAL - LOGIC CONTROL
transistor is energized providing a ground return for a UNIT (LCU).
relay coil which is powered by the helicopter
a. Ensure all electrical power is off.
electrical circuitry. This accomplishes elevation error
cancellation and prevents the turret from depressing
b. R e m o v e a c c e s s p a n e l a f t o f a m m u n i t i o n
further than the 5 degree down angle. A burst length
compartment above forward crosstube on left side of
limiting circuit with burst limit overide logic
helicopter.
interfaces with the gun control unit. The program
switch on the LCU selects the proper time delay for
c. Disconnect electrical connectors from LCU.
the weapon installed. The burst limit overide disables
Protect receptacles and plugs with caps or electrical
the time delay function by disconnecting the trigger
tape (C121).
signal from the timing circuit. A four input OR circuit
is provided to interface the 180 degree, 1.5 degree
d. R e m o v e m o u n t i n g s c r e w s a n d w a s h e r s .
azimuth, and turret electrical interlocks to the gun
Remove LCU from helicopter.
control unit. A 180 degree false coincidence circuit is
provided to prevent turret latch-up when the selected
sight position differs from the weapon boreline by 9-516. ~ REPAIR - LOGIC CONTROL
more than 180 degrees due to rapid rotation of the
UNIT (LCU).
helmet sight or mode switching. Other LCU circuits
a. Repair connectors and tighten or replace loose
include a transistor inverter for the reticle and an
or missing mounting screws.
elapsed time indicator.
b. Replace LCU if case is damaged or defective.
9-513. ~ CLEANING - LOGIC Evacuate removed LCU to higher maintenance level
CONTROL UNIT (LCU). for disposition.
9-192
TM 55-1520-236-23
9-517. m INSTALLATION - LOGIC
CONTROL UNIT (LCU).
a. Position LCU in place and install with mounting
screws and washers.
Cleaning solvent is flammable and toxic,
b. Remove protective caps or electrical tape and
Provide adequate ventilation. Avoid
connect electrical connectors to LCU.
prolonged breathing of solvent vapors
and contact with skin or eyes.
9-518. ~ TURRET BUFFER
AMPLIFIER.
b. Remove grease, fungus, and ground-in dirt
with a clean, lint-free cloth dampened with dry
9-519. q D E S C R I P T I O N - T U R R E T
BUFFER AMPLIFIER. cleaning solvent (C112).
The turret buffer amplifier contains the buffering c. Remove dirt from electrical connectors with a
circuitry to eliminate noise and to provide loads for bristle brush.
the turret resolvers which are compatible with the
resolver design requirements. This unit also contains
relay interlock switching which will cause 9-521. m REMOVAL - TURRET BUFFER
interruption of the firing voltage if an internal power
AMPLIFIER.
supply failure occurs. The line-of-sight signals
a. Ensure all electrical power is OFF.
buffered by the buffer amplifier isolate the resolvers
from incompatible capacitance loading effects within
b. Remove left side turret fairing.
the logic control unit and the turret control unit in
order that required signal accuracy can be
c. Disconnect electrical connectors from turret
maintained. Signal noise from the turret control unit
buffer amplifier and protect with caps or electrical
which would otherwise result in erratic FCC and/or tape (C121).
turret response, is eliminated by the turret buffer
amplifier. Buffers between the turret and the IFCU
d. Remove mounting screws and washers and
provide low impedance line drivers and isolate turret remove amplifier.
resolvers from external loads. The configuration of
the grounds within the turret buffer amplifier provide
a means to eliminate possible ground loops which 9-522. @ REPAIR - TURRET BUFFER
can be detrimental to resolver signal accuracy. The AMPLIFIER.
turret buffer amplifier also processes the helicopter
supplied 10 volt reference to be applied to the turret a. Repair connectors, and tighten or replace loose
such that the resulting resolver reference voltages or missing mounting screws.
are compatible with the remainder of the weapon
system components. The turret buffer amplifier b. R e p l a c e t u r r e t b u f f e r a m p l i f i e r i f c a s e i s
provides its own separate symmetrical power supply damaged or defective. E v a c u a t e t u r r e t b u f f e r
for the buffer amplifiers and interlock relays within amplifier to higher maintenance level for disposition.
the unit. The unit is located in series with the ships
wiring between the turret and the remainder of the
ships wiring. Signal lines not requiring buffering are
straight through connections within the turret buffer 9-523. ~ I N S T A L L A T I O N - T U R R E T
amplifier. The unit is located on the bulkhead just aft BUFFER AMPLIFIER.
of the turret.
a. Position turret buffer amplifier on bulkhead
9-520. ~ CLEANING - TURRET BUFFER just aft of turret and install mounting screws and
AMPLIFIER. washers.
a. Remove moisture and loose dirt with a clean, b. Remove protective caps or tape and install
soft cloth. electrical connectors.
9-193
TM 55-1520-236-23
9 - 5 2 4 . ~_ M 6 5 O R M 6 5 / C - N I T E 9-526. ~ m FUNCTIONAL TEST - M65
TOW MISSILE SUBSYSTEM CIRCUITRY. OR M65/C-NITE TOW MISSILE SUBSYSTEM
CIRCUITRY.
a. Requirements.
The laser beam is dangerous and can (1) Test equipment.
cause blindness if it enters the eye either
directly or reflected from a shiny surface. (a) Auxiliary power. Auxiliary power unit
Therefore, during ground operation, (T14).
laser light leakage due to improper
mounting of the TSU window cover may (b) Hydraulic. Hydraulic ground test cart
cause injury to the eye. Ensure that the (T11).
window cover is mated to the TSU
window prior to firing the LAAT laser (2) Special tools.
with the LASER switch on the LHG.
(a) TOW simulator evaluation missile TSEM)
9-525. ~ _ DESCRIPTION - M65 OR (T70).
M65/C-NITE TOW MISSILE SUBSYSTEM
(b) IR target simulator (T88).
CIRCUITRY.
(c) Corrector lens (T87).
The M65 TOW missile subsystem circuitry provides
the capabilities to acquire and track a target, b. Preparation for Testing.
compensate for effects of helicopter motion, launch a
TOW missile, and guide the missile to the target. The (1) General. Q u a l i f i e d a r m a m e n t p e r s o n n e l
telescopic sight unit (TSU) portion of the TOW missile shall be present during all tests specified herein.
subsystem interfaces with the universal turret system
circuitry, serving as a flexible sighting unit, and also (2) Configuration. For the purpose of this test,
interfaces with the helmet sight subsystem for use the universal turret will be assumed to have a 20MM
during target acquisition. A laser range finder (LRF) is weapon.
utilized to determine distance to target. The laser
rangefinder interfaces with the fire control computer
(FCC). Range data is displayed in the telescopic sight
NOTE
unit (TSU) and head-up display (HUD). The
M65/C-NITE TSU contains a forward looking infrared
For functional test of M65 TOW missile
(FLIR) sensor which provides the capability to track
launcher system refer to TM 9-1425-
the IR beacon of the TOW 2 missile. The FLIR sensor
473 series maintenance manuals.
allows the system to detect and track targets during
periods of darkness, under obscured battlefield
conditions, or in the presence of missile
countermeasures. The M65/C-NITE components are (3) Weapon system preparation.
FLIR control panel (FCP), FLIR power supply (FPS),
and FLIR missile tracker (FMT). For description and (a) Check all systems components for proper
additional information pertaining to M65 TOW missile installation.
subsystem components, refer to TM
55-1520-236-10 and TM 9-1425-473 series (b) Verify that the launchers are properly
maintenance manuals. For maintenance information connected, four launchers installed, and the TSEM
and procedures pertaining to M65 TOW missile installed in No. 1 missile position. (See figure 9-29.)
subsystem components, refer to TM 9-1425-473
series maintenance manuals. For information and (c) Open (off) all circuit breakers.
maintenance procedures pertaining to the interface
control unit (IFCU), refer to paragraph 9-504. (d) Install ground safety pin in each outboard
ejector rack.
9-194 Change 15
TM 55-1520-236-23
(e) Position IR target simulator (T88) and
corrector lens (T87) in accordance with TM 9-1425-
473-20.
(4) Control switch positions. P o s i t i o n t h e
following switches as indicated:
(a) Pilot armament control panel.
MASTER ARM OFF
WPN CONTR GUNNER
WING STORE RKT
(b) Gunner armament control panel.
WING STORE RKT
LASER SAFE/
TURRET DEPR LIMIT DEPR LIMIT
PLT ORIDE OFF
TSU\GUN SLEW RATE HIGH
Change 15 9-194.1/(9-194.2 blank)
TM 55-1520-236-23
Figure 9-29. ~ TOW Missile Launcher Positions
(5) Electrical power. Check that the aircraft
TURRET SLEW GND TEST
battery is connected, then apply 28-volt dc external
RANGE SHORT
electrical power.
RD RMNG 750
(6) Circuit breakers. E n g a g e t h e f o l l o w i n g
circuit breakers:
(c) TOW control panel (TCP). NOTE
MODE SELECT OFF Ensure circuit breakers in battery
CAMERA OFF compartment are engaged.
MISSILE SELECT 1
LASER ARM OFF (a) DC circuit breaker panel.
GEN FIELD
DC VM
(d) Head up display. CAUT LT
INV
PWR STBY
GEN BUS RESET
MODE NORM
(e) Sight hand control (SHC). (b) Ac circuit breaker panel.
STOW/TRK/ACQ STOW HUD BLWR
HUD PWR
(f) Telescopic sight unit (TSU).
ARMT CONTR
TMS PWR
FILTER SELECT LEVER CLEAR
TMS BLWR
WPN CONTR
(g) - FLIR control panel (FCP).
WPN FIRE
HSS PWR
OFF/ON/BIT OFF
REF XFMR
BORESIGHT OFF
Change 15 9-195
TM 55-1520-236-23
SECU PWR (a.1) - Position FCP OFF/ON/BIT switch
WING STORE PWR to ON.
TURRET PWR
TURRET DRIVE MOTOR (b) Position the TCP MODE SELECT switch to
TSU/GUN.
(7) Power switch positions. Position the
following switches as shown: (c) Verify that system status indicator on TCP
moves from OFF to TEST after approximately 1 0
ALTNR OFF RESET seconds.
BATTERY RUN
NON-ESNTL BUS MANUAL
ELECT PWR/EMER OFF ELEC PWR (d) Verify that within 120 seconds after TCP
system status indicator reads TEST in step (c), the
TCP system status indicator moves to PWR ON.
Before proceeding, clear turret area of (d.1) Verify FCP mode indicator displays
any obstructions and warn personnel to TEST.
remain on exterior of safety barrier.
(e) Verify that all BIT indicators on the TCP
are black.
To ensure immediate control of the
system, do not apply hydraulic power to NOTE
system unless electrical power is applied.
(-) DET HOT will remain displayed on
( 8 ) H y d r a u l i c p o w e r . A p p l y 1500 25 p s i FCP mode indicator until FLIR IR detectors
hydraulic power to system No. 2. have cooled to operating temperature. This
indication may take as long as 15 minutes
(9) Special test equipment. Position the to clear screen.
following test equipment switches or controls as
indicated:
TOW system evaluator missile (TSEM). (e.1) - Verify BIT indicators on FCP are
black.
POWER OFF
FUNCTION LAMP TEST (f) Apply air pressure to the pitot system to
simulate 100 5 knots airspeed.
c. Testing Procedures.
(g) To assure proper operation of the airspeed
(1) Initial system tests. Perform the following pressure transducer verify that 5.0 1.0 volts are
steps for initial system tests: present between terminals Cl and E2 on terminal
board 19TB6. This terminal board is located on the LH
NOTE side of the A/Cat approximately STA. 148.50 and WL
50.
For this test, one technician will be
required in the gunner position, one (h) R e l e a s e a i r p r e s s u r e f r o m t h e p i t o t
technician in the pilot position, and one system.
technician outside the helicopter.
(i) Move MAG switch on LHG to LO.
(a) Position the pilot MASTER ARM switch to
STBY, WPN CONTR switch to GUNNER, HUD PWR (i.1) _ Move MAG switch on LHG to
switch to ON, and adjust HUD BRT knob. DAY.
9-196 Change 15
TM 55-1520-236-23
(j) M o v e S T O W / T R K / A C Q s w i t c h t o T R K . (s) R e t u r n L A S E R / S A F E TURRET DEPR
Observe that TSU turret follows the inputs from SHC LIMIT switch to DEPR LIMIT.
transducer stick and that status flag in TSU is visible.
Verify that turret weapon does not follow the sight.
(2) Telescopic sight controls. Perform the
following steps for initial system turn-on:
(k) P o s i t i o n L A S E R S A F E / T U R R E T D E P R
LIMIT switch to OFF.
(a) - Position FCP OFF/ON/BIT switch
to OFF.
(a.1) Position MODE SELECT switch to STBY
TOW on TOW control panel (TCP). Verify that TCP
system status indicator remains at PWR ON.
Do not depress TSU or gun barrels during
the following check if gun barrels era (a.2) - V e r i f y F C P m o d e i n d i c a t o r
installed. Barrels could strike the ground indicates OFF.
with sufficient force to cause system
damage. (b) Position STOW/TRK/ACQ switch to TRK
and press LHG ACTION switch. Observe that turret
(l) Press ACTION switch on LHG. Observe weapon will not follow inputs from SHC transducer
that turret weapon follows TSU turret when moved stick.
through the limits with SHC transducer stick.
Observe that GUNS flag in TSU sight flashes when at (c) Release LHG ACTION switch and return
limit stops of the turret weapon. STOW/TRK/ACQ switch to STOW.
NOTE (d) Position TCP MODE SELECT switch from
STBY TOW to ARMED MAN. Verify that TCP system
Guns flag may not flash if gun turret status indicator remains at PWR ON.
exceeds TSU turret in azimuth, due to (d.1) - Observe that FCP mode
tolarence in stop location. indicator indicates OFF.
(m) Release ACTION switch. Observe that (e) Position MASTER ARM switch on pilot
turret weapon returns to STOW. armament control panel from STBY to ARM to STBY.
Verify that system status indicator on TCP moves
from PWR ON to ARMD to PWR ON during this
(n) Move LOS of TSU to approximately O
degrees azimuth and elevation and press LHG sequence.
ACTION switch and trigger. Observe that turret
weapon will not fire. (e.1) - Verify that FCP mode indicator
changes from OFF to PWR ON or DET HOT to OFF
during this sequence.
(o) Release ACTION switch. Position pilot
MASTER ARM switch to ARM. (f) p o s i t i o n W P N C O N T R s w i t c h o n p i l o t
armament control panel to PILOT.
(P) Move LOS on TSU to approximately O
degrees azimuth and elevation and press LHG (g) Position MASTER ARM switch from STBY
ACTION switch and trigger. Observe that turret to ARM to STBY. Verify that system status indicator
weapon fires. on TCP remains at PWR ON during this sequence.
(q) R e l e a s e A C T I O N s w i t c h a n d p o s i t i o n (g.1) - V e r i f y F C P m o d e i n d i c a t o r
MASTER ARM switch on pilot armament control indicates OFF during this sequence.
panel to STBY.
(h) Position WPN CONTR switch on pilot
(r) Return STOW/TRK/ACQ switch to armament control panel to FIXED and repeat step (g).
STOW. Return WPN CONTR switch to GUNNER.
Change 15 9-197
TM 55-1520-236-23
(i) Position STOW/TRK/ACQ switch on SHC (p.1) Press and hold ACTION switch. Use,
to TRK and return to STOW. Verify that system status SHC stick to drive TSU from stop to stop vertically.
indicator remains in the PWR ON position during this Verify that TSU can be driven stop to stop in less than
sequence. 27 seconds. Release ACTION switch.
NOTE (q) Position TSU optics to LO using MAG
switch on TSU LHG grip.
Steps (j), (k), (l), and (m) should be done (r) Press and hold ACTION switch. Use SHC
in rapid succession in order to maintain stick to drive TSU from stop to stop horizontally.
the TEST indication. Read these steps Verify that TSU can be driven stop to stop in less than
before their initiation. 3 seconds. Release ACTION switch.
(r.1) Press and hold ACTION switch. Use
(j) Press and hold BIT pushbutton on TCP.
SHC stick to drive TSU from stop to stop vertically.
Verify that A, R, and G flags are visible in TSU
Verify that TSU can be driven stop to stop in less than
eyepiece. Verify that ascend and descend pointers
2 seconds. Release ACTION switch.
and prelaunch window are displayed on head up
display (HUD). Release BIT SWITCH after verifying the
(s) Position TSU OPTICS to HI using MAG
above and check that system status indicator on TCP
switch and position TCP MODE SELECT switch to
reads TEST.
TSU/GUN.
(k) Position TCP MODE SELECT switch from
(t) Press and hold ACTION switch. Use SHC
ARMED MAN to OFF to ARMED MAN in less than 5
stick to drive TSU from stop to stop horizontally.
seconds. Verify that system status indicator on TCP
Verify that TSU can be driven stop to stop horizontally
moves from TEST to OFF to TEST. There should be no
in less than 8 seconds. Release ACTION switch.
10-second delay from OFF to TEST on TCP system
status indicator.
(t.1) Press and hold ACTION switch. Use
SHC stick to drive TSU from stop to stop vertically.
(l) With system status indicator reading TEST
Verify that TSU can be driven stop to stop vertically in
from step (k), position STOW/TRK/ACQ switch on
less than 4 seconds. Release ACTION switch.
sight hand control to TRK and return it to STOW.
Verify that system status indicator cycles from TEST
(u) Position gunner armament control panel
to PWR ON to TEST during this sequence.
TSU/GUN SLEW RATE switch to LOW.
(m) With system status indicator reading
(v) Press and hold ACTION switch. Use SHC
TEST from step (l), position MASTER ARM switch on
stick to drive TSU from stop to stop horizontally.
pilot armament control panel from STBY to ARM to
Verify that TSU can be driven stop to stop horizontally
OFF. Verify that system status indicator on TCP
in less than 63 seconds. Release ACTION switch.
moves from TEST to ARMD to OFF during this
sequence.
(v.1) Press and hold ACTION switch. Use
SHC stick to drive TSU from stop to stop vertically.
(n) P o s i t i o n p i l o t M A S T E R A R M s w i t c h t o
Verify that TSU can be driven stop to stop vertically in
ARM, the STOW/TRK/ACQ switch on SHC to TRK
less than 27 seconds. Release ACTION switch.
and position TCP MODE SELECT switch to STBY
TOW.
(w) R e t u r n STOW/TRK/ACQ switch to
STOW.
(o) Position TSU optics to HI using MAG
switch in TSU LHG grip. Observe that TSU is now in (3) Helmet sight tracking.
HI mode.
(a) Position MASTER ARM switch on pilot
(p) Press and hold ACTION switch. Use SHC panel to STBY.
stick to drive TSU from stop to stop horizontally.
Verify that TSU can be driven stop to stop in less than (b) C o n n e c t h e l m e t s i g h t l i n k a g e s t o t h e
63 seconds. Release ACTION switch. BUILT-IN TEST (BIT) brackets.
9-198 Change 15
TM 55-1520-236-23
(c) P o s i t i o n HSS B I T s w i t c h o n g u n n e r (c) Position pilot MASTER ARM switch to
control panel to BIT and release. Check that a GO ARM.
indication appears on HSS test indicator.
(d) Position SHC STOW/TRK/ACQ switch to
TRK and MAG switch to HI.
NOTE
Completion o f B I T c i r c u i t r e q u i r e s (e) Select missile No. 1 or any other odd-
approximately two seconds. numbered missile position which indicates a missile
present. Using the SHC, adjust the TSU position for
the azimuth and elevation LOS to be approximately
(d) Connect pilot and gunner Iinkages to their zero with respect to the ADL.
respective helmets and check for freedom of
movement in all directions. Adjust helmet sight
reticle on helmet until full reticle pattern can be seen.
(e) Position STOW/TRK/ACQ switch to TRK.
Position ACQ switch to PHS and check that gunner
helmet sight reticle retracts automatically. Check that
TSU follows pilot helmet sight as it is aimed to left,
right, up, and down. Release ACQ switch.
(f) If installed, return gunner helmet sight
reticle to the down position.
(g) Hold STOW/TRK/ACQ switch in ACQ
position. Verify that TSU follows gunner helmet sight
as it is aimed to left, right, up, and down. Release
STOW/TRK/ACQ switch and check that gunner
helmet sight reticle retracts.
(h) Position STOW/TRK/ACQ switch to
STOW. Observe that TSU returns to 0.0 position.
(4) Steering commands and constraints
tests. Pilot steering commands on the HUD are a
function of the TSU azimuth and elevation gimbal
angles. In the prelaunch mode, the TSU LOS for
azimuth steering commands is biased 0.75 degree
right for left side missiles and 0.75 degree left for
right side missiles. This bias is displayed on the HUD
by offsetting the apparent TSU LOS reticle
approximately 1/3 of the distance across either half
of the TOW prelaunch mode limits display. Logic
prevents prefiring a TOW missile until LOS rate,
gimbal angle, attack logic, launcher position status
and roll constraints are satisfied. After launch there is
no bias.
(a) Position HUD PWR switch to ON and
MODE switch to NORM.
(b) Position TCP MODE SELECT switch to
ARMED MAN.
Change 15 9-198. 1/(9-1 98.2 blank)
TM 55-1520-236-23
(f) Depress LHG ACTION switch: Note that (5) Launcher/TSU alignment and slaving test.
the TOW prelaunch window is displayed on HUD.
(a) A p p l y h y d r a u l i c p o w e r t o h e l i c o p t e r .
(g) Verify that the TSU LOS reticle on the Position TCP MODE SELECT switch to ARMED MAN
HUD is approximately 1/3 of the distance to the right and MASTER ARM switch to ARM on pilot armament
of the ADL to the edge of the prelaunch limits when control panel. Position TSU MAG switch to HI.
the AZ and EL LOS is zero. Position HUD PWR switch to ON and HUD MODE
switch to NORM.
(h) Release LHG ACTION switch.
(b) Select missile No. 1 on the TCP. Verify
(i) Select missile No. 2 or any other even- that the missile status indicator on the TCP for missile
numbered missile position which indicates a missile No. 1 indicates MSL and the TOW missile selection
present. indicator appears on the HUD display outside the
upper left corner of the prelaunch limit display.
(j) Repeat steps (a) and (b).
(c) Set STOW/TRK/ACQ switch on SHC to
(k) Verify that the TSU LOS is biased by the TRK and track TSU to 0 degrees azimuth and 0
same amount to the left of the ADL when the AZ and degrees elevation.
EL LOS is zero.
(d) Press and hold ACTION switch on LHG.
Verify that only left launcher is slaving to TSU LOS in
(l) Move the TSU LOS through azimuth and
elevation.
elevation; observe that the HUD indicates the
corresponding movement of the TSU LOS.
(e) Drive TSU up slowly in elevation until TSU
LOS reticle falls outside the inner rectangle. Verify
(m) Move the TSU LOS slowly to the right
that TSU LOS reticle flashes.
until the TSU LOS reticle falls outside the prelaunch
window and verify that the reticle flashes.
NOTE
(n) Move the TSU LOS slowly to the left.
The alignment procedures may have to
Verify that the reticle stops flashing when it is inside
be accomplished before the HUD will
the prelaunch window and that it starts flashing
operate properly.
again as it moves outside the prelaunch window on
the left side. Verify that an X appears on the reticle at
3.75 azimuth or 7.5 - 8 elevation which are the (f) Recenter the TSU LOS reticle within the
limits of travel for the TSU LOS. prelaunch window and verify that it stops flashing.
Drive the TSU down slowly until the TSU LOS reticle
(o) Release LHG ACTION switch. falls below the prelaunch window and verify that the
reticle flashes.
(P) R e t u r n t h e S T O W / T R K / A C Q switch to
STOW. (g) Select missile No. 2 and repeat steps (a)
through (f), verifying the action of the right launcher,
and the right missile select indicator on the HUD.
(q) Position TCP MODE SELECT switch to
OFF. (6) Armament control tests. Operation during
the preparation for launch and guidance of a missile
(q.1) m Position FCP OFF/ON/BIT switch shall be verified as follows:
to OFF.
(a) Pilot turret control and firing while in the
TOW mode.
(r) Position pilot MASTER ARM switch to
OFF. 1 Position WPN CONTR switch on pilot
armament control panel to PILOT and MASTER ARM
(s) Position HUD PWR switch to STBY. switch to ARM.
Change 15 9-199
TM 55-1520-236-23
2 With MODE SELECT switch on TCP in unpowered TSEM loaded into a launcher wiII not
any of the TOW modes (STBY TOW, ARMED MAN, or affect the outcome of tests not requiring the TSEM.)
ARMED AUTO) and STOW/TRK/ACQ switch on SHC
in either TRK or STOW, check that gunner PILOT IN (c) Manual missile selection and firing.
CONT indicator is illuminated and that pilot can fire
NOTE
the turret weapon while using his helmet sight.
Shearpin depression limits must be
3 Position the WPN CONTR switch to
within tolerance for the launcher to be
GUNNER and repeat step 2.
acceptable for firing. Both pods of all
launchers must be verified. To avoid a
(b) TSEM operating procedure. Installation
double effort, check the upper outboard
and operation of the TSEM shall be as follows:
position last.
1 After loading the TSEM into launcher
1 Move launcher armament control handle
and lowering the arming lever, position POWER
to up position.
switch to ON. Check that POWER light and SHEAR
PIN light illuminate.
2 Turn TSEM to ON and press reset button.
2 Position SELF TEST switch to AUTO and
3 Connect TSEM power cable to TSEM and
press RESET button.
to DC power connector located in the ammunition
bay.
3 When TSEM is fired in a normal
sequence, the following will be observed on rear
4 Position TSEM mode select switch to
panel of the TSEM:
AUTO and power switch to ON.
a The START and WIRE SIGNAL AMPL
5 Press TSEM RESET switch and verify
lights illuminate simultaneously, the PREFIRE and -
that power lamp is illuminated.
12 lights illuminate in sequence.
6 Rotate mode select switch to LAMP TEST
b The YAW, PITCH, FIRE, MSL GONE,
and verify that all TSEM lamps illuminate.
and ZERO lights illuminate in sequence.
7 Rotate mode select switch to SP GO
c The WIRE CUT and SQUIB DISC lights
and verify that shearpin lamp illuminates.
then illuminate and WIRE SIGNAL AMPL light
extinguishes.
8 Rotate launcher armament control
handle to ARMED position and secure it with the
d The previously mentioned lights will
captive locking pin. Verify that shearpin lamp goes
remain illuminated until RESET button is depressed,
out.
Exception: the SHEAR PIN light will remain
illuminated until launcher arming lever is raised.
9 Rotate TSEM mode select switch to SP
GO and verify that shearpin lamp illuminates. If
NOTE
shearpin lamp does not illuminate, this launcher
In the first simulated firing following position should not be used until readjustment and
TMS turn on, or following a BIT verification of shearpin depression is accomplished.
sequence, the PITCH and YAW balance
lights may not illuminate. This should not 1 0 Push RESET button.
be interpreted as an abnormal firing
sequence unless the PITCH and YAW 1 1 Position MASTER ARM switch on pilot
lights fail to illuminate on successive armament control panel to ARM. Set HUD power
firings. switch to ON and MODE switch to NORM.
4 At the end of test, or when use of TSEM is 1 2 Position MODE SELECT switch on TCP
not called for in a test, or when TSEM is to be down to ARMED MAN. Verify that MISSILE SELECT switch
loaded, position POWER switch to OFF. (An is on missile position No. 1.
9-200
TM 55-1520-236-23
1 3 Verify that missile status indicator on 2 3 Using the TSEM, verify that a proper
TCP for missile No. 1 indicates MSL. firing sequence takes place. Lights on TSEM will
show proper sequence according to subparagraph (b)
1 4 Set STOW/TRK/ACQ switch on SHC to 3 above.
TRK.
2 4 Verify that indicator for missible No. 1
1 5 Set MAG switch on LHG to HI. on TCP switches from MSL to barber pole pattern.
1 6 Press LHG ACTION switch. Verify the 2 5 When the postlaunch window
appearance of A flag in the eyepiece of TSU and the disappears, press RESET button on TSEM and verify
prelaunch window and TSU LOS reticle on the HUD. that the indicator for missile No. 1 on the TCP again
indicates MSL.
NOTE
2 6 Press and hold ACTION switch on the
Within constraint limitations means that LHG and drive the TSU LOS out of constraints in
the elevation and azimuth needles are elevation. Pull trigger to confirm missile will not fire.
within the inner rectangle and the ascend
and descend pointers are not visible. 27 Press CONST OVRD switch on the SHC.
Verify the appearance of the A flag in the eyepiece of
1 7 While observing the HUD, maintain the the TSU and prelaunch window on the HUD. RDY flag
LOS reticle within window limits using SHC tracking should not appear.
stick. Verify that R flag is visible in the eyepiece of
TSU. 2 8 Momentarily press the TRIGGER on the
LHG. The ACTION switch may be released with the
1 8 Position TSEM mode select switch to TRIGGER switch.
MSL GONE. Verify that R flag disappears in the
2 9 Reset the TSEM and with the TSU LOS
eyepiece of TSU and that the post launch window
replaces the prelaunch window on the HUD. Position reticle in constraints, pull ACTION switch and
TSEM mode select switch to AUTO. TRIGGER switch on LHG. Push gunner WIRE CUT
switch and observe wire cut indicator on TSEM.
NOTE
2 9 . 1 - Repeat step 29 using LHG
The ACTION and trigger switch on the WIRE CUT switch.
pilot cyclic grip will be depressed and
held through steps 19 through 21. Read 3 0 Repeat step 29 using pilot wire cut
all of these steps before depression of the button.
trigger.
3 1 Remove TSEM from missile position
No. 1, cycle (install) the TSEM through the remaining
1 9 Hold pilot helmet sight at 0 degree
missile positions, and repeat steps 3 through 31 for
elevatlon and 0 degree azimuth and press pilot cyclic
each position selected.
stick ACTION and trigger switch. Verify that turret
weapon fires.
( d ) Automatic selection and firing.
2 0 Press the trigger and ACTION switch on
LHG. Verify that turret weapon firing is interrupted. 1 Install TSEM in missile position No. 1.
2 Set mode select switch on TSEM to
2 1 Verify that turret weapon resumes
AUTO.
firing after a time delay of 2.8 TO 3.2 s e c o n d s .
Release pilot cyclic grip trigger and ACTION switch. 3 Set MASTER ARM switch on pilot
Release LHG trigger and ACTION switch. armament control panel to ARM. Set MODE SELECT
switch on TCP to ARMED AUTO. Set HUD PWR
2 2 Verify the appearance of postlaunch switch to ON and MODE switch to NORM.
window on the HUD. The window will disappear at
completion of firing sequence, approximately 23 4 Set STOW/TRK/ACQ switch on SHC to
seconds. TRK.
Change 15 9-201
TM 55-1520-236-23
5 Set MAG select switch on LHG to HI. 9-527. ~ M TROUBLESHOOTING -
M65 OR M65/C-NITE TOW MISSILE
SUBSYSTEM CIRCUITRY.
6 Press the LHG ACTION switch and, by
observing the HUD, maintain the TSU LOS reticle a. For troubleshooting procedures, refer to TM
within maneuver constraints. 55-1520-236-T.
7 Momentarily press the TRIGGER on the b. M65 TOW missile subsystem.
LHG. Note the completion of the firing sequence by Troubleshooting of the M65 TOW missile subsystem
observing that an X appears over the missile image is accomplished during BIT (built-in test) procedures
selected, then disappears with the prelaunch and also by use of Test Set, Guided Missile System
window. The postlaunch window replaces the (TSGMS). Refer to TM 9-1425-473 series
prelaunch window on the HUD, then disappears at maintenance m a n u a l s f o r troubleshooting
wire cut. Verify that the TSEM firing sequence is in procedures.
accordance with (b)3 above.
8 Return the STOW/TRK/ACQ switch to
STOW.
9-528. m S E R V O ELECTRONIC
9 Check that the MISSILE SELECT switch
CONTROL UNIT (SECU).
on the TCP has automatically selected missile No. 2 or
the next available missile. Check HUD for correct L-R 9-529. @ DESCRIPTION - SERVO
TOW indication.
ELECTRONIC CONTROL UNIT (SECU).
The servo electronic control unit (SECU) provides
1 0 R e p e a t s t e p s 5 t h r o u g h 9 for all
regulated power and contains signal switching, servo
remaining missile positions. Verify that the HUD and
amplifier, logic, and buffering circuitry necessary to
TCP indications are normal and verify the test firing
align the pitch angle of the TOW missile launchers
sequence defined by Figure 9-29.
with the pitch angle of the line-of-sight (LOS) of the
telescopic sight unit (TSU). Slaving of the two pitch
1 1 For missile position No. 8, set TCP
angles ensures that the TOW missile will reliably
CAMERA switch to AUTO. Verify that camera
enter the field of view of the infrared receiver of the
operations (if available) start when the LHG TRIGGER
TSU. The TOW missile can be guided to target only if
is pressed and stop with the loss of the postlaunch
the initial launch thrust positions the missile within
window on the HUD.
this field of view. During the attack mode, when the
gunner selects a missile for firing, the launcher
1 2 Position gunner PLT ORIDE switch to
containing the selected missile is activated. Upon
PLT ORIDE Observe that TCP system status indicator
activation, the SECU initial command drives the
moves to OFF.
launcher up. Angular position signals from the TSU
resolver are routed to the SECU, processed through
1 3 Turn TSEM off.
buffer amplifier stages, then applied to the respective
launcher resolver. The launcher resolver output
1 4 Place pilot MASTER ARM in OFF, PLT
provides position feedback to the servo amplifier loop,
ORIDE in OFF, and TCP MODE SELECT switch in
and the accelerometer provides launcher
STBY TOW.
acceleration feedback to the servo amplifier loop. The
servo amplifier output to the hydraulic actuator servo
1 5 Turn CAMERA (if available) switch to
coil allows the hydraulic actuator to change the pitch
OFF.
angle of the activated launcher when hydraulic
pressure is provided to the actuator. The SECU also
1 6 Position HUD power switch to OFF.
has a detector circuit which decreases the servo
amplifier gain when the launcher approaches the
d. Conclusion of Tests. Upon completion of the mechanical elevation stop at either extreme.
preceding tests, de-energize and disconnect auxiliary Hydraulic pressure is applied to the activated
power unit and hydraulic ground test cart. Remove launcher through the hydraulic solenoid valve and
TSEM from launcher. the launcher pitches from stow position to the correct
9-202 Change 15
TM 55-1520-236-23
pitch angle relative to the TSU LOS. When fired, the d. R e m o v e m o u n t i n g s c r e w s a n d w a s h e r s
missile is launched into the field of view of the securing SECU to structure and remove SECU.
infrared receiver, and wire transmitted command
e. L o o s e n t w o s c r e w a s s e m b l i e s o n f r o n t o f
signals from the M65 guidance and command
SECU. Open door assembly and slide printed wiring
functional group steers the missile along the TSU
assemblies out, if required.
LOS. After launch, the SECU activate signal ceases
and the launcher is returned to stow position. The 9 - 5 3 3 . m R E P A I R SERVO
hydraulic solenoid is turned off after a delay of 1 . 5 ELECTRONIC CONTROL UNIT (SECU).
0.75 seconds. The SECU is located on forward
bulkhead of the oil cooler compartment. (Refer to a. Repair connectors, and tighten or replace loose
paragraph F-9 in Appendix F for equipment location or missing mounting screws.
charts).
b. Replace SECU if case is damaged or defective.
Evacuate removed SECU to higher maintenance level
9-530. 9 CLEANING SERVO
for disposition.
ELECTRONIC CONTROL UNIT (SECU).
C. Replace printed wiring assemblies as required.
a. Remove moisture and loose dirt with a clean,
soft cloth. SERVO
9-534. m I N S T A L L A T I O N
ELECTRONIC CONTROL UNIT (SECU).
a. Position SECU in place on forward wall of
oil coaler compartment with electrical jacks
Cleaning solvent is flammable and toxic. down and secure with four mounting screws and
Provide adequate ventilation. Avoid washers.
prolonged breathing of solvent vapors
and contact with skin or eyes. b. Remove protective caps or electrical tape
from connectors and connect to respective
b. Remove grease, fungus, and dirt with a clean, receptacles on SECU.
lint-free cloth dampened with dry cleaning solvent
(C112). c. Close and secure oil cooler compartment ac-
cess panel or screen.
c. Remove dirt from electrical connectors with a
bristle brush. d. I n s t a l l p r i n t e d w i r i n g a s s e m b l y i n S E C U
case. Close door and fasten two screw assemblies.
9-531. ~ INSPECTION SERVO ELECTRO-
NIC CONTROL UNIT (SECU). 9 - 5 3 5 . ~ W I N G STORES
a. Inspect SECU case for cracks or dents. ARMAMENT SYSTEMS CIRCUITRY.
b. Inspect SECU for secure mounting. 9-536. DESCRIPTION WING
STOREP A R M A M E N T S Y S T E M S
c. Inspect electrical connectors for broken pins or
CIRCUITRY.
cracked inserts.
d. Inspect printed wiring assemblies for cracked, The wing stores armament systems consist of the
broken, loose or missing hardware and components; XM138 rocket management subsystem circuitry,
burned components and wiring; cracked, chipped or XM18 minigun circuitry, and wing stores jettison
broken wiring board. circuitry.
9-532. ~ REMOVAL SERVO ROCKET
9 - 5 3 7 . ~ X M 1 3 8
ELECTRONIC CONTROL UNIT (SECU). SUBSYSTEM
M A N A G E M E N T
CIRCUITRY.
a. Ensure all electrical power is OFF.
9-538. m DESCRIPTION ROCKET
b. Remove oil cooler compartment access panel.
MANAGEMENT SUBSYSTEM CIRCUITRY.
c. Disconnect electrical connectors from SECU.
The rocket management subsystem circuitry enables
Protect receptacles and plugs with caps or electrical
the pilot to determine the number of rockets on-board
tape (C121).
before and after firing, select the warhead and fuze
Change 12 9-203
TM 55-1520-236-23
type, set the fuze to compensate for forest canopy or
bunker cover thickness to be penetrated, select the
rate at which the rockets wilI be fired, select singles,
pairs, or quads, select the total number of rockets to
be fired, select the range in meters, and to launch the
rockets from rocket launchers mounted on any or all
of the four wing stations. With the systems armed,
rockets may be launched by pressing either the pilot
WING ARM FIRE switch or gunner WING ARM FIRE
switch (when in PLT ORIDE mode).
Figure 9-31.
9-539. m FUNCTIONAL TEST - ROCKET
MANAGEMENT SUBSYSTEM CIRCUITRY.
The folIowing functional test of the XM138 rocket
management subsystem (RMS) is designed to be
performed using the RMS on-board built-in test (BIT)
(figures 9-30 and 9-31).
Ensure no live ammunition is present in
any of the armament systems.
(1) The first routine is a digital display test and
a. Open all circuit breakers and place all switches checks the display segments by lighting all segments
to their OFF or de-energized positions. and displaying a lighted eight (8) in all eight positions
of the RND REM Panel on the display unit (DU). The
b. Connect a 28 Vdc external power source to RMS BIT will identify a fault during the first routine by
helicopter external power receptacle and energize displaying a number less than eight (8) in the position
power source. containing the fault (figure 9-30).
c. Place pilot MASTER ARM switch in STBY (2) The second routine is a line replaceable unit
position. (LRU) fault identification and location test which
d. Press the pilot RMS display unit TEST switch. automatically follows the first routine. This test
The RMS BIT test will perform two routines when the provides for the detection arid isolation of any LRU
TEST switch is pressed. (DU and four operations units) malfunction and non-
compliant verification of LRU functions. Test results
are visually displayed on the RND REM panel of the
pilot display panel, If all LRUs are functioning properly
as determined by the test routine the number seven
(7) will be displayed for each of the five LRUs (figure 9-
31). A malfunction or non-complaint of any LRU will
cause the associated digital display to be blanked
indicating the LRU should be replaced.
e. The BIT test may be performed at any time but
Figure 9-30. ONLY if the MASTER ARM switch is in the STBY
position. Switching to the ARM position will override
the TEST switch and terminate any test in progress,
returning the system to normal operation.
f. An additional verification of the defective LRU
will be the activation of the equipment status
indicator flag on the malfunction LRU.
9-204 Change 12
TM 55-1520-236-23
(1) The equipment status indicator flags permit
the last LRU status to be displayed after primary
power outages or after primary power has been
removed.
Cleaning solvent is flammabla and toxic,
(2) T h e e q u i p m e n t s t a t u s i n d i c a t o r s a r e
Provide adequate ventilation. Avoid
magnetic-latching and mechanically resettable.
prolonged breathing of solvent vapors
and contact with skin or eyes.
9-540. m T R O U B L E S H O O T I N G - b. Remove grease, fungus, and dirt with a clean,
XM138 ROCKET MANAGEMENT lint-free cloth dampened with dry cleaning solvent
SUBSYSTEM CIRCUITRY. (C112).
NOTE
c. Remove dirt from electrical connectors with a
bristle brush.
A filter (21A121) is installed between
airframe wiring and display unit to
prevent excessive noise in fm radio 9-544. q INSPECTION - OPERATIONS
system. If a noise problem exists in fm UNIT (OU).
radio system, turn RMS off to determine
if filter is defective. Replace filter if a. Inspect OU case for cracks or damage.
required.
b. inspect electricaI connector for damaged pins
and cracked connector inserts or hood.
c. Inspect OU for secure mounting.
a. For troubleshooting procedures, refer to TM
55-1520-236-T.
9-545. g R E M O V A L - O P E R A T I O N S
UNIT (OU).
b. XM138 Rocket Management Subsystem.
a. Insure all electrical power is off.
Troubleshooting of the XM138 rocket management
subsystem is accomplished during BIT (built-in-test)
b. Remove OU access panel(s) (Outboard and
procedure.
inboard leading edge access panels on the left and
right wing).
9-541. m OPERATIONS UNITS (OU).
c. Disconnect two electrical connectors from
each OU. Protect receptacles and plugs with caps or
9-542. g D E S C R I P T I O N - electrical tape (C121).
OPERATIONS UNITS (OU).
d. Remove four mounting bolts and washers to
The operations units receive electrical command
remove the OU from the wing leading edge bulkhead.
signals from the integrated control and display unit.
The station unit evaluates the information and
provdes the proper signals to set the fuzes on the 9-546. R REPAIR - OPERATIONS UNIT
rockets for desired running time and to provide power (OU).
for the electronic circuitry.
a. Repair connectors, and tighten or replace loose
9-643. ~ CLEANING - OPERATIONS or missing mounting or assembly screws or bolts.
UNIT (OU).
b. Replace OU if case is damaged or defective.
a. Remove moisture and loose dirt with a clean, Evacuate removed OU to next higher echelon for
soft cloth. repair or disposition (TM 9-1270-217-13&P).
Change 3 9-206
TM 66-1620-236-23
9-547. ~ INSTALLATION - The XM-18 minigun circuitry enables the pilot or
OPERATIONS UNIT (OU). gunner (when in PLT ORIDE mode) to select and fire
either or both XM-18 miniguns mounted on inboard
a. Position OU on the wing leading edge bulkhead wing stations. With the system armed, either or both
and install mounting bolts and washers. miniguns may be fired by pressing either the pilot
WING ARM FIRE switch or gunner WING ARM FIRE
b. Remove protective caps or electrical tape from switch (when in PLT ORIDE mode).
two electrical connectors and install on OU.
9-550. ~ FUNCTIONAL TEST - XM18
9-548. ~ X M 1 8 MINIGUN MINIGUN CIRCUITRY.
CIRCUITRY.
The following functional test of the XM18 minigun
9-549 .~ DESCRIPTIONXM18 MINIGUN circuitry is designed to be performed using a test set
CIRCUITRY. as indicated in figure 9-32, or a suitable equivalent.
Figure 9-32.
9-206
TM 55-1520-236-23
e. Place WPN CONTR switch on pilot ARMT panel
in PILOT position. Check that no lights are illuminated
on the test set.
Ensure no live ammunition is present in
f. P e r f o r m s t e p s 1 t h r o u g h 1 5 i n t h e X M 1 8
any of the armament systems. Only
minigun checkout chart, table 9-41.
dummy ammunition with smooth cases
like live ammunition shall be used.
g. Place WPN CONTR switch on pilot ARMT panel
a. Open all circuit breakers and place all switches in GUNNER position.
to their OFF or de-energized positions.
h. Perform steps 1 through 15 in the XM18
b. Connect the two XM18 test set cables to minigun checkout chart, table 9-41.
connectors (21A10P1 and 21A11P1)at inboard wing
stores disconnect area in wings on the helicopter. i. With the turret gun installed and operational,
position turret full left and perform steps 7,8, 11, 12,
13, and 15 in the XM18 minigun checkout chart, table
c. Connect a 28 Vdc external power source to 9-41. No FIRED light shall illuminate.
helicopter external power receptacle and energize
power source. j. With the turret gun installed and operational,
position turret full right and perform steps 7, 8, 11,
d. Close WPN CONT, RH GUN, and LH GUN 12, 13, and 15 in the XM18 minigun checkout chart,
circuit breakers. table 9-41. No FIRED light shall illuminate.
Table 9-41. m X M 1 8 Minigun Checkout Chart
Pilot Gunner Pilot Gunner
WING WING WING WING Pilot MASTER Test Set Test Set
STORE STORE ARM FIRE ARM FIRE ORIDE ARM BAT CHG FIRED
Step Switch Switch Switch Switch Switch Switch Lights Lights
1 GUN either OFF STBY on off
2 GUN GUN fire OFF STBY on off
3 GUN GUN fire OFF STBY on off
4 GUN GUN fire OFF OFF on off
5 GUN GUN fire OFF OFF off off
6 GUN RKT fire OFF ON off on
release off
7 GUN GUN fire OFF ON off on
release off
8 RKT GUN fire OFF ON off off
9 GUN GUN fire ON ON off off
10 GUN RKT fire ON ON off off
Change 14 9-207
TM 55-1520-236-23
Table 9-41. ~ XM18 Minigun Checkout Chart (Cont)
Pilot Gunner Pilot Gunner
WING WING WING WING Pilot MASTER Test Set Test Set
STORE STORE ARM FIRE ARM FIRE ORIDE ARM BAT CHG FIRED
Step Switch Switch Switch Switch Switch Switch Lights Lights
11 RKT GUN fire ON ON off on
release off
12 GUN GUN fire ON ON off on
release off
13 GUN GUN fire OFF ON off on
release off
14 GUN RKT fire ON ON off off
15 RKT GUN fire OFF ON off on
release off
9-551. m TROUBLESHOOTING - XM18 tripped circuit breakers are omitted from indications
MINIGUN CIRCUITRY. of trouble. Such trouble is usually easily detected and
corrected. Broken wiring is always a probable cause
Refer to paragraph F-9 in Appendix F for wiring of circuit malfunction or failure and has not been
diagram. Use Table 9-42 and perform checks as included.
necessary to isolate trouble. In the following table,
NOTE
Before you use this table, be sure you
have performed all normal operational
checks. If you have a malfunction which
is not listed in this table, notify the next
higher level of maintenance.
Table 9-42. ~ Troubleshooting XM18 Minigun Circuitry
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. With switch breakers on AC/ARMT circuit breaker panel in WPN FIRE, LH GUN, and RH GUN positions,
MASTER ARM switch in ARM, and WING STORE switch in GUN, XM 18 miniguns do not fire when pilot
WING ARM FIRE switch is pressed.
STEP 1. Check for defective wiring.
If defective, repair wiring.
U.S. GOVERNMENT PRINTING OFFICE: 1989- 654-031/50029
9-208
TM 55-1520-236-23
Table 9-42. ~ Troubleshooting XM18 Minigun Circuitry (Cont)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
STEP 2. Check for defective master arm relay (19K31).
If defective, replace relay (paragraph 9-16).
STEP 3. Check for defective WING ARM FIRE switch.
If defective, replace switch (paragraph 9-16).
STEP 4. Check for defective WING ARM FIRE switch on pilot cyclic stick.
Handle in accordance with instructions pertinent to the cyclic stick (paragraph 11-30).
2. With switch breakers on AC/ARMT circuit breaker panel in WPN FIRE, LH GUN, and RH GUN, MASTER ARM
switch in ARM, and WING STORE switch in GUN, one XM18 minigun fires, but the other does not fire.
STEP 1. Check for defective ground connection to airframe on the side which does not fire.
If defective, repair ground connection.
STEP 2. Check for defective wiring.
If defective, repair wiring.
STEP 3. Check for defective wing disconnect connector (21J1-21P1 or 21J2-21P2) on the side which does
not fire.
If defective, replace connector (paragraph 9-16).
STEP 4. Check for defective LH GUN or RH GUN switch breaker which controls the side that does not fire.
If defective, replace circuit breaker (paragraph 9-23).
3. With switch breakers on AC/ARMT circuit breaker panel in LH GUN and RH GUN, TURRET PWR circuit
breaker closed, PILOT ORIDE switch in PILOT ORIDE, and WING STORE switch in GUN, neither XM18
minigun fires when WING STORES FIRE switch on gunner cyclic stick is pressed.
STEP 1. Check for defective wiring.
If defective, repair wiring.
STEP 2. Check for defective ARMT CONTR circuit breaker.
If defective, replace circuit breaker (paragraph 9-23).
STEP 3. Check for defective WING STORES FIRE switch on gunner cyclic stick.
Handle in accordance with instructions pertinent to the cyclic stick (paragraph 11-54).
9-209
TM 55-1520-236-23
Table 9-42. 9 Troubleshooting XM18 Minigun Circuitry (Cont)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
STEP 4. Check for defective connector (21A9P1), (21A8P1), (21J1-21P1), (21J2-21P2).
If defective, replace connector (paragraph 9-16).
STEP 5. Check for defective turret system circuitry.
Refer to TM9-1090-206 series maintenance manuals.
4. With TURRET CONTR circuit breaker and minigun switch breakers in LH GUN and RH GUN positions, PILOT
ORIDE switch positioned to PILOT ORIDE, and WING STORE switch in GUN position, one XM18 minigun
fires, but the other does not fire when gunners WING STORES FIRE switch is pressed.
STEP 1. Check for defective wiring.
If defective, repair wiring.
STEP 2. Check for defective ARMT CONTR circuit breaker.
If defective, replace circuit breaker (paragraph 9-23).
STEP 3. Check for defective WING STORES FIRE switch on gunner cyclic stick.
Handle in accordance with instructions pertinent to the cyclic stick (paragraph 11-54).
STEP 4. Check for defective connector (21A10P1), (21A11P1), (21J1-21P1), (21J2-21P2).
If defective, replace connector (paragraph 9-16).
STEP 5. Check for defective turret system circuitry.
Refer to TM9-1090-206 series maintenance manuals.
9-652. m W I N G S T O R E S J E T T I S O N 9-554. ~ F U N C T I O N A L T E S T W I N G
CIRCUITRY. STORES JETTISON CIRCUITRY.
9-653. ~ DESCRIPTION - WING
STORES JETTISON CIRCUITRY. The functional test of the wing stores jettison circuitry
is designed to be performed using a test set as
The wing stores jettison circuitry enables the pilot to indicated in figure 9-33, or equivalent.
select wing station weapons (inboard or outboard) to
be jettisoned in an emergency situation. Selected
wing station weapons are jettisoned by pressing the a. Open all circuit breakers and place all switches
pilot or gunner WING STORES JETTISON switch. to their OFF or de-energized positions.
9-210
TM 55-1520-236-23
Figure 9-33.
9-211
TM 55-1520-236-23
b. Connect wing stores jettison test set cables to e. Ensure that WING STORE JETTISON switch on
respective helicopter receptacles (21SQ1J1, gunner instrument panel is in the down position and
21SQ2J1, 21SQ3J1, and 21SQ4J1). that metal guard is in place over the switch toggle.
c. Connect a 28 Vdc external power source to
helicopter external power receptacle and energize f. P l a c e W I N G S T O R E S s w i t c h b r e a k e r s o n
power source. AC/ARMT circuit breaker panel to PLT JETT and GNR
JETT. Check that no JETTISON lights on test set are
d. Ensure that JETTISON SELECT switches on illuminated and perform the checkout procedures, in
pilot miscellaneous panel are in OFF position. wing stores jettison checkout chart, table 9-43.
Table 9-43. Wing Stores Jettison Checkout Chart
Pilot OUTBD Pilot INBD Gunner
JETTISON JETTlSON JETTISON Pilot Gunner
SELECT SELECT SELECT JETTISON JETTISON Results
Switch Switch Switch Switch Switch Test Set
Step (21S5) (21S4) (21S2) (s1S3) (21S1) Jettison Lights
1 Close PLT JETT circuit breaker. No test set
jettison lights
2 OFF OFF BOTH Depress & OFF No test set
Release jettison lights
3 OFF OFF INBD Depress & OFF No test set
Release jettison lights
4 OFF OFF OUTBD Depress & OFF No test set
Release jettison lights
5 OUTBD OFF BOTH Depress & OFF Outboard lights
Release illuminate &
extinguish
approximately
0.5 seconds later
6 OFF INBD BOTH Depress & OFF Inboard lights
Release illuminate and
extinguish approx.
0.5 seconds later
7 OUTBD INBD BOTH Depress & OFF Outboard and
Release inboard lights
illuminate and
extinguish approx.
0.5 seconds later
OUTBD INBD BOTH Released JTSN No test set
jettison lights
OUTBD OFF BOTH Released JTSN No test set
jettison lights
9-212
TM 55-1520-236-23
Table 9-43. ~ Wing Stores Jettison Checkout Chart (Cont)
Pilot OUTBD Pilot INBD Gunner
JETTISON JETTSON JETTISON Pilot Gunner
SELECT SELECT SELECT JETTlSON JETTlSON Results
Switch Switch Switch Switch Switch Test Set
Step (21S5) (21S4) (21S2) (21S3) (21S1) Jettison Lights
10 OFF INBD BOTH Released JTSN No test set
jettison lights
11 OFF OFF BOTH Released OFF No test set
jettison lights
12 Close GNR JETT circuit breaker. No test set
jettison lights
13 OFF OFF INBD Released JTSN Inboard lights
illuminate
14 OFF OFF OUTBD Released JTSN Outboard lights
illuminate
15 OFF OFF BOTH Released JTSN Outboard and
inboard lights
illuminate
16 Insert jumper wires between pins A & C for both connectors 20P8J01 & 20S8J01
17 OFF INBD BOTH Depress & OFF Outboard lights
Release illuminate and
extinguish approx.
0.5 seconds later
18 OFF OFF INBD Released JTSN Outboard lights
illuminate and
remain illuminated
19 Repeat Step 13
20 Open GNR JETT circuit breaker
21 Repeat Steps 1,2,3,4,7,8,9,&10
22 Repeat Step 5 No test set
jettison lights
23 Repeat Step 6 Only outboard
Iights illuminate
and extinguish
approximately 0.5
seconds later
9-213
TM 55-1520-236-23
Table 9-43. Wing Stores Jettison Checkout Chart (Cont)
Pilot OUTBD Pilot INBD Gunner
JETTISON JETTISON JETTISON Pilot Gunner
SELECT SELECT SELECT JETTlSON JETTISON Results
Switch Switch Switch Switch Switch Test Set
Step (21S5) (21S4) (21S2) (21S3) (21S1) Jettison Lights
24 Remove jumper wires from connectors 20P8J01 & 20S8J01
25 Remove test set. Restore Wing stores wiring to normal configuration.
9-555. TROUBLESHOOTING - WING tripped circuit breakers are omitted from indications
STORES JETTISON CIRCUITRY. of trouble. Such trouble is usually easily detected and
corrected. Broken wiring is always a probable cause
Refer to paragraph F-9 in Appendix F for wiring of circuit malfunction or failure and has not been
diagram. Use Table 9-44 and perform checks as included.
necessary to isolate trouble. In the following table,
NOTE
For troubleshooting procedures, refer to
TM 55-1520-236-T and table 9-44 below.
Table 9-44. Troubleshooting Wing Stores Jettison Circuitry
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. WING STORES JTSN and PLT JTSN circuit breakers are closed. Pilot JETTISON SELECT switches are
positioned as required to jettison appropriate wing stores. Gunner JTSN SEL switch is in BOTH position and
gunner JETTISON switch is in OFF position. The appropriate (outboard, inboard, or both) wing stores do not
jettison when pilot collective JETTlSON switch is depressed.
STEP 1. Check for defective wiring.
Replace or repair wiring.
STEP 2. Check for defective PLT JETT or WING STORES JTSN circuit breakers. (21CB1 and/or 21CB2).
Replace defective circuit breaker(s) (paragraph 9-23).
9-214 Change 3
TM 55-1520-236-23
Table 9-44. Troubleshooting Wing Stores Jettison circuitry (Cont)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
STEP 3. Check for defective pilot collective JETTISON switch (21S3).
Replace defective switch (paragraph 9-16).
STEP 4. Check for defective pilot JETTISON SELECT switches (21S4 and\or 21S5).
Replace defective switch(s) (paragraph 9-16).
STEP 5. Check for defective or incorrectly installed diodes (21CR3, 21CR4).
Replace defective diodes (paragraph 9-16).
STEP 6. Check for defective pilot jettison switch relay (21K3).
Replace defective relay (paragraph 9-16).
STEP 7. Check for defective jettison control relay (21K2) or pilot jettison control relay (21K4).
Replace defective relay (paragraph 9-16).
2. With conditions same as condition 1, appropriate wing stores are jettisoned on one side, but not on the other
side when pilot collective JETTISON switch is depressed.
STEP 1. Check for defective wiring.
Repair wiring, if defective (paragraph 9-16).
STEP 2. Check for defective wing disconnect connectors (21J1/21P1, 21J3\21P3 or 21J2/21P2,
21J4/21P4) on side that does not jettison properly.
Replace defective connector (paragraph 9-16).
3. WING STORES JTSN, PLT JETT, and GNR JETT circuit breakers are closed. Pilot JETTISON SELECT switches
are both positioned to OFF. Gunner JTSN SEL switch is positioned as required to jettison appropriate wing
stores. Pilot collective JETTISON switch is released. The appropriate (outboard, inboard, or both) wing
stores do not jettison when gunner JETTISON switch is positioned to JTSN.
STEP. 1 Check for defective wiring.
Replace or repair wiring.
STEP 2. Check for defective GNR JTSN circuit breaker (21CB5).
Replace circuit breaker (paragraph 9-23).
9-215
TM 55-1520-236-23
Table 9-44. Troubleshooting Wing Stores Jettison Circuitry (Cont)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
STEP 3. Check for defective gunners JETTISON switch (21S1).
Replete defective switch (paragraph 9-16).
STEP 4. Check for defective gunner JTSN SEL switch (21S2).
Replace defective switch (paragraph 9-16).
STEP 5. Check for defective or incorrectly installed diodes (21CR5, 21CR6).
Replace defective diodes (paragraph 9-16).
STEP 6. Check for defective gunner jettison control relay (21K5).
Replace defective relay (paragraph 9-16).
STEP 7. Check for defective jettison control relay (21K2).
Replace defective relay (paragraph 9-16).
4. With conditions same as condition 3, appropriate wing stores are properly jettisoned on one side but not on
the other side when gunner JETTISON switch is positioned to JTSN.
STEP 1. Check for defective wiring.
Repair wiring, if defective.
STEP 2. Check for defective wing disconnect connectors (21J1/21P1, 21J3/21P3) or (21J2/21P2,
21J4/21P4) on side that does not jettison properly.
Replace defective connector (paragraph 9-16).
9-556. ~ FIRE CONTROL provides continuous gun directing command signals
COMPUTER (FCC). proportional to the ballistic prediction angle,
including compensation for effects of range, air
9-557. DESCRIPTION - FIRE density, helicopter pitch and roll, total velocity, and
CONTROL COMPUTER (FCC). other effects to meet the weapons laying accuracy
requirements. Ballistic corrections for aerial rocket
The fire control computer (FCC) contains a 16 bit, fire include effects of rotor downwash, weather
parallel, general purpose, micro-programmable vaning, and time of flight. The FCC concurrently
processor, memory, analog and digital interface, and stores ballistic equations for eight different rockets
power supply electronics housed in one unit. The FCC and two turreted weapons. Simultaneous gun and
9-216
TM 55-1520-236-23
rocket solutions are provided. The FCC performs BIT (built-in test) functions. The interfaces with the
computations necessay for target position M65 missile subsystem and radar altimeter are
determination, weapon prediction angle tested by utilizing HUDS equipment in a simulated
compensation, boresight compensation, data for mission sequence and observing the HUDS display,
head up display (HUD) symbology, and built-in self Refer to TM9-1270-220-13 for functional test
test (BIT). The FCC interfaces, directly and also by procedures.
means of auxiliary equipment, with all armament
systems except the XM18 gun pods. Refer to TM9- 9-563. TROUBLESHOOTING - HEAD
1270-218-13 for maintenance information and UP DISPLAY SUBSYSTEM (HUDS)
procedures pertaining to FCC. CIRCUITRY.
9-558. FUNCTIONAL TEST - FIRE
CONTROL COMPUTER (FCC).
Functional testing of the FCC is by BIT (built-in test)
functions. Refer to TM9-1270-218-13 for functional b. HUDS. Troubleshooting of the HUDS is
test procedure. accomplished by BIT (built-in test) functions, Refer to
TM9-1270-220-13 for troubleshooting procedures.
9-559. TROUBLESHOOTING - FIRE
CONTROL COMPUTER (FCC).
a. For subsystem troubleshooting, refer to TM
55-1520-236-T.
9-564. FIRE AND FLIGHT AIR
DATA SUBSYSTEM CIRCUITRY.
b. FCC. Troubleshooting of FCC is by BIT (built-in
test) functions. Refer to TM9-1270-218-13 for 9-565. DESCRIPTION - FIRE AND
troubleshooting procedures. FLIGHT AIR DATA SUBSYSTEM
CIRCUITRY.
The fire and flight air data subsystem (ADS) supplies
digital true airspeed, absolute (static) pressure, and.
9-560. HEAD UP DISPLAY free-stream air temperature signals to the fire control
SUBSYSTEM (HUDS) CIRCUITRY. computer. An analog radar altitude signal is fed to the
ADS from the radar altimeter to provide ground effect
9-561. DESCRIPTION - HEAD UP correction. The ADS interfaces with the fire control
DISPLAY SUBSYSTEM (HUDS) CIRCUITRY. computer and radar altimeter. Refer to TM9-1270-
219-13 for maintenance information and procedures
The HUDS circuitry generates aircraft situation and pertaining to ADS components.
weapons aiming symbology which is projected into
the pilot forward field of view. The subsystem 9-566. FUNCTIONAL TEST - FIRE
interfaces with the M65 TOW missile subsystem, the AND FLIGHT AIR DATA SUBSYSTEM
radar altimeter, the fire control computer, and the CIRCUITRY.
caution panel on the pilot instrument panel. For
description and additional information pertaining to Functional testing of ADS components is by BIT (built -
HUDS components, refer to TM9-1270-220-13. in test) functions. Refer to TM9-1270-219-13 for
Refer to TM9-1270-220-13 for maintenance functional test procedures.
information and procedures pertaining to HUDS
components. 9-567. TROUBLESHOOTING - FIRE
AND FLIGHT AIR DATA SUBSYSTEM
9-562. FUNCTIONAL TEST - HEAD CIRCUITRY.
UP DISPLAY SUBSYSTEM (HUDS).
a. For subsystem troubleshooting, refer to TM
Functional testing of HUDS components and the
55-1520-236-T.
interface with the fire control computer are tested by
Change 3 9-217
TM 55-1520-236-23
b. ADS. Troubleshooting of ADS is accomplished relay assembly located on the outboard side of
by BIT (built-in-test) functions. Refer to TM 9- pilots ash receiver. When switch is in NORM
1270-219-13 for troubleshooting procedures. position the ACTION switch governs the laser
emission. When switch is in CONT position the laser
9-568. ~ C O L L E C T I V E POSITION emissions are continuous. 28 vdc power is supplied
TRANSDUCER. to the AIM-1/EXL laser gunsight subsystem through
the TURRET DRIVE MOTOR circuit breaker 19CB7
9-569. ~ DESCRIPTION - COLLECTIVE located on the pilot armament circuit breaker panel.
POSITION TRANSDUCER.
9-575. ~ FUNCTIONAL TEST - AIM-1/EXL
The collective position transducer located in the LASER GUNSIGHT SUBSYSTEM CIRCUITRY.
tower transmission compartment furnishes
collective position data to the fire control computer.
the transducer is powered from the IFCU. Refer to
paragraph 11-1 for maintenance and rigging The AIM-1/EXL Laser is very dangerous.
procedures. (Refer to fire control system wiring Looking at the laser beam or its
diagrams and equipment location charts in reflection from a shiny surface can cause
Appendix F, paragraph F-9). permanent blindness. Ensure that the laser
protective cover is kept over the emitter
9-570. ~ AIRBORNE LASER TRACKER (ALT) and that the AIM power switch is off prior
to testing. The laser shall be used only
CIRCUITRY.
in controlled areas. Night vision goggles
shall be used with this test.
9-571. R DESCRIPTION - AIRBORNE LASER
TRACKER (ALT) CIRCUITRY. a. Open all circuit breakers and place all switches
to their OFF or de-energized positions.
The ALT consists of an ALT receiver, ALT
electronics unit, and ALT control panel. The ALT b. Remove aiming light protective cover/warning
searches for, locks onto, and tracks pulse coded flag.
laser reflected energy from targets designated by a
ground or airborne scout using a laser designator. c. Close TURRET DRIVE MOTOR circuit breaker.
Target output data from the ALT cues the
telescope sight unit (TSU) to the target.
9-572. ~ TROUBLESHOOTING - AIRBORNE
LASER TRACKER (ALT) CIRCUITRY. Do not drive turret to stops during this check.
For troubleshooting procedures, refer to TM 55- d. Place AIM switch to CONT position.
1520-236-T. Continuous IR laser emission tracks with the turret
gun.
9-573. ~ AIM-1/EXL LASER GUNSIGHT
SUBSYSTEM CIRCUITRY. e. Place AIM switch in NORM position. Press
cyclic ACTION switch.
9-574. ~ DESCRIPTION - AIM-1/EXL LASER
GUNSIGHT SUBSYSTEM CIRCUITRY. f. Place AIM switch in OFF position.
The AIF-1/EXL aiming light is mounted on the gun 9. Open TURRET DRIVE MOTOR circuit breaker.
saddle of the universal turret. It enables low-
h. Install aiming light protective cover/warning
light/night target acquisition for the turret gun by
flag.
using a boresighted infrared laser beam that can
only be viewed with night vision goggles (NVGs).
The AIM-1/EXL subsystem can be used in conjunc- 9-576. ~ TROUBLESHOOTING - AIM-1/EXL
tion with the Helmet Sight Subsystem (HSS) when LASER GUNSIGHT SUBSYSTEM CIRCUITRY.
NVGs are worn. The AIM-1/EXL aiming light can
operate in continuous mode or activated when For troubleshooting procedures, refer to TM 55-
ACTION switch on pilot cyclic control is pressed. 1520-236-T.
Subsystem operations are controlled by the switch/
9-218 Change 19
TM 55-1520-236-23
CHAPTER 10
FUEL SYSTEMS
SECTION I. FUEL SYSTEMS
10-1. FUEL SYSTEM. gallons or below. Both cells are vented by a single
overboard vent line. R A closed circuit refueling
10-2. DESCRIPTION - FUEL SYSTEM. receiver located above and forward of the right wing
allows for pressure or gravity refueling of the entire
a. The fuel system is of the crashworthy type, system. q E A cap and adapter assembly located
designed to resist fuel spillage and reduce fire above and forward of the right wing allows for gravity
hazards in the event of crash impact. All fuel cells, the refueling of the entire system.
interconnect lines between cells, and fuel supply
lines are self-sealing. Breakaway fittings are
b. An electrically operated boost pump in each
designed to break between self-closing valves if a
fuel cell delivers fuel to a fuel manifold. Two fuel
crash impact occurs. Fuel is contained in two
pressure switches are installed to illuminate the FWD
crashworthy, interconnected fuel cells installed in
FUEL BOOST or AFT FUEL BOOST lights, when boost
fuselage compartments forward and aft of the
pump pressure drops below rated pressure. Fuel from
transmission (figures 10-1 and 10-2). A check valve is
the manifold passes through an electrically operated
installed between the fuel cells to restrict fuel from
fuel shut-off valve to a fuel filter. Fuel is then routed to
the aft cell flowing to the forward cell during a nose
the engine. Thermal relief valves allow fuel to return
down condition. Sump drains are provided under
from the engine to the fuel ceils after engine
each cell. The sump drain valve on the aft cell may be
shutdown.
used for system defueling. Each fuel cell has a
transmitter probe for fuel quantity indications. Afloat
switch is installed in each cell to illuminate the FUEL 10-3. TROUBLESHOOTING - FUEL
LOW caution lights when the fuel supply drops to 26 SYSTEM.
After aircraft has been defueled, a small
amount of fuel may be present in the
cells. Care should be taken to catch
remaining fuel in a suitable container
when removing fuel cell components.
NOTE
Perform all normal operational checks
prior to using table 10-1. If a malfunction
is detected that is not listed in the table,
notify the next higher maintenance level.
Perform troubleshooting of the fuel system in
accordance with table 10-1.
Change 16 10-1
TM 55-1520-236-23
Table 10-1. Troubleshooting Fuel System
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
1. FUEL FILTER lamp illuminated.
STEP 1. Remove filter element and check for clogged filter.
Replace filter element if dirty or clogged (paragraphs 10-7 and 10-11).
2. AFT or FWD FUEL BOOST caution lamps illuminated.
STEP 1. Check for sound of pump running.
If pump is running but there is no indication of fuel flow to engine, pump has failed or lines are
loose or clogged. Check manifold and shutoff valves for malfunction if lights are off without flow
to engine. Replace pump (paragraph 10-27 and 10-30).
STEP 2. If pump is not running, check for electrical continuity (appendix F).
If electrical continuity is not present, repair wiring. If continuity is normal, replace pump.
3. FUEL LOW lamp illuminated.
STEP 1. Defuel helicopter and then refuel. FUEL LOW lamp should go out after approximately 26 gallons of
total fuel capacity is in fuel cells.
If lamp remains on, check low level warning switch. Replace if defective (paragraph 10-20 and
10-23).
STEP 2. Check electrical circuit for continuity.
If continuity is not normal, repair as required.
10-2 Change 16
TM 55-1520-236-23
10-4. OPERATIONAL CHECK - FUEL 10-7. REMOVAL - FUEL FILTER.
SYSTEM.
a. Open left side of engine compartment cowling.
Refer to paragraphs 9-276, 9-354, and 9-358 for opera-
tional check of fuel system. b. Disconnect fuel hose from outlet coupling on
top of filter.
10-5. FUEL FILTER. c. Drain fuel from filter by opening drain line
valve. Use a suitable tool to slightly depress self-
closing valve of filter outlet coupling to admit some air
10-6. DESCRIPTION - FUEL FILTER. and assist drainage.
The filter (10, figure 10-2) is mounted on a bracket d. Open V-band trunnion clamp (47, figure 10-2)
located on left side of the engine compartment deck. and remove bowl (43) and filter element (45) from
The filter contains a replaceable paper-type element filter head (49). Separate element (45) and packings
(45) and has an internal bypass, with electrical (44, 46, and 48) from bowl. Discard filter element and
connection to the FUEL FILTER caution lamp to warn packings.
when the filter is about to be bypassed due to
clogging. Piping connections on the filter include the e. 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 p l u g , r e m o v e
inlet line, drain line, and a quick disconnect outlet screws (53), washers (52) and remove pressure
coupling. switch (51). Remove packings (50).
Change 16 10-2.1/(10-2.2 blank)
TM 55-1520-236-23
Figure 10-1.
Change 16 10-3
TM 55-1520-236-23
Figure 10-2.
10-4 Change 19
TM 55-1520-236-23
Figure 10-2. Fuel System (Sheet 2 of 4).
Change 19 10-5
TM 55-1520-236-23
Figure 10-2. Fuel System (Sheet 3 of 4)
10-6 Change 22
TM 55-1520-236-23
Figure 10-2. Fuel System (Sheet 4 of 4)
NOTE 10-9. CLEANING FUEL FILTER BOWL.
Filter head (49) will usually be left in
place, but can be ramoved as in the
following step.
f. Remove the filter head (49) by disconnecting
the inlet pressure and drain lines from the filter head. Cleaning solvent is flammable and toxic.
Detach the head assembly from bracket by removing Provide adequate ventilation. Avoid
four bolts, nuts, and washers. prolonged breathing of solvent vapors
and contact with skin or eyes.
10-8. INSPECTION FUEL FILTER.
a. Inspect filter element (45, figure 10-2) for a. Clean bowl (43, figure 10-2), V-band trunnion
contamination to determine if any corrective action is clamp (47), and exposed surfaces of head assembly
needed beyond replacement of element and (49) with solvent (Cl 12).
packings.
b. Remove excess solvent with clean, dry cloth.
b. Inspect filter head assembly (49) and bowl (43)
for damage. 10-10. REPAIR OR REPLACEMENT
FUEL FILTER.
c. Inspect V-band trunnion clamp (47) for
serviceable condition. a. Install new filter element (45, figure 10-2) and
new packings (44, 46, and 48).
d. Inspect pressure switch (51) for cracks, broken
pins, and corrosion. b. Replace packings (50) if damaged or leaking.
Change 16 10-7
TM 55-1520-236-23
c. Replace pressure switch (51) if electrical con- trapped on outlet side of the shutoff valve. The valve is
nector is damaged. equipped with an ON-OFF lever and position indicator
to allow manual operation of the valve.
d. Replace filter head assembly (49) and/or bowl
(43) if damaged. 10-14. REMOVAL FUEL SHUTOFF VALVE.
10-11. INSTALLATION FUEL FILTER.
a. Open engine and transmission cowling doom
a. If removed, position filtered head assembly
(49, figure 10-2) on outboard side of mounting bracket b. Disconnect engine fuel inlet hose (10, figure
and install four bolts, nuts, and washers. Connect drain 10-3) from filter outlet coupling. Open filter drain valve,
and inlet lines to fittings. and manually open fuel shutoff valve (4) to release
trapped fuel. After short period of drainage, close both
NOTE
valves.
Ensure that plug is installed In pressure
tap port of filter. c. Perform function check of fuel shut-off valve
(4) prior to removal to determine whether valve motor
b. Place new packing (44) on boss in bottom of will open and dose fuel valve.
fitter bowl. Place new filter element (45) in bowl (43)
and seat firmly on boss. d. Disconnect electrical connector (3) from shut-
off valve (4).
c. Install new packing (48) around tip of bowl (43)
next to damping flange. e. Disconnect fuel inlet hose (1) and fuel outlet
hose (8) from valve (4). Cap open ends of hoses.
d Place new packing (46) around center boss in
filter head Install bowl (43) and filter element (45) into f. Remove four nuts (7), washers (6), and
fitter head assembly (48). screws (2). Remove shutoff valve inlet and outlet
connectors (5 and 9).
NOTE
g. Do not remove packing installed in fuel shut-
Install V-band damp assembly with off valve (4) ports where connectors (5 and 9) were
clamp latch on left side of the fuel filter removed.
and gap (drain) at the 6 oclock position.
10-15. INSPECTION FUEL SHUTOFF
e. Install V-band trunnion damp (47) around
VALVE.
mating flanges of fitter head and bowl. Torque nut 50
inch-pounds.
a. lnspect valve for external damage and leakage.
f. Connect hose from engine fuel control inlet to
outlet coupling (11) on fitter head. Ensure that a mini- b. Inspect connectors for damaged threads or
mum of 1.5 inches exists between hose and engine air mating surfaces.
diffuser. Close cowling.
c. Inspect electrical connector for broken or bent
g. During next ground run-up, check fuel filter pins.
and connections for leaks. Also check that FUEL
FILTER caution lamp does not Iight. d. Inspect packings at fuel valve inlet and outlet
for damage. Replace fuel shutoff vaIve if either packing
10-12. FUEL SHUTOFF VALVE. is damaged or missing.
10-13. DESCRIPTION FUEL SHUTOFF 10-16. REPAIR OR REPLACEMENT FUEL
VALVE. SHUTOFF VALVE.
A motor-operated shutoff valve (4, figure 10-3) is a. Replace fuel shutoff valve if motor will not
installed in the fuel supply system between the check open and close the valve.
valve manifold and the fuel fitter. The valve is mounted
on front of the engine forward firewall at left side. An b. Replace fuel shutoff valve if inspection
internal bypass valve allows the thermal relief of fuel requirements are not met.
10-8 Change 22
TM 55-1520-236-23
Figure 10-3.
10-17. INSTALLATION - FUEL SHUTOFF baffle. Install four mounting screws (2), nuts (7), and
VALVE. washers (6).
a. Install connector (5, figure 10-3) and connector
(9) as follows: c. Connect fuel inlet hose (1) from check valve
manifold (12) to inlet connector (9).
(1) Inspect open ports in fuel shutoff valve (4),
where connectors (5 and 9) will be installed, for d. Connect fuel outlet hose (8) from fuel filter (11)
presence of serviceable packings (not illustrated). if to valve outlet connector (5).
either packing is unserviceable or missing, install
new packing.
e. Connect electrical connector (3) to receptacle
on valve motor. Lockwire connector.
(2) Identify connector (5) by threads that match
fuel outlet hose (8). Identify connector (9) by threads
f. Reconnect engine fuel inlet hose (10) to outlet
that match fuel inlet hose (1). Position connectors (5
coupling of fuel filter. Close cowling.
and 9) on fuel shutoff valve (4) and install four screws
(2), washers (6), and nuts (7), Torque nuts evenly.
b. Position shutoff valve (4) on front of engine g. At next ground run-up, check shutoff valve for
forward firewall, at left side just below induction proper operation and for leaks.
10-9
TM 65-620-236-23
10-18. LOW LEVEL WARNING (FLOAT) (5) Remove packings (71 and 72).
SWITCHES.
10-19. DESCRIPTION - LOW LEVEL 10-21. INSPECTION - LOW LEVEL
WARNING (FLOAT) SWITCHES. WARNING (FLOAT) SWITCHES.
There are two low level warning (float) switches (36 a. Inspect threads for damage.
and 70, figure 10-2) installed, one in the aft fuel cell
and one in the forward fuel cell. The switches will b. Inspect electrical lead for frayed or damaged
cause the FUEL LOW lamps to light when ap- insulation.
proximately 26 gallons of fuel remain in fuel
cells. c. Inspect sensing holes at top and bottom of
switch for obstructions.
10-20. REMOVAL - LOW LEVEL WARNING
(FLOAT SWITCHES).
10-22. REPAIR OR REPLACEMENT - LOW
a. Defuel helicopter (paragraph 1-3), LEVEL WARNING (FLOAT) SWITCHES.
b. Perform functional test of low level warning
float switches to confirm that FUEL LOW worded a. Replace low level warning switches that were
segment in caution panel illuminates when battery found to be inoperative in functional check in
switch is positioned to ON, START. paragraph 10-20.b.
c. Remove screw-mounted panel from underside b. Replace low level warning switches that failed
of fuselage below forward and/or aft fuel cell. to meet inspection requirements (paragraph 10-21).
d. Disconnect electrical leads at terminal board. 10-23. INSTALLATION - LOW LEVEL
Refer to Appendix F. WARNING (FLOAT) SWITCHES.
e. Remove low level warning (float) switch (36, a. Install low level warning (float) switch (70
figure 10-2) from aft fuel cell. figure 10-2) in forward fuel cell.
(1) Remove nut (42) and cover (41 ). (1) Install packing (71) on switch (70) and insert
electrical leads down through fitting assembly (74).
(2) Remove bolts (40). Screw switch tightly onto fitting assembly.
(3) Withdraw fitting (39) from fuel cell. (2) Install packings (71 and 72) and install
fitting assembly (74) using frangible clips (75),
(4) Remove switch (36) from fitting (39) washers (76), and bolts (77).
(5) Remove packings (37 and 38). (3) Connect electrical leads to terminal board
(Appendix F).
f. Remove low level warning (float) switch (70,
figure 10-2) from forward fuel cell, b. Install low level warning (float) switch (36) in
aft fuel cell.
(1) Loosen clamp and remove hose (80).
(1) Install packing (37) on switch (36) and insert
(2) Remove bolts (77), washers (76), and electrical leads down through fitting (39). Screw
frangible clips (75). switch tightly onto fitting.
(3) Withdraw fitting assembly (74) from fuel (2) Install packing (38) and install fitting (39)
cell. using bolts (40). Install-cover (41) and nut (42)
(4) Remove switch (70) from fitting assembly (3) Connect electrical leads to terminal board
(74). (Appendix F).
10-10 Change 16
TM 55-1520-235-22
10-24. TEST PROCEDURES LOW LEVEL b. Remove Iockwire and screw (5). Turn arm (4) to
WARNING (FLOAT) SWITCHES (AVIM). 180 counterclockwise position.
Refer to paragraph 9-276 (13) for test procedures.
10-25. FUEL BOOST PUMPS. NOTE
10-26. DESCRIPTION FUEL BOOST This arm shuts off fuel to the pumping
PUMPS. cavity. Upon removal of the cartridge,
approximately one pint of fuel will be
An electric motor-driven fuel boost pump (4, figure lost.
10-4) is mounted into the bottom of each fuel cell, to
deliver fuel at a rate up to 990 pounds per hour at 5 to c. Remove fuel pump drain plug (3) and drain
residual fuel from fuel pump into suitable container.
30 psi pressure. Each pump is submerged in fuel, with
its outlet connected to a hose leading to an external
fuel line. Electrical leads and a seal drain line are d. Remove Iockring (6) securing fuel pump
provided on the lower exterior face of the pump. cartridge (2) to fuel pump housing (1).
e. Remove fuel pump cartridge (2) from fuel pump
10-27. REMOVAL FUEL BOOST PUMPS.
housing (1) using cartridge removal tool (figure 10-2.2).
Discard packings (7).
NOTE f. Clean cartridge cavity and Iockring of all foreign
Removal of boost pump from forward or matter.
aft fuel cell is the same except for 10-28. INSPECTION FUEL BOOST PUMPS.
location and access.
a. Inspect connectors and fittings for cracks and
a. Drain both fuel cells (paragraph 1-3). damaged threads.
b. Remove screw-mounted panel from underside of b. Inspect electrical leads for frayed or damaged
fuselage below forward and/or aft fuel cell. insulation.
10-29. REPAIR OR REPLACEMENT FUEL
c. Disconnect boost pump electrical leads from
BOOST PUMPS. (AVIM)
terminal board (Appendix F).
a. Replace gasket if leaking or damaged.
d. Remove seal drain tube (12, figure 10-4) from
union (11) on pump (4). b. Replace pump having damaged connectors or
electrical leads.
e. Remove bolts (9), washers (8), and frangible clips
(7) from mounting flange of pump. c. if pump is replaced, remove ail fittings from old
pump for installation on new pump.
f. Lower pump assembly enough for access to hose
connection (1) on pump discharge fitting (2).
Disconnect hose and remove pump and gasket (3). 10-29.1 REPAIR OF FUEL BOOST PUMP
Cover open port. CARTRIDGE (CRASHWORTHY).
10-27.1. REMOVAL - FUEL BOOST PUMP
CARTRIDGE (CRASHWORTHY). Refer to TM 55-2915-335-30&P.
a. Disconnect electrical wiring from fuel pump 10-30. INSTALLATION FUEL BOOST
cartridge (2, figure 10-4.1) PUMPS.
A bent inlet shut-off valve arm may NOTE
prevent the shut-off valve from com- Installation of boost pump in forward or
pletely opening causing a restricted fuel aft fuel cell is the same except for
flow. Apply pressure directly over valve location and access.
spring when opening or closing valve
stem assembly. Trying to compress
valve spring from free end of valve arm a. Place gasket (3, figure 10-4) on mounting flange
will cause valve arm to bend. When of pump (4). Uncover mounting port of fuel cell. insert
removing or installing shoulder screw, pump partially into port and connect fuel hose (1) to
keep valve arm depressed. outlet fitting (2).
Change 16 10-11
TM 55-1520-236-23
b. Install frangible dips (7) at 7 and 10 oclock c. Install locking (6) securing fuel pump
positions for forward cell, and at 5 and 8 oclock posi- cartridge (2) to fuel pump housing (1).
tionsfor aft cell. Look up with reference to most aft
pump bolts as 12 oclock position. Install bolts (9) and d install fuel pump drain plug (3) into fuel pump.
washers (8). Torque bits 50 TO 70 inch-pounds. Connect positive electrical lead with the short straight
slot screw (8).
c. Connect seal drain tube (12) to union (11) on
pump.
d Connect electrical leads from pump to
terminal board. See circuit wiring diagram (Appendix
F). A bent inlet shut-off valve arm may pre-
vent the shut-off valve from completely
e. Service fuel cell and check for leaks (para- oepning causing a restricted fuel flow.
graph 1-3). Apply pressure directly over valve
spring when opening or closing valve
10-30.1 . INSTALLATION FUEL BOOST stem assembly. hying to compress
PUMP CARTRIDGE (CRASHWORTHY). valve spring from free end of valve arm
will cause valve arm to beind When re-
NOTE moving or installing shoulder screw,
keep valve arm depressed.
Do not use removal tool to Install
cartridge. e. Turn fuel shut-off arm (4) clockwise into
position, aligning arm and screw hole. Press shaft end
Visually inspect that fuel bleed valve is of arm up, measure gap between arm and base of fuel
installed on top of fuel pump housing (1, figure 104.1) pump cartridge. Fill gap with fiat washers (part number
on cartridge type pumps. AN960PD416/AN960PD416L) to eliminate any
possibility of bending arm. Install electrical lead under
shoulder of screw and Iockwire (C151).
f. Turn on master switch and fuel pump and
check for proper fuel pressure.
If fuel bleed valve is not installed, en-
gine surging/flameout will occur when 10-31. TEST PROCEDURES FUEL BOOST
the fuel level is below the top of the fuel PUMPS.
boost pump housing and the boost
pump is off or inoperative Refer to paragraph 9-358 for operational check of fuel
boost pumps.
b. Lightly lubricate packings (7, figure 104.1)
using grease (C59). Install packings (7) on new
cartridge (2). insert fuel boost pump cartridge (2) into 10-32. FUEL QUANTITY TRANSMITTERS.
fuel pump housing (1) ensuring arrows on fuel pump
and fuel pump housing align. Refer to paragraph 8-221.
10-12 Change 22
TM 55-1520-236-23
Figure 10-4. Fuel Boost Pump
10-12.1
TM 55-1520-236-23
Figure 10-4.1. Fuel Boost Pump Cartridge
10-12.2
TM 55-1520-236-23
Figure 10-4.2. Work Aid for Fuel Pump Cartridge Removal
10-12.3/(10-12.4 blank)
TM 55-1620-236-23
10-33. CHECK VALVE MANIFOLD. 10-38. INSTALLATION CHECK VALVE MANIFOLD.
10-34. DESCRIPTION CHECK VALVE MANIFOLD. a. Check that fittings and pressure switches are prop-
erty installed, with gaskets, in manifold assembly (figure
A valve manifold (3, figure 10-2), located just ahead of 10-2).
engine forward firewall at left side, is connected into fuel
pressure lines ahead of the shutoff valve. The manifold b. Hold manifold with flow arrows pointing aft, and out-
contains two separate check valve elements which pre- let elbow at aft inboard side. Insert two screws, with wash-
vent reverse flow, except through bypasses which will ers under heads, downward through manifold. Place a
relieve thermal expansion of trapped fuel. One outlet port spacer on lower end of each screw.
of the manifold is used, another is plugged. Two pressure
switches are installed in the inlet side of the manifold, to c. Align manifold assembly to mounting holes in deck,
cause lighting of FWD FUEL BOOST or AFT FUEL and tighten screws securely.
BOOST caution panel segments if either fuel boost pump
fails to deliver normal pressure. d. Connect fuel line from shutoff valve inlet arrow of
manifold. Connect fuel pressure line and hose to manifold
inlet fittings.
10-35. REMOVAL CHECK VALVE MANIFOLD.
e. Connect electrical connectors to pressure switches.
a. Open transmission cowling door at left side.
f. Check for proper operation and for leaks.
b. Disconnect electrical connectors from both pres-
sure switches on check valve manifold. 10-39. CLOSED CIRCUIT REFUELING RECEIVER.
c. Provide a small container to catch trapped fuel. 10-40. DESCRIPTION CLOSED CIRCUIT REFUEL-
Disconnect fuel lines from fittings at manifold inlets and ING RECEIVER.
outlet. Cap open ends of tines.
The closed circuit refueling receiver is located on the fuse-
d. Remove two screws, washers, and spacers from lage above and forward of the right wing. The receiver
manifold (3). accepts either a closed circuit refueling nozzle or a gravity
fill nozzle. The receiver is capable of accepting fuel at the
10-36. lNSPECTION CHECK VALVE MANIFOLD. rate of 100 gallons per minute (GPM). The receiver auto-
matically shuts off when system is full, system internal
a. Inspect manifold for cracks and fittings for damaged pressure exceeds 2.5 PSI, or flow rate exceeds 130 GPM.
threads.
10-41. REMOVAL CLOSED CIRCUIT REFUELING
b. Inspect pressure switches for cracks and bent or RECEIVER.
broken pins.
a. Defuel as required.
10-37. REPAIR OR REPLACEMENT CHECK VALVE b. Remove screws (24, figure 10-2), washers (25),
MANIFOLD. and bus-conductor (54).
a. Replace pressure switches having cracks or loose c. Remove retainer (27), receiver assembly (26), gas-
and broken pins. ket (28), and packing (29).
b. Replace gaskets and elbow or plug at manifold out- 10-42. INSPECTION CLOSED CIRCUIT REFUELING
let if leaking or damaged. RECEIVER.
c. Replace manifold assembly if damaged or malfunc- Inspect for damage, freedom of operation and corrosion.
tion occurs. Transfer outlet fittings and pressure switches
to replacement assembly as required.
Change 19 10-13
TM 55-1520-236-23
10-43. REPAIR OR REPLACEMENT g. Remove lower half of valve (62) from upper
CLOSED CIRCUIT REFUELING RECEIVER. half of valve (60) and remove pecking (63).
Replace if defects in paragraph 10-42 are noted. 10-54. INSPECTION AFT DEFUEL A N D
SUMP DRAIN VALVE.
10-44. lNSTALLATION RECEIVER
ASSEMBLY. a. Inspect valve for cracks and damaged
threads.
a. Position packing (29, figure 10-2), gasket,
and receiver assembly (26) in opening in aircraft. b. Inspect shutoff function of upper valve for
Position retainer (27) on outboard face of receiver damage that would allow leakage.
assembly.
10-55. REPAIR OR REPLACEMENT AFT
b. Install screws (24), washers (25), and bus-
DEFUEL AND SUMP DRAIN VALVE.
conductor (54). Position bus-conductor at ten oclock
position, under screw head. Torque bolts evenly 50 TO
70 inch-pounds. a. Replace valve having cracks and/or damaged
threads.
Paragraphs 10-45 through 10-50 have been deleted.
b. Replace valve having faulty shutoff operation
10-51. DEFUEL AND SUMP DRAIN VALVE. (if applicable) (C-137).
10-52. DESCRIPTION DEFUEL AND SUMP 10-56. INSTALLATION AFT DEFUEL AND
DRAIN VALVE. SUMP DRAIN VALVE.
A defuel and sump drain valve (60 and 62, figure 10-2) a. Place packing (64, figure 10-2) on upper valve
is installed on the bottom of the helicopter beneath the (60), insert in plate (56), and install nut (54).
aft fuel ceil. The valve is a two-piece valve which will
automatically dose the valve opening when the lower b. Install packing (63) and Iower half of valve (62)
valve is removed for defueling and draining. A special on upper half of valve (60).
fitting is required to open the upper valvefor defueling
and draining operations. The valve will drain fuel from
c. Place packing (55) in position and install plate
both the forward and aft fuel cells.
(56) using frangible dips (57) at 5 and 8 oclock posi-
tions, washer (58) and bolts (59). Torque bolts 50 TO
10-53. REMOVAL AFT DEFUEL AND 70 inch-pounds.
SUMP DRAIN VALVE.
d. Connect hose (61) to lower valve.
a. Defuel forward and aft fuel cells (paragraph
1-3).
NOTE
b. Remove access cover beneath aft fuel cell.
Aircraft only needs to be refueled to a
c. Disconnect clamp and remove hose (61, level high enough to check sump drain
figure 10-2). valve for leakage.
d. Deleted. e. Refuel aircraft (paragraph 1-3).
e. Remove bolts (59), washers (58), frangible f. Inspect drain valve for leakage. If no Ieakage
clips (57), and plate (56) with upper and lower halves occurs, continue to refuel aircraft. if there is any evi-
of valve assemblies (60, 62) attached and remove dence of leakage, recheck torque of bolts (59). If leak-
packing (55). age is still present, repeat steps in paragraphs 10-53
through 10-56.
f. Remove nut (54) and upper half of valve (60)
from plate (56) and remove packing (64). g. Install access cover.
10-14 Change 22
TM 55-1520-236-23
10-57. FORWARD SUMP DRAIN VALVE. b. Install packing (80) and lower half of valve (81)
on upper half of valve (79).
10-58. DESCRIPTION FORWARD SUMP
DRAIN VALVE. c. Place packing (72) in position and install fitting
assembly (74) using frangible dips (75) at 2 and 5
The sump drain valve (79, figure 10-2) is located beneath oclock position, washers (76) and bolts (77). Torque
the forward fuel cell. The valve provides a means of bolts 50 TO 70 inch-pounds.
draining residual fuel from the forward fuel cell.
d Conned hose (82) to lower half of valve (81).
10-59. REMOVAL FORWARD SUMP
DRAIN VALVE. NOTE
a. Defuel forward and aft fuel cells (paragraph Aircraft only needs to be refueled to a
1-3). level high enough to check sump drain
valve for leakage.
b. Remove access cover beneath forward fuel cell.
e. Refuel aircraft (paragraph 1-3).
c. Disconnect clamp and remove hose (82,
figure 10-2). f. Inspect drain valve for leakage. If no leakage
occurs, continue to refuel aircraft. If there is any
d. Remove bolts (77), washers (76), frangible evidence of leakage, recheck torque of bolts (77). If
dips (75), and fitting assembly (74) with upper and Ieakage is still present, repeat steps in Paragraph
lower halves of valves assemblies (78, 81) attached 10-59 through 10-62.
and remove packing (72).
g. Install access cover.
e. Remove nut (73) and upper half of valve (79)
from fitting assembly (74) and remove packing (78).
10-63. HOSES AND TUBING.
f. Remove lower half of valve (81) from upper
half of valve (78) and remove packing (80). 10-64. DESCRIPTION HOSES AND
TUBING.
10-60. INSPECTION FORWARD SUMP
DRAIN VALVE. Flexible hoses of fire resistant material are used in the
crashworthy fuel system. The crossover hose (14,
a. Inspect valve for cracks and damaged figure 10-2), engine fuel inlet hose (11), fuel and vent
threads. fitting hoses (23) and cheek valve manifold to shutoff
valve hose are self-sealing crashworthy hoses. The
b. lnspect valve for correct operation of shutoff hoses are scoured with robber cushioned damp to
function. prevent chafing. Aluminum alloy tubing is used in the
system to serve as drain lines.
10-61. REPAIR OR REPLACEMENT
FORWARD SUMP DRAIN VALVE. 10-65. REMOVAL HOSES AND TUBING.
a. Replace valve having cracks and damaged a. Defuel forward and aft cells (paragraph 1-3).
threads.
b. Hold end fittings to prevent kinking or twisting
b. Replace valve having faulty shutoff operation. of hoses and tubing when removing. Cover open ends
to prevent contamination.
10-62. INSTALLATION FORWARD SUMP
DRAIN VALVE. 10-66. lNSPECTION HOSES AND
TUBING.
a. Place packing (78, figure 10-2) on upper half
of valve (78), insert in fitting assembly (74) and install a. Inspect tubing for kinks, dents, and deep
nut (73). scratches.
Change 22 10-15
TM 55-1520-236-23
b. Inspect fuel crossover hose (14, figure 10-2) Ball size
for: Hose dash size diameter (inches)
(1) Any surface abrasion deep enough to cut -3 0.080
outer fabric braid. -4 0.132
-5 0.200
(2) Brittleness or powdering due to -6 0.260
temperature or aging. -8 0.350
-10 0.450
(3) Cracks, cuts, or tears. -12 0.575
-16 0.781
(4) Hose saturated with fluid. -20 1.015
-24 1.250
c. Inspect fuel crossover hose (14) for loose or -32 1.684
damaged clamps attaching hose to end fitting. In-
spect crossover hose (14) for damage. h. Inspect remaining hoses for cuts, kinks, or
twisted areas.
d. Inspect vent lines (23) for:
i. Inspect end fittings for damaged threads, burrs,
(1) Two or more broken wires per plait or more or other damage.
than six broken wires per lineal foot or any broken
wire where kinking is suspected. 10-67. REPAIR OR REPLACEMENT
HOSES AND TUBING.
(2) Evidence of dents, kinks, or twisting.
a. Replace hoses with indications of defects noted in
(3) Evidence of brittleness. Check by flexing paragraph 10-66.
hose.
b. Tighten or replace loose or damaged fuel hose
(4) Seepage/wetness around the end fitting or clamps (paragraph 10-66).
any part of the hose.
c. Replace hoses having cuts, kinks, or twisted
e. Inspect self-sealing covered hoses (1, 8, and areas.
10, figure 10-3).
d. Replace tubing having kinks, dents, or deep
(1) Surface abrasion deep enough to cut the scratches.
outer fabric braid.
e. Replace hoses having damaged end fittings.
(2) Brittleness or powdering due to
temperature or aging. 10-68. INSTALLATION HOSES AND
TUBING.
(3) Evidence of inner hose pulling out of the a. Do not try to pull hoses or tubing into position
outer cover at end fittings, Inspect for reduction of by tightening nuts. Position tubes properly between
inside diameter. connecting points to avoid stressing.
(4) Cracks, cuts, or tears in outer cover.
b. Hold end fittings when installing hoses. Ensure
that hoses do not become twisted during tightening of
(5) Soaked outer cover, saturated with fluid. end fittings.
f. Inspect self-sealing covered hoses (1, 8, and
10-69. FUEL CELL FITTINGS.
10), for loose or damaged clamps at hose ends.
10-70. DESCRIPTION FUEL CELL
g. To check the inside diameter of a marginally
FITTINGS.
kinked or dented hose for deformation, use ball size
shown below and verify it will roll through the hose to
indicate unrestricted flow.
10-16 Change 16
TM 55-1520-236-23
elbows, vents, pressure line outlets, fuel quantity
transmitter, and governor bleed line inlet (figure
10-2).
10-71. MAINTENANCE - FUEL CELL
FlTTINGS. Ensure that check valve is installed with
direction-of-flow arrow pointing into
Any fuel cell fitting can be removed for replacement of cell.
parts to correct leaks, or for access to parts within
cells. Observe the following:
c. If governor bleed return inlet fitting is removed
a. Replace defective seal or packing under fitting. from rear side of aft fuel cell, make certain of correct
Be sure mating surfaces are clean and free of burrs reassembly. Install check valve (35, figure 10-2) with
and nicks. direction-of-flow arrow pointing into the cell,
NOTE d. Torque bolts 50 TO 70 inch-pounds.
Note position of frangible clips on
system and reinstall in same location. 10-72. INSPECTION - FUELL CELL
FlTTINGS.
b. If crossover hose elbow on aft cell is removed,
make certain that check valve and pin are correctly Inspect for leakage after refilling fuell cells and during
reinstalled (figure 10-2). initial operation.
SECTION Il. FUEL CELLS
10-73. FUEL CELLS. 10-75. INSPECTION - ACCEPTANCE/
REJECTION CRITERIA - FUEL CELLS.
10-74. DESCRIPTION - FUEL CELLS.
a. Defuel helicopter (paragraph 1-3).
a. T h e t w o f u e l c e l l s a r e r e m o v a b l e u n i t s
contained in fuselage compartments, one forward of
the pylon and one aft, between the main longitudinal NOTE
beams. The cells are crashworthy, self-sealing and
have a 50 caliber ballistic protection level. Openings The access panel just ahead of the wings
in the cells are provided with metal fittings bonded can be removed without removal of the
into the laminated cell walls. Each fitting has a wings.
pattern of threaded inserts for attachment of
equipment and for securing cell in position by means
of frangible clips. b. Remove 12 screws (81, figure 10-2)
securing cap and adapter assembly (82) to fuselage.
Remove cap and adapter assembly (82).
b. Each fuel cell is designed to retain fuel in event
of crash impact. The cell is constructed of high
strength multiple ply material and incorporates self- c. Remove screws (24) securing refueling
sealing compound between plies. The cell is retained receiver assembly (26) to fuselage. Remove receiver
in the structure by frangible clips designed to break (26) and retainer (27).
away before crash forces rupture the cell. High
strength fittings are used to attach system
components to the cell. The fuel cell is sufficiently d. Feel the interior of the cell horizontal shelf all
flexible to permit installation in fuselage; yet is rigid the way to the fuselage forward and aft vertical wall
enough to eliminate need for hangers or cord lacings. for activation (sponginess) (paragraph 10-78).
10-17
TM 55-1520-236-23
CAUTION 10-76. REMOVAL - FORWARD FUEL CELL
(AVIM).
Use safety precautions with electrical
device. Use only a sealed battery a. Defuel system and remove access panel
powered light. (paragraph 1-3).
e. A fuel call maybe questionable when inspected b. Disconnect electrical leads and remove boost
along the shelf area and additional inspection may be pump assembly (paragraph 10-27).
required. Additional inspection is performed by
completely draining the fuel system and removing the c. Disconnect electrical leads of low level warning
fuel pump and frangible mounting clips around the cell (float) switch (70, figure 10-2). Disconnect drain hose
fitting. The feel test is then performed inside and outside (80) from valve (79). Remove two bolts (77), washers
the cell bottom. In addition to any sponginess that may (76), and frangible clips (75), securing cell to fuselage
be detected from the inside, the cell wetness that can structure. Remove four remaining bolts (77) securing
be felt on the bottom exterior is cause for cell removal sump fitting (74) to fuel cell. Remove fitting (74) with
and possible additional inspection. drain valve (79) and low level warning (float) switch (70)
from helicopter.
Premaintenance Requirements for Fuel Cells
c1. Remove leftwing (Refer to Chapter 2).
Conditions Requirements
d. Remove screw mounted access panel from left
Model AH-1S side of fuselage just ahead of wing.
Part No. or Serial No. All e. Remove left and right side access panels located
below wings. Loosen clamp on fuel crossover hose (14).
Special Tools None Remove four bolts, frangible clips, washers, and
spacers from bulkhead crossover flanges and fuel call.
Test Equipment None Remove six bolts and washers from crossover and cell
flange.
Support Equipment (S3) (S6)
f. Open hydraulic compartment access doors.
Minimum Personnel Two
Required g. Remove ECU (paragraph 13-9).
Consumable Materials (C12) (C74) (C75) (C53) h. Remove fuel quantity transmitter probe (22)
(C102) (C52) (C117) (C29) (paragraph 8-224).
(C107) (C112) (C137)
i. Disconnect hose assemblies at vent (21) fuel
Special Environmental 70 degrees F fitting. Remove five bolts and frangible clips securing
Conditions (21 degrees C) cell to fuselage structure. Remove remaining bolt
securing fitting to fuel cell. Remove fitting from
helicopter.
f. If the fuel cells have separated or activated per
install new fuel cell. j. Remove refueling receiver assembly (26,
figure 10-2), packing (29), retainer (27), gasket (28), and
g. If packing (29) or packing (84) was pulled from mounting screws (24) from fuselage. Remove
groove in the cell, replace packing. cap and adapter assembly (82), packing (84), retainer
(83) and mounting screws (81) from fuselage.
h. If fuel cells are acceptable, install parts that were
removed in steps b and c. Torque screws 45 TO 55 k. Remove forged fitting, located on inner access
inch-pounds. panel near lower forward corner, by removing two bolts
at base of fitting and four bolts and washers which
secure fitting to panel. Keep bolts, radius block, and
shim with fitting.
10-18 Change 18
TM 55-1520-236-23
l. R e m o v e s c r e w - m o u n t e d i n n e r p a n e l f r o m g. Open transmission cowling. Remove induction
fuselage beam. baffles for access to top ports of aft fuel tank cell
(paragraph 2-125).
m. Remove screws which secure upper fuel cell
access panel to left side of fuselage at contour. h. Disconnect hose assembly (23) by removing
Remove panel. six bolts and frangible clips securing hose fitting
to fuselage structure.
n. Remove clamps and ties from structure and
cable assemblies as necessary to obtain a clear area
for cell removal from left side. Tie cable assemblies i. Remove fuel quantity transmitter (probe) (22)
out of the way. (paragraph 8-224). Remove four cell attachment
screws and washers.
o. Collapse upper portion of fuel cell inward to
clear beam. Collapse cell downward and remove from j. Disconnect fuel pressure line hose from tank out-
cavity. let on left side of deck, forward of valve mani-
p. Preserve fuel cell by fogging with oil (C77). fold. Remove two bolts and frangible clips securing
Cover cell openings with barrier material (C23). fitting to fuselage structure, Remove two bolts and
washers securing fitting to cell. Remove fitting from
10-77. REMOVAL - AFT FUEL CELL.
helicopter.
(AVIM)
a. Defuel system and remove lower skin panel k. Install fitting and jack at aft jack point. Raise
(paragraph 1-3). jack only until snug against fitting.
CAUTION
b. Remove seal drain tube and boost pump
(paragraph 10-27).
Prior to removal of aft fuel cell access
c. D i s c o n n e c t e l e c t r i c a l l e a d s o f l o w l e v e l panel, perform procedure outlined in
warning (float) switch (36, figure 10-2). Remove nut paragraph 2-5.
(42) and cover (41). Remove two bolts (40) securing
switch fitting (39) to cell. Remove fitting (39) and l. Remove mounting screws and aft fuel cell
switch (36) from helicopter. access panel from right side of fuselage directly
behind wing attachments.
m. Collapse and remove fuel cell.
d. Remove clamp and hose (61) from defuel and n. Preserve fuel cell by fogging with oil (C77).
sump drain valve (62). Remove two bolts (59), Cover cell openings with barrier material (C23).
washers (58), and frangible clips (57) securing valve, 10-78. INSPECTION - BOTH CELLS.
plate (56), and cell to fuselage structure. Remove four (AVIM)
remaining bolts (59) and washers (58) securing valve
and plate to fuel cell. Remove valve and plate from a. Inspect all interior and exterior surfaces for
helicopter. loose seams, cuts, abrasions, scuffed surfaces, tears,
blisters, and for any area that appears to have become
e. Remove left and right side access panels soaked with fuel (activated).
located below wings. Loosen clamp on fuel crossover
hose (14). Remove four bolts, frangible clips, NOTE
washers, and spacers from bulkhead crossover
flanges and fuel cell. Remove six bolts and washers An activated fuel cell is a cell that has
from crossover and cell flange. absorbed fuel in the inner liner. The walls
of the cell are flabby and spongy. The
f. Remove oil cooler intake duct from left side of inner liners are separated and ballooned
fuselage for access. Disconnect bleed line from check from the structure. It must b e
valve (35). Remove two bolts (38), frangible clips (32), understood that a serviceable cell may
and washers (34) securing plate (31) with check valve have blemishes. These blemishes do not
(35) attached) and cell to structure. Remove two bolts have a spongy feeling. These blemishes
and washers securing plate to cell. are not cause for rejection.
Change 12 10-19
TM 55-1520-236-23
b. I n s p e c t m e t a l f i t t i n g s t o m a k e c e r t a i n b. Apply two coats of cement (C29) to the buffed
protective finishes are intact and the coil-type inserts area. Allow each coat to dry 10 TO 15 minutes.
are installed and in good condition.
c. The following damages are prohibited for field
repair and can be repaired only by an authorized fuel
cell overhaul facility.
Cleaning solvent is flammable and toxic.
(1) P a s s t h r o u g h h o l e s ( h o l e s m a d e b y a Provide adequate ventilation. Avoid
projectile that enters through one surface of the fuel prolonged breathing of solvent vapors
cell and exits through the opposite surface). and contact with skin or eyes.
(2) D a m a g e t h a t e x t e n d s i n t o a c o r n e r o r c. B u f f c e l l a r e a t o b e p a t c h e d l i g h t l y a n d
stepped-off area or that involves a cut longer than 2.0 thoroughly with sandpaper (C102) and wash with
inches, or that is caused by the seepage or diffusion of MEK (C74) to remove buffing dust.
fuel between the fabric plies.
d. Apply two coats of cement (C29). Allow each
10-79. CLEANING - FUEL CELLS (AVIM) coat to dry 10 TO 15 minutes.
a. Remove surface dirt and grime by scrubbing
the fuel cell with warm, soapy water. Air dry surface.
b. Purge fuel cell thoroughly with fresh air; scrub
and rinse with warm, soapy water; and rinse in clean, Cleaning solvent is flammable and toxic.
clear water. Air dry. Provide adequate ventilation, Avoid
prolonged breathing of solvent vapors
10-80. REPAIR OR REPLACEMENT - and contact with skin or eyes.
FUEL CELLS (AVIM).
e. Freshen cemented area of patch and cemented
area of cell with MEK (C74).
f. While still tacky, apply edge of patch to edge of
cemented area on the cell. With a roller or blunt
instrument roll or press the patch to the cemented
Make no repairs on the radius of a cell or area on the cell. Hold part of the patch off the
in the fitting area of a cell. Cells with such cemented area and roll or press it down 0.50 TO 1.0
damage should be forwarded to depot for inch across at a time so as not to trap air between
repair. No damage area larger than two patch and cell.
inches should be repaired at AVIM.
g. Seal coat edge of patch 0.50 inch with one coat
of cement (C29) and allow the patch to remain
undisturbed for six hours.
h. After the damaged area has been patched on
the outside of the cell and the repair allowed to stand
Cleaning solvent is flammable and toxic. a minimum of six hours, the cell is then ready to have
Provide adequate ventilation. Avoid the patch applied on the inside of the cell.
prolonged breathing of solvent vapors
and contact with skin or eyes,
WARNING
a. Use a piece of fabric (C53) large enough to
cover damage at least 2.0 inches from cut in any Cleaning solvent is flammable and toxic.
direction. Buff this material lightly and thoroughly Provide adequate ventilation. Avoid
with sandpaper (C102) and wash with MEK (C74) to prolonged breathing of solvent vapors
remove buffing dust. and contact with skin or eyes.
10-20 Change 3
TM 55-1520-236-23
i. Lightly and thoroughly buff a piece of fabric p. Seal coat patch and area 0.50 inch from edge
(C52) large enough to cover damage at least 2 . 0 of patch with two coats of cement (C29). Allow the
inches from cut in any direction. Wash buffing dust first coat to dry 15 minutes and the second coat to dry
off patch with MEK (C74). 12 hours or more.
j. Apply two coats of cement (C29) to patch,
10-81. INSTALLATION - FORWARD FUEL
opposite red fabric side. Allow each coat to dry 10 TO
CELL (AVIM).
15 minutes.
a. Check fuselage cavity, including access panels,
for any foreign objects or rough surfaces which could
damage fuel cells.
Cleaning solvent is flammable and toxic.
P r o v i d e a d e q u a t e v e n t i l a t i o n . Avoid
prolonged breathing of solvent vapors
and contact with skin or eyes. Cleaning solvent is flammable and toxic.
Provide adequate ventilation. Avoid
k. B u f f c e l l a r e a t o b e p a t c h e d lightly and prolonged breathing of solvent vapors
thoroughly with sandpaper (C102) and then wash off and contact with skin or eyes.
buffing dust with MEK (C74).
l. Apply two coats of cement (C29) to buffed area
b. Wipe surfaces with a cloth saturated with
and allow each coat to dry 10 TO 15 minutes.
solvent (C112) and wipe dry with a clean cloth before
solvent evaporates. Use MEK (C74) on bare metal
surfaces, n a p h t h a ( C 7 5 ) o n s u r f a c e s o f o t h e r
materials.
c. Remove old sealing compound from edges of
Cleaning solvent is flammable and toxic.
access panels and mating surfaces on structure.
Provide adequate ventilation. Avoid
prolonged breathing of solvent vapors
and contact with skin or eyes.
m. F r e s h e n c e m e n t e d a r e a o f patch and
cemented area of cell with MEK (C74).
Do not fold the fuel cell if the ambient
temperature of the work area is less than
n. While still tacky, apply edge of patch to edge of
70 degrees F (21 degrees C). Move cell
cemented area, centering patch over cut in cell. Hold
into warm area before folding cell. Do
part of patch off the cemented area and roll or press it
not allow the fuel cell to remain in its
down 0.50 TO 1.0 inch across at a time so as not to
folded condition for more than 30
trap air between patch and cell.
minutes. Non-visible permanent damage
to cell walls may occur. Do not use wire
or other thin diameter material to restrain
cell, permanent damage to self-sealing
characteristics of the cell could result.
Cleaning solvent is flammable and toxic. d. Partially flatten fuel cell by pushing in on sides
Provide adequate ventilation. Avoid allowing cell to collapse downward (see figure 10-5).
prolonged breathing of solvent vapors Apply straps or large diameter ropes vertically around
and contact with skin or eyes. cell to temporarily retain this shape. Sprinkle with talc
(C117) and place fuel tank cell in cavity, remove
o. Remove red fabric from patch by moistening straps or ropes and allow cell to expand. Align all
with MEK (C74). fittings with openings in structural panels.
10-21
TM 55-1520-236-23
Figure 10-5. Collapsing Forward Fuel Cell
10-22
TM 55-1520-236-23
NOTE
The materials and construction features n. Position forged tension fitting on matching holes
of the cells used in the crashworthy near lower forward corner of beam access panel. Reinstall
system results in fuel cells that are rigid shim under base of fitting. Install high-tensile bolt (NAS
and self-supporting. Ease of installation 624-14), with radius block under head, in aft bolt hole of
of the cells is related to temperatures of base. Install bolt (NAS 1304-8), with thin steel washer, in
the cells and the work area. As a general forward bolt hole of base. Install four bolts, with thin steel
rule a temperature above 70 degrees F (21 washers, through upright leg of fitting into inserts of panel.
degrees C) is desirable in the work area o. Connect electrical leads of low level warning (float)
when installing the cells. Heat can be switch, boost pump, and transmitter (Appendix E).
applied to the cell provided a temperature p. Return cable assemblies installation to original
of 120 degrees F (49 degrees C) is not configuration at left side access panel.
exceeded. q. Install outer access panel with screws on fuselage
NOTE ahead of wing location.
A T handle, fabricated per figure 10-6, r. Install left wing (paragraph 2-343).
can be used to align fuel cell fittings to s. Install access panels below wings and on lower
structure openings. The tool is inserted skin.
through the hole in the structure and
screwed into the fitting. Manipulate the 10-81.1. PRESSURE TEST FUEL SYSTEM.
fitting as desired by grasping the T
handle. CAUTION
NOTE Do not use masking tape to seal openings.
In the following instructions do not
tighten bolts securing frangible clips to a. Cap main fuel lines and vent connections.
structure until all clips have been b. Use regulated low pressure (3/4 to 1 PSI, IAW TM
installed and fuel cell properly 55-1500-204-25/1) filtered, compressed air source with
positioned. To ensure a satisfactory seal manometer or accurate gage and shutoff valve,
at bolted connections, alternately snug
up and torque opposite bolts at each CAUTION
connection. Do not apply excessive pressure, as severe
damage to cell and structure may result.
e. Install vent and fuel discharge fitting (21, figure
10-2) and hose (15) in fuel cell access cover-at hydraulic c. Apply pressure until gage indicates 3/4 to 1 PSI in
compartment floor. cells and crossover tubes. Shut off air pressure. Cells
f. Install fuel quantity transmitter (probe) (22) should hoId this pressure for 15 minutes.
(paragraph 8-226). d. Locate and correct any leakage indicated by loss
g. Install retainer (27, figure 10-2), gasket (28), of pressure, and repeat tests until results are satisfactory.
packing (29) and refueling receiver assembly (26) at e. Refuel aircraft.
right side of fuselage. . Install retainer (83),
packing (84), cap and adapter assembly (82) at right CAUTION
side of fuselage. Do not operate electrical equipment while
h. Connect fuel hose and install boost pump defueling or refueling aircraft.
assembly (13) (paragraph 10-30).
i. Install drain valve and low level warning (float) 10-82. INSTALLATION - AFT FUEL CELL (AVIM).
switch fitting in fuel cell and helicopter structure.
Lockwire drain valve (C137). a. Check fuselage cavity, including access panel for
j. Install fuel crossover hose to cells and helicopter freedom from foreign objects or rough surfaces which
structure. Install clamp. could damage fuel cell.
k. Install drain hose to valve (17). Install clamp.
l. Adjust position of cell in cavity so that all frangible
clips are bearing on helicopter structure. Torque bolts
securing clips to cell and structure 4 5 T O 5 5
Cleaning solvent is flammable and toxic.
inch-pounds.
Provide adequate ventilation, Avoid
m. Position inner access panel to opening in left
prolonged breathing of solvent vapors and
main beam. Apply sealing compound (C107) to provide
fume-tight seal between mating surfaces. Install screws contact with skin or eyes.
and thin aluminum alloy washers.
Change 18 10-23
TM 56-1520-236-23
Figure 10-6. Installed Forward Fuel Cell
10-24
b. Wipe surfaces with a cloth saturated with i. Install governor bleed line check valve and plate
solvent (C112) and wipe dry with a clean cloth before to fuel cell with two bolts and washers. Secure plate to
solvent evaporates. Use MEK (C74) on bare metal helicopter structure with two bolts, washers, and
surfaces, and naphtha (C75) on surfaces of other frangible clips. Connect hose.
materials. j. Install boost pump and drain tube (paragraph
10-30).
c. Remove old sealing compound from edges of k. Install low level warning (float) switch fitting with
access panel and mating surface on structure. two washers and bolts. Secure fitting and cell to
helicopter structure. Install nut and cover securing
CAUTION switch fitting to helicopter structure.
l. Install defuel and dump drain valve in fuel cell with
Do not fold the fuel cell if the ambient four washers and bolts. Secure valve, plate, and cell to
temperature of the work area is less than structure with two bolts, washers, and frangible clips.
70 degrees F (21 degrees C). Move cell Install drain hose and clamp. Lockwire drain valve.
into warm area before folding cell. Do not m. Install fuel crossover hose to fuel cell with six
allow the fuel cell to remain in its folded bolts and washers. Alternately snug up and torque
condition for more than 30 minutes. opposite bolts to ensure a satisfactory seal. Install
Nonvisible permanent damage to cell crossover hose and cell to fuselage structure with four
walls may occur. Do not use wire or other bolts, washers, spacers, and frangible clips. (See note
thin diameter material to restrain cell, as above.) Torque bolts 45 TO 55 inch-pounds. Install
permanent damage to self-sealing clamp on crossover hose.
characteristics of the cell could result. n. Install induction baffles (paragraph 2-128).
o. Close left and right side access panels below
d. Partially flatten fuel cell by pushing in on sides, wings.
allowing ceil to collapse downward (figure 10-7). Apply p. Remove jack.
straps or ropes vertically around cell to temporarily
retain this shape. Sprinkle with talc (C117) and place 10-83. PRESSURE TEST FUEL SYSTEM.
fuel tank cell in cavity, remove straps or ropes and allow
cell to expand. Align all fittings with openings in CAUTION
structural panels.
Do not use masking tape to seal
NOTE openings.
In the following instructions do not a. Cap main fuel lines and vent connections.
tighten bolts securing frangible clips to b. Use regulated low pressure (3/4 PSI, IAW TM
structure until all clips have been 55-1500-204-23 (Series) filtered, compressed air
positioned. To ensure a satisfactory seal source with manometer or accurate gage and shut off
at bolted connections, alternately snug valve.
up and torque opposite bolts at each CAUTION
connection.
Do not apply excessive pressure, as
e. Apply sealing compound (C107) to provide severe damage to cell and structure may
fume-tight seal between mating of access panel and result.
fuselage. Install panel with mounting screws.
c. Apply pressure until gage indicates 3/4 to 1 PSI
f. Install vent fitting in fuel cell access cover and in cells and crossover tubes. Shut off air pressure. Cells
secure to helicopter with six bolts, washers and should hold this pressure for 15 minutes.
frangible clips. Connect hose. d. Locate and correct any leakage indicated by loss
of pressure, and repeat tests until results are
g. Install fuel quantity transmitter probe (paragraph satisfactory.
8-226). e. Refuel aircraft.
h. Install fuel pressure line fitting in fuel cell with two CAUTION
bolts and washers. Secure fitting and cell to helicopter
structure with two bolts, washers, and frangible clips. Do not operate electrical equipment while
Connect hose. defueling or refueling aircraft.
Change 18 10-25
TM 55-1520-236-23
Figure 10-7. Collapsing Aft Fuel Cell
10-26
TM 55-1520-236-23
CHAPTER 11
FLIGHT CONTROLS
SECTION 1. FLIGHT CONTROLS
11-1. FLIGHT CONTROL SYSTEM. to steady the stick and pedals against movement of
their own accord and to induce artificial control feel.
The main rotor cyclic and tail rotor controls also
11-2. DESCRIPTION - F L I G H T CONTROL incorporate a stability and control augmentation
SYSTEM. system (SCAS). The operator has the option to use the
SCAS system or to turn it off at the SCAS control
The primary flight control systems are the main rotor panel. A separate system of control linkage for
collective, fore-and-aft cyclic and lateral cyclic, and operation of the synchronized elevator is attached to
tail rotor controls. Each of these is a system of the fore-and-aft cyclic control at the swashplate.
mechanical linkage, assisted by hydraulic cylinders,
connecting the pilot and gunner control sticks and 11-3. TROUBLESHOOTING - FLIGHT
pedals to those mechanisms which rotate with and CONTROL SYSTEM.
directly control the main rotor and tail rotor. Main
rotor cyclic and tail rotor controls incorporate The following table is provided as an aid in adjusting
electrically operated magnetic brakes and force trims cyclic and collective sticks for proper feel and tension.
NOTE
Before using this table, be sure all normal
operational checks have been
accomplished. If a malfunction is
detected which is not listed in this table,
notify the next higher maintenance level.
Table 11-1. Troubleshooting Flight Control System
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. Collective stick light or heavy on downstroke.
STEP 1. Check balance spring on collective cylinder for proper adjustment (paragraph 11-7).
If force is not equal, adjust balance spring (paragraph 11-7).
STEP 2. Check friction clamp and/or friction nut for proper adjustment (paragraph 11-16).
If adjustments are not within limits, adjust friction clamp and nut (paragraph 11-16).
2. Cyclic feels loose, has tendency to fall to left or right.
11-1
TM 55-1520-236-23
Table 11-1. Troubleshooting Flight Control System (Cont)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
STEP 1. Check friction nut adjustment.
If friction nut is loose, adjust nut (paragraph 11-37).
STEP 2. Check tension on force gradient spring.
If tension is weak, replace spring (paragraph 11-68).
3. Gunner cyclic stick will not remain in a fixed position.
STEP 1. Check for a weak or damaged gunner longitudinal cyclic control spring in the gunner longitudinal
cyclic controls.
If spring is weak or damaged, replace spring (paragraph 11-159).
STEP 2. Check for weak or damaged gunner lateral cyclic control springs in the gunner lateral cyclic
controls.
If springs are weak or damaged, replace springs (paragraphs 11-159).
4. Flight controls binding.
STEP 1. Check for obstructions or foreign objects,
Reposition or remove obstructions. Remove foreign objects,
STEP 2. Isolate binding component in collective system by detaching tube assemblies from bellcranks and
collective sticks. Actuate each component to detect binding part.
Remove, replace, or repair defective parts (paragraphs 11-145 and 11-1 48).
STEP 3. Isolate binding component in cyclic system by detaching tube assemblies from bellcranks, cyclic
sticks, magnetic brakes, and jackshaft. Actuate each component to detect binding part.
Remove, replace, or repair defective parts (paragraphs 11-26 and 11-1 48).
STEP 4. Isolate binding component in tail rotor control system by detaching tube assemblies from
bellcranks and magnetic brake. Actuate each component to detect binding part.
Remove, replace, or repair defective parts (paragraphs 11-71 and 11-1 48).
STEP 5. Isolate binding component in elevator control system by detaching tube assemblies from
bellcranks, walking beams and horn assembly. Actuate each component to detect binding part.
Remove, replace, or repair defective parts (paragraphs 11-136 and 11-1 48).
11-2 Change 3
TM 55-1520-236-23
11-4. COLLECTIVE SYSTEM. 1 1 - 7 . R I G G I N G - COLLECTIVE SYSTEM.
a. Accomplish rigging without hydraulic p o w e r
11-50 DESCRIPTION - COLLECTIVE unless otherwise stated.
SYSTEM.
b. Install all components of the collective control
The collective controls system includes gunner and system with the following exceptions:
pilot collective stick assemblies, tube assemblies,
bellcranks, and a dual hydraulic cylinder. The (1) Leave hydraulic cylinder (2, figure 11-1)
hydraulic cylinder is connected to the collective lever disconnected from collective lever (1).
which actuates the mast-mounted scissors and
sleeve assembly to control pitch of the main rotor (2) Leave tube assembly (5) disconnected from
blades. bellcrank (7).
(3) Leave tube assembly (6) disconnected from
Premaintenance Requirements for bellcrank (7).
Collective Controls
c. Adjust tube assembly (10) to length of 2 2 . 1 3
Conditions Requirements inches between clevis hole centers and install in
helicopter. C o a t c l e v i s t h r e a d s w i t h c o r r o s i o n
prevention compound (C43) when adjusting tube
assembly.
Model AH-1S
d. Check breakaway force on collective lever
Part No. or Serial No. All (1) and adjust friction collet on mast if required.
Refer to paragraph 5-63i for correct breakaway
Special Tools None force and procedure to adjust friction.
Test Equipment None e. Place pilot collective control stick (13) full down
and apply stick friction to hold in position.
Support Equipment (S2)
f. Loosen jamnut at upper end of tube assembly
Minimum Personnel Two (5). Push tube assembly (5) up to bottom out valve
Required lever in full up position (detail D). Hold, pressure on
tube assembly (5) to keep piston and valve lever
Consumable Materials (C43), (C138) bottomed in full up position. Bottom out piston
against top of cylinder (2). Adjust length of tube to fit
Special Environmental N/A on bellcrank (7), then shorten length by three full
Conditions turns to assure that piston will not bottom out during
operation. Connect tube assembly (5) to bellcrank (7)
and tighten jam nut on tube assembly. Valve lever will
now be near full down position.
11-6. INSPECTION - COLLECTIVE
SYSTEM. g. Check rod end on tube assembly (5) to ensure
that there is not more than 1.25 inch exposed threads
a. Inspect control system in place for secure (detail C). If more than 1.25 inches of threads are
installation, damage, chafing, and freedom of exposed, adjust length of tube assembly (10). Do not
operation through full travel. exceed one inch of exposed threads on (10) (detail B).
Ensure that nut and bolt that attaches control tube (5)
to hydraulic cylinder valve (4) is tightened sufficiently
b. If required, remove components for detailed to remove axial play only. Back off to first castellation
inspection. Refer to paragraphs 11-8, 11-17, and 11- Do not clamp clevis. The bolt must turn freely and
145 thru 11-154. cotter pin must be installed.
Change 5 11-3
TM 55-1520-236-23
ALL DIMENSIONS ARE IN INCHES UNLESS OTHERWISE
Figure 11-1. Collective Controls (Sheet 1 of 2)
11-4 Change 2
TM 55-1520-236-23
ALL DIMENSIONS ARE IN INCHES UNLESS OTHERWISE NOTED
1. Collective lever 11. Cover 21.
2. Hydraulic cylinder assembly 12. Boot 22. Extension tube
3. Cylinder support 13. Pilot collective control stick 23. Clamp
4. Hydraulic cylinder valve 14. Down - lock strap 24. Boot/flange assembly
5. Tube assembly 15. Tube assembly 26. Nut
6. Droop compensator tube assembly 16. Tube assembly 26. Lock
7. Bellcrank and support 17. Boot 27. Clamp
8. Tube assembly 18. Gunner collective control stick 28. Transducer
9. Bellcrank 19. Rod end bearing 29. Bracket
10. Tube assembly 20. Lock
F i g u r e 1 1 - 1 . Collective Controls (Sheet 2 of 2)
11-5
TM 55-1520-236-23
h. Adjust extension tube (22), rod end bearing end bearing (19) will fit on collective lever (1), then
(19) and attach to collective lever as follows: shorten one full turn of extension tube (22) to
compensate for change that occurs when hydraulic
(1) Position collective lever (1, figure 11-1) to power is applied.
3.84 TO 3.90 inch dimension as shown on detail A.
(2) Remove Iockwire and loosen nut (21). (d) Tighten nut (25) and measure length of
exposed threads. Maximum acceptable exposed
thread is 0.80 inch.
CAUTION
(e) Torque nut (25) 800 TO 1000 inch-
Maintain collective stick in full down pounds and Iockwire nut (25) to lock (26) with
Iockwire (C138).
position.
(3) Ensure that collective lever (1) is in position (f) Position top of boot (24) 8.0 inches from
top of extension tube (22) as shown on detail E and
set in step (1). Push down on extension tube (22) with
tighten clamp (23). Position lower end boot (24) on
approximately 100 pounds of force untiI tube
movement stops (approximately 0.060 TO 0.130 hydraulic cylinder assembly (2) and tighten clamp
inch). Maintain this position and adjust rod end (27).
bearing (19) to fit on collective lever (1), then shorten (6) Attach rod end bearing (19) to collective
one full turn of rod end bearing (19) to compensate for lever (1). Comply with procedure outlined in
change that occurs when hydraulic power is applied. paragraph 7-66.
(4) Measure exposed threads on rod end bear- i. Check low pitch blade angle of main rotor to
ing (19). If lock (20) can be installed and if less ensure it is within limits (paragraph 5-14).
than 0.80 inch of thread is exposed, torque nut (21)
450 to 600 inch-pounds, Iockwire nut to lock (20) j. Check complete collective control system for
with Iockwire (C138) and proceed to step (6): If security and safetying of components.
there are insufficient exposed threads to install
lock (20) or if exposed threads on rod end bearing k. Apply hydraulic power with ground test unit
(19) are in excess of 0.80 inch, make adjustment at (S2). Check operation of controls through full range of
nut (25) as outlined in step (5). travel. Check pilot collective control stick for correct
friction adjustments (paragraph 11-16).
(5) If exposed threads on rod end bearing (19)
were in excess of 0.80 inch in preceding step, make l. With a force gage (fish scale), check for
adjustment at nut (25) as follows: approximate equal force required to raise or to lower
collective control stick with hydraulic boost on. If
(a) Thread rod end bearing (19) into tension necessary, adjust by adding or removing AN960-10
tube (22) until 0.80 inch of threads are exposed. washers at top of spring on hydraulic cylinder valve
Torque nut (21) 450 TO 600 inch-pounds and (detail D). A maximum of six AN960-10 washers can
Iockwire to lock (20) with Iockwire (C138). be used.
(b) Loosen clamps (23) and (27). Slide boot
NOTE
(24) up until nut (25) is exposed, Remove Iockwire and
loosen nut (25).
The adjusting washers are in addition
to the four washers used for assembly.
m. Connect droop compensator tube assembly (6)
Maintain collective stick in full down
to bellcrank (7).
position.
(c) Ensure that collective lever (1) is at n. Deleted.
position, set in step (1). Push down on extension tube
(22) with approximately 100 pounds of force. O. Deleted.
Maintain this position and adjust extension tube (22)
on hydraulic cylinder assembly (4) to length so rod p. Install access covers.
11-6 Change 12
TM 55-1520-236-23
11-10. REMOVAL - PILOT COLLECTIVE
STICK (AVIM).
K747 main rotor blades have a tendency a. Remove cover (4, figure 11-2) with attaching
to attain a higher percent RPM during screws (2) and washers (3).
autorotation than B540 main rotor
blades. DO NOT RIG beyond the limits b. Remove screw-mounted panel (figure 2-3)
established in paragraph 5-14, to obtain from left side of fuselage for access to lower end of
a lower main rotor percent RPM. stick assembly.
q. Perform maintenance test flight (TM 55-1520- c. Disconnect collective system tube assemblies
236-MTF). (8, figure 11-2) from collective lever (5) and throttle
system tube assemblies (7) from throttle lever (6), by
11-8. PILOT COLLECTIVE STICK. removing bolts, nuts, and washers.
d. Disconnect electrical cable connector (19).
11-9. D E S C R I P T I O N - PILOT
COLLECTIVE STICK.
e. Remove bolt (11), screw (12), nuts (15),
washers (14), and shims (13) which secure outboard
The pilot collective control stick is on the left side
stick support (9) to structure. Measure and record
console. There is a split switch box at the top with an
thickness of shims (13). Tag shims (13) for installation
electrical cable extending down past the base of the
in same location.
stick. A support assembly at the base of the collective
stick houses the collective friction shoes, a collective f. Remove three bolts (16), washers and shim (18)
lever and a throttle lever. Located between the base of
from inboard support (10). Measure and record
the stick and the top is a throttle friction nut, throttle
thickness of shim (18). Tag shim for installation in
grip, collective friction nut, and a boot and support
same location.
assembly. A strap (14, figure 11-1) is provided to
secure the control stick in low pitch position. The pilot
collective stick has a mechanical advantage of 1.1 TO g. The following may be accomplished to ease
removal of collective stick. Remove pin (2, figure 11-3)
1 ratio over the gunner collective stick.
and lift control heed (1) and electrical harness (5) from
Premaintenance Requirements for pilot collective stick.
Pilots Collective Stick
h. Move collective stick (1, figure 11-2) down
Conditions Requirements through console to remove from helicopter.
Model AH-1S
11-11. DISASSEMBLY - P I L O T
Part No. or Serial No. All
COLLECTIVE STICK (AVIM).
Special Tools (T61)
a. Remove six countersunk screws (3, figure 11-
None 3) attaching forward and aft boots (4 and 27) to boot
Test Equipment
support assembly (25). Remove boots.
Support Equipment (S2)
b. Remove nuts (18), washers (16 and 17), and
Two two bolts (15) that attach collective lever assembly
Minimum Personnel
(19) to elbow assembly (20). Pull lever off elbow.
Required
Consumable Materials (C5), (C31), (C37), c. Disconnect plug in electrical harness (5).
(C88), (C91), (C102),
(C112), (C138)
Special Environmental None
Conditions
11-7
TM 55-1520-236-23
Figure 11-2. Pilot Collective Stick Installation
11-8
TM 55-1520-236-23
Figure 11-3. Pilot Collective Stick Assembly (Sheet 1 of 4)
11-9
TM 55-1520-236-23
1. Control head 18. Nut
2. Pin 19. Lever assembly
3. Screw 20. Elbow assembly
4. Boot, aft 21. Nut
5. Electrical harness 22. Washer
6. Clamp 23. Bracket
7. Washer 24. Washer
8. Screw 25. Screw
9. Clamp 26. Boot support assembly
10. Screw 27. Boot forward
11. Washer 28. Washer
12. Washer 29. Washer
13. Nut 30. Washer
14. Electrical connector 31. Friction screw
15. Bolt 32. Nut
16. Washer
17. Washer 209001-159-2
Figure 11-3. Pilot Collective Stick Assembly (Sheet 2 of 4)
11-10
TM 55-1520-236-23
Figure 11-3. Pilot Collective Stick Assembly (Sheet 3 of 4)
11-11
TM 55-1520-236-23
Figure 11-3. Pilot Collective Stick Assembly (Sheet 4 of 4)
11-12
TM 55-1520-236-23
d. Remove screw (10), washers (11 and 12), and p. Remove spring pin (85) and pin (83). Remove
nut (13) attaching electrical harness (5) to bracket cotter pin (69), drag linkage (73, and shoe assemblies
(23). Remove screw (8) and washer (7) attaching (78 and 84) from tube assembly (66) and elbow
electrical harness to boot support (26). assembly (20). Separate drag linkage from shoe
assemblies by removing cotter pin (72) and pins (71).
e. Remove pin (2) and lift control head (1) and
electrical harness (5) from pilot collective stick. q. Remove two nuts (76 and 77), washers (68 and
75), and bolt (67). Remove retaining ring (64).
f. Slide washers (28, 29 and 30), friction screw Separate collective friction nut (65) from tube
(31) and throttle friction nut (32) from stick tube (79). assembly (66) and remove both items from stick tube
(79).
g. Remove screw (25), washers (22 and 24), nut
(21), and bracket (23). r. Cut safety wire and remove nut (70) and plate
(74) from stick tube (79). Press stick tube out through
h. Remove screw (63), washers (59 and 62), and base of elbow assembly (20).
nuts (58). Slide boot support assembly (26) from
control stick. 11-12. INSPECTION - PILOT COLLECTIVE
STICK.
i. Remove nut (51), washer (52), and bolt (49).
Remove cotter pin (57), nut (56), washer (55), and
shims (54). Measure thickness of shims and tag for
instalIation at same location. Press shaft (50) from
outboard support (81) and remove throttle lever
Cleaning solvent is flammable and
assembly (53).
toxic. Provide adequate ventilation.
Avoid prolonged breathing of
j. Remove nut (48), and washer (47), pinion gear solvent vapors and contact with skin
(46), key (44) and shim (45) from drive assembly (43). or eyes.
Measure and record thickness of shim (45), Tag shim
for installation in same location. a. Clean exposed surfaces by wiping with dry
cloth dampened with solvent (C112). Do not
k. Rotate grip assembly (60) until pin (61) appears allow solvent to enter bearings.
in small hole in grip assembly. Remove pin and slide
grip assembly from stick tube (79). b. V i s u a l inspection:
l. Press drive assembly (43), guide (42), and (1) All threaded areas for thread damage.
throttle tube assembly (38) with attached hardware
from stick tube (66). Separate drive assembly, guide (2) Inspect all bearings in accordance with TM
and throttle tube assembly. 55-1500-204-25/1 and for wear that exceeds 0.005
inch radial or 0.030 inch axial.
m. Remove nut (33), washer (34), bearings (35
and 37), and ring (36) from throttle tube assembly (3) All bolt holes for wear, maximum allowable
(38). 0.005 inch.
n. Remove two countersunk screws (82). Pull (4) All items for corrosion and mechanical
outboard support assembly (81) off elbow assembly damage. Maximum allowable 0.005 inch for
(20). Pull inboard support assembly (92) off elbow corrosion and 0.010 inch for mechanical. Inspect for
assembly. Remove bearings (80 and 91) if bearings or dents or distortions that would affect operation.
supports (81 or 82) are unserviceable. Refer to TM 55-
1500-204-25/1 . (5) All items for cracks or broken parts.
o. Remove nut (87), washers (88 and 89), and bolt (6) All pins for grooving.
(90) from friction clamp (86). Slide clamp off elbow
assembly (20). (7) Gears for broken or damaged teeth.
Change 5 11-13
TM 55-1520-236-23
c. Fluorescent penetrant inspect to verify NOTE
suspected flaws found during visual inspection of
control head (1, figure 11-3), inboard support (92), M a x i m u m allowable repair of
outboard support (81) and elbow (20) in accordance mechanical and/or corrosion damage
with TM 43-0103. within distance of one diameter from
edge of hole is 25 percent of area.
d. Magnetic particle inspect to verify suspected
flaw found during visual inspection of stick tube (79) (1) Use fine to medium grades of sandpaper
(C102) or crocus cloth (C37). Do not use grinding
in accordance with TM 43-0103.
wheels. Polish out mechanical damage only deep
enough to remove traces of damage. Polish out
11-13. REPAIR OR REPLACEMENT - corrosion damage to twice the depth of the deepest
PILOT COLLECTIVE STICK (AVIM). pit. Do not remove more material than necessary to
blend repair smoothly into surrounding surface.
a. Replace all damaged components unless
covered by a specific repair. (2) Touch up repair area on aluminum parts
with chemical film (C31) and primer (C88 or C91).
b. Repair mechanical and corrosion damage as Touch up repair area on steel parts with primer (C88
follows: or C91).
c. Repair of throttle grip (1, figure 11 -4) is limited
to replacement of bearings (2). Remove and replace
bearings in accordance with TM 55-1 500-204-25/1.
Position base upper bearing 1.42 inch from upper
The chemical film material is extremely end of grip,
dangerous. Contact with combustible
materials will cause explosion or fire. d. Repair of throttle tube is authorized at next
Avoid contact with skin or eyes. higher maintenance level.
ALL DIMENSIONS ARE IN INCHES UNLESS OTHERWISE NOTED.
209001-96A
Figure 11-4. Bearing Installation - Pilot Throttle Grip
11-14
TM 55-1520-236-23
e. R e p l a c e d a m a g e d t h r e a d e d i n s e r t s . in rivet head to be installed 0.030 inch below surface of
accordance with TM 55-1500-204-25/1 and as lining. Rivet linings (2 and 4) to elbow (5) and support
follows: (1) using MS20426AD3 or CR3212-04-07 rivets.
(1) Remove damaged helical coil insert with
g. Replace bearing in throttle lever (2, figure 11-
extraction tool or other suitable tool. Clear hole of all
6) in accordance with TM 55-1500-204-25/1 and as
metal chips, Check threads with helical coil gage.
follows:
(2) Determine inserting tool of correct size.
install helical coil insert until top of coil of insert is
one-quarter to one-half turn below start of tapped
threads. Break tang with long-nosed pliers or other Repair is limited to one time. Replace
suitable tool. Ensure that tang is removed from hole. lever if second repair is required.
(3) After repair, ensure that threads will take (1) Remove damaged bearing (1).
required torque.
(2) Install new bearing.
f. Replace friction linings as follows (figure 11-5):
(1) Drill rivets from worn linings and remove
linings (2 and 4) from support (1) or elbow (5).
Stake depth must not exceed 0.010 inch.
(3) Segment stake bearing in three places on
both sides. Place new stake 60 degrees from old
Cleaning solvent is flammable and toxic. stake.
Provide adequate ventilation. Avoid
prolonged breathing of solvent vapors h. Replace bearings in collective lever as follows
and contact with skin or eyes. (figure 11-36):
(2) Wipe bonding area on replacement linings NOTE
(2 and 4), elbow (5), and support (1) with solvent
(C112). Lightly sand the faying surfaces of linings, This procedure is applicable to all 209-
elbow, and support with 400 grit sandpaper (C102). 001-051-1 bearings.
Remove residue with solvent.
(1) Remove the staked lip from around one side
(3) Mix by weight, 100 parts A with 33 parts B of the old bearing by either filing or machining. Use
(C14). Adhesive shall be used within forty minutes after care as not to damage ears of lever. Press old bearing
mixing. from lever.
(4) Apply mixed adhesive to faying surface of (2) Apply primer (C88 or C91) to outer race of
linings (2 and 4), elbow (5), and support (1). Join detail new bearing and install new bearing in lever while
parts while adhesive is tacky and within pot life time. primer is wet.
Ensure proper alignment of parts and avoid trapping
air within the bondlines. Clean off adhesive squeeze- (3) Using anvil bearing staking tool set (T61)
out prior to curing. Cure for 24 hours at 70 TO 95 and suitable press, lay over the outer lip of the pre-
degrees F (21 TO 35 degrees C) maximum strength grooved race onto the chamfer of the lever housing
obtained in 7 days, or using a properly regulated without touching the inner lip of the bearing or cause
source of heat, cure bond at 160 TO 170 degrees F any cutting action on the outer lip.
(71 TO 77 degrees C) for 115 minutes with firm
contact to 10 psi applied to parts. (4) Ensure that after staking there is no more
than 0.008 inch gap between the outer housing
(5) Drill two No. 40 holes in each support lining chamfer of lever and the staked lip on both side of
(2) and three No. 40 holes in elbow lining (4). Counter- bearing (figure 11-36).
sink holes 100 degrees to a sufficient depth to allow
Change 16 11-15
TM 55-1520-236-23
Figure 11-5. Friction Lining Repair
11-16
TM 55-1520-236-23
ALL DIMENSIONS ARE IN INCHES UNLESS OTHERWISE NOTED.
1. Bearing
2. Throttle lever
3. Old segment stake 120 degrees apart
4. New segment stake 120 degrees apart and
60 degrees from old segment stake
209001-99A
Figure 11-6. Throttle Lever Bearing Installation
11-17
TM 55-1520-236-23
i. Collective friction tube repair is limited to
replacing the connector assembly (figure 11-7).
(1) Drill out six rivets (3) attaching connector
assembly (1) to tube (2).
(2) I n s t a l l n e w c o n n e c t o r w i t h b a s e 1 . 7 3
inches from centerline of rivet holes.
(3) Drill six No. 40 holes in connector using
tube as template. Rivet tube to connector.
j. Replace worn or damaged nutplates on boot
support assembly in accordance with TM 55-1500-
204-25/1.
11-14. A S S E M B L Y - PILOT COLLECTIVE
STICK (AVIM).
a. Insert stick tube (79, figure 11-3) up through
elbow assembly (20). Place flat spot, at base of stick
tube, inboard.
NOTE
Use bolt (67) to maintain plate (74) and
elbow assembly (20) alignment while Figure 11-7. Collective Friction
tightening nut (70). Tube Repairs
b. Install plate (74) and nut (70) on stick tube (79).
Tighten nut and secure with Iockwire (C138). e. Install drag link assembly (73) on connector at
base of tube assembly (66). Secure with cotter pin
NOTE (69).
Do not tighten nuts (76 and 77). Nuts f. Place shoe assemblies (78 and 84) into slot in
will be tightened during collective elbow assembly (20) and secure with pin (83). Secure
friction adjustment. pin (83) with spring pin (85).
c. Screw collective friction nut (65) on tube NOTE
assembly (66). install both items and retaining ring
(64) on stick tube. Align hole in base of tube assembly Do not tighten nut (87). Nut will be
with hole in plate (74). Install bolt (67) with washers tightened during collective friction
(68 and 75) through hole in tube assembly (66), plate adjustment.
(73), and elbow assembly (20). Install two nuts (76
and 77) on bolt (67).
NOTE g. Install bolt (90, figure 11-3), washers (88 and
89) and nut (87) on clamp (86). Place clamp on inboard
Pins (71) must be inserted from inboard side of elbow assembly (20) with bolt up and aft.
side.
h. Install inboard support assembly (92) and
d. A t t a c h d r a g l i n k a s s e m b l y ( 7 3 ) t o s h o e outboard support assembly (81) on elbow (20). Attach
assemblies (78 and 84) with pins (71). Secure with outboard support to inboard support with two
cotter pins (72). countersunk screws (82).
11-18
TM 55-1520-236-23
NOTE q. Attach boot support assembly (26, figure 11-3)
to plate (74) with screws, washers, and nuts (58).
Install bearings (80 and 91) in supports Position bracket (23) on left forward leg of boot
(80 and 91) if removed during support assembly, and secure with screw (25),
disassembly. washers (22 and 24) and nut (21).
i. Install ring (34), bearings (35 and 37), washer r. Install throttle friction nut (32, figure 11-3),
(34) and nut (33) on throttle tube assembly (38). Align friction screws (31), washers (28 and 30), washer
large hole in ring with hole in throttle tube. (31), and assembled control head on stick tube (79).
Secure components to stick tube with pin (2).
j. Mate drive assembly (43), guide (42), and
throttle tube assembly. Insert mated components s. Attach electrical cable (5) to boot support (25),
into stick tube (79), drive assembly first. with screw (8), washer (7), and clamp (6). Attach cable
to bracket (22) with bolt (15), washers (11and 12), nut
k. Install grip assembly (60) on stick tube (79). (13), and clamp (9).
Align large hole in grip assembly with large hole in
ring (36) and throttle tube (38). Install pin (61) through t. Install collective lever assembly (19) on elbow
grip, ring, and throttle tube. assembly (20) with arms down. Secure with bolts
(15), washers (16 and 17) and nuts (18).
l. Install shim (45) tagged during disassembly, key
(44), pinion gear (46), washer (47) and nut (48) on u. Attach forward and aft boots (4 and 27) to boot
drive assembly (43). support (26) with six countersunk screws (3).
NOTE 11-15. I N S T A L L A T I O N - PILOT
Check for smooth operation by rotating
COLLECTIVE STICK (AVIM).
grip (60) through full travel.
m. Install shim (54, figure 11-3), tagged during a. I n s t a l l c o l l e c t i v e s t i c k ( 1 , f i g u r e 1 1 - 2 up
disassembly, and throttle lever assembly (53) on shaft through console.
(50). Position throttle lever with gear teeth facing
small end of shaft. b. Attach inboard support (10) to airframe with
bolts (16) and washers. Lower bolt also passes
n. With throttle grip (60) set at midtravel, match through friction clamp (17). Shim (18) as required
centerline of throttle lever gear (53) to pinion gear between support and airframe at upper right hand
(46). Install shaft (50) into inboard support assembly bolt.
(92) and secure with washer (55), nut (56), and cotter
pin (57). Secure throttle lever to shaft bolt (49), c. Attach outboard support (9) to airframe with
washer (51), and nut (52). screw (12), bolt (11), washers (14), and nuts (15).
Shim (13) as required between outboard support and
o. Check mating between pinion gear (11, figure airframe to a maximum gap of 0.003 inch.
11-8) and throttle lever gear (10). Surfaces of gear
teeth should be flush within 0.020 inch. If pinion d. Connect electrical cable (19).
gear rides too high on lever gear, remove shim from
point C and add to point B. If pinion gear rides too low, e. C o n n e c t c o l l e c t i v e t u b e a s s e m b l y ( 8 ) t o
on lever gear, remove shim from point B and add to collective lever (5) with bolts, washers, and nuts.
point C. Continue procedure until required dimension Place one washer under bolt head and one washer
is obtained. under nut. Secure nut with cotter pin.
p. A d j u s t t h r o t t l e b r e a k a w a y f o r c e . R e f e r t o f. Connect throttle tube assembly (7) to throttle
paragraph 11-16. lever (6) with bolt inboard, washers, and nut. Place
steel washer under bolt head and stainless steel
NOTE washer under nut. Secure nut with cotter pin.
Rotate throttle grip through full travel to
ensure throttle lever is centered on pinion g. Adjust collective friction settings (paragraph
gear. 11-16).
11-19
TM 55-1520-236-23
Figure 11-8. Pilot Collective Stick Adjustments
11-20
TM 55-1520-236-23
h. Install access panels. collective stick can be moved when the
pilot friction nut (6) is fully tightened.
i. Install collective stick cover (4).
j. Check collective rigging (paragraph 11-7). NOTE
IPs collective friction may be set at 4
k. Check power lever control rigging (paragraph
to 6 lbs. on training aircraft only
4-105).
(TH-1S and TAH-1S).
i. P e r f o r m m a i n t e n a n c e t e s t f l i g h t ( T M
55-1520-236-MTF). (3) Set maximum stick friction as follows:
11-16. ADJUSTMENT - PILOT COLLECTIVE (a) Place pilot collective stick at approximate
STICK. midtravel position.
a. Adjust pilot collective stick friction to set minimum (b) Loosen nuts (8 and 9) on tension bolt (7).
and maximum friction loads as follows: (figure 11-8).
(c) Attach a force gage (fish scale) to stick grip
(1) Apply hydraulic power with hydraulic test within 0.5 inch of center and perpendicular to stick
stand (S2). grip. Check for breakaway force of 14 TO 16 pounds.
NOTE if breakaway force is not within limits, adjust friction nut
(6) to obtain breakaway force within limits.
if not using hydraulic power, open
(d) Tighten upper nut (8, figure 11-8) on tension
access door below left wing and
bolt (7) fingertight and secure with lock nut (9).
disconnect control tube (8, figure 11 -1)
Recheck breakaway force to ensure that it is within
from bellcrank (7) to allow movement of
limits.
control stick.
(e) Disconnect hydraulic power ground test
(2) Set minimum stick friction as follows:
unit.
(a) Place pilot collective stick at approximate
(f) Check for security and safetying of
midtravel position.
collective control stick components.
(b) Fully loosen collective friction nut (6, figure
11-8). (g) Ensure that gunner collective stick can be
moved when pilot collective friction nut (6) is fully
(c) Attach a force gage (fish scale) to grip (5) tightened.
within 0.5 inch of center and perpendicular to stick grip
(check for breakaway force to 9 TO 11 pounds. b. Adjust throttle breakaway force as follows:
NOTE
if not using hydraulic power, breakaway NOTE
force should be 11 to 13 pounds.
Steps (1, (2), (7), and (8) will be followed
(d) if breakaway force is not within limits, if collective stick is installed in
remove cover and adjust bolt (12) and nut (13) on helicopter.
friction clamp (14) to obtain breakaway force within
limits. (1) Remove left side access panel.
(e) If breakaway farce cannot be adjusted (2) Disconnect throttle tube assembly from
by use of bolt (12) and nut (13) an friction clamp (14), throttle lever (10, figure 11-8).
remove pilots collective stick and check the friction
liner on the elbow (4, figure 11-5), for glazing, broken (3) Set throttle friction nut (4) to minimum friction
wires and uneveness. setting.
(4) Measure breakaway force at point A on lever
(10). Use a spring scale to apply force in direction
illustrated by arrows.
Maximum stick friction must be set
within limits to ensure that the gunner
Change 12 11-21
TM 55-1520-236-23
NOTE
It Is necessary to equally add or remove
laminations of shims at points B and C
because tooth surfaces on pinion (11)
and lever (10) must remain flush within
0.020 inch.
(5) Add or remove shims at points B and C to
obtain a breakaway force of 0.50 TO 1.50 pounds.
Refer to paragraph 11-11 for shim removal and
paragraph 11-14 for shim installation.
11-22 Change 12
TM 55-1520-236-23
Figure 11-9. Gunner Collective Stick Installation
Change 12 11-22.1/(11-22.2 blank)
TM 55-1520-236-23
(6) R e p e a t s t e p ( 4 ) t o d e t e r m i n e w h e t h e r b. Disconnect collective system tube assembly (4,
breakaway force is now within tolerance. If figure 11-9) from collective lever (2), and throttle
necessary, repeat shimming procedure. system tube assembly (3) from throttle lever of control
stick.
(7) Connect throttle tube assembly to throttle
lever (10) (paragraph 11-15). c. Remove bolts (15 and 20), washers (16, 17, and
21), and one nut (18) that attach support assembly
(8) Install access covers. (19) to airframe. Loosen bolt (23).
11-17. GUNNER COLLECTIVE STICK. NOTE
Bolt (23) and washer (22) will stay with
11-18. D E S C R I P T I O N - GUNNER
collective stick assembly.
COLLECTIVE STICK.
d. Remove collective stick by lowering it down
The collective control mounted in the gunner left side
through console.
console is a dual control for occasional or emergency
use. It has only the essential functions of collective
pitch and throttle control. There are no electrical 11-20. DISASSEMBLY - GUNNER
switches. Because of the difference in length of the COLLECTIVE STICK (AVIM).
pilot and gunner collective stick more force (1.1 to 1
ratio) is required to move gunner collective stick than a. Remove nut (40, figure 11-10), screw (44), and
is required to move pilot collective stick. washers that attach throttle lever (42) to shaft (39).
Remove cotter pin (37), nut (36), and washer (35).
Premaintenance Requirements for Press shaft from support assembly (32) and remove
Gunner Collective Stick throttle lever and shims (38). Measure and record
thickness of shims (38). Tag shims for installation in
Conditions Requirements same location.
Model AH-1S
b. Remove nut (46) and washer (47), pinion gear
(48), key (13), and shim (49) from drive assembly (12).
Part No. or Serial No. All Measure and record thickness of shim (49). Tag shim
for installation in same location.
Special Tools None
c. Remove nut (7), screw (1), and washers (2, 3, 5,
Test Equipment None and 6) that attach throttle grip (26) to throttle tube (9).
Remove throttle grip (26) and ring (4).
Support Equipment None
d. Remove screws (23) that attach boot (24) to
Minimum Personnel One elbow (18). Remove boot.
Required
e. Remove nuts (15), bolts (21), and washers (14
Consumable Materials (C112), (C137) and 22) from elbow (18). Remove control stick (8),
throttle tube (9), guides (10 and 11) and drive
Special Environmental None
assembly (12) from elbow.
Conditions
f. Remove nuts (16), bolts (20), and washers (17
and 19) that attach collective lever (27) to elbow.
Separate collective lever (27) from elbow (18) and
11-19. R E M O V A L - GUNNER elbow from support assembly (32). Remove bolt (29)
COLLECTIVE STICK (AVIM). and washer (30) from support assembly.
a. Remove screw-mounted panel from left side of g. Remove bearings (28, 31, 33, 34, 45 and 50) if
fuselage above ammunition compartment for access bearings or support (32) or lever (27) are
to lower end of control stick. unserviceable. Refer to TM 55-1500-204-25/1.
11-23
TM 55-1520-236-23
1 1 - 2 1 . INSPECTION - GUNNER 11-22. REPAIR OR REPLACEMENT -
COLLECTIVE STICK. GUNNER COLLECTIVE STICK (AVIM).
a. Replace all damaged components unless
covered by a specific repair.
b. Repair mechanical and corrosion damage
(paragraph 11-1 3).
Cleaning solvent is flammable and toxic.
Provide adequate ventilation. Avoid c. Replace unserviceable bearing (25) in throttle
prolonged breathing of solvent vapors grip (26, figure 11-10). Remove and replace bearing
and contact with skin or eyes. in accordance with TM 55-1500-204-25/1.
d. Replace unserviceable bearing (50) in
collective lever (27) (paragraph 11-12).
11-23. ASSEMBLY - GUNNER
Do not allow solvent to enter bearings. COLLECTIVE STICK (AVIM).
a. Clean exposed surfaces by wiping with dry NOTE
cloth dampened with solvent (C112).
If bearings (28, 31, 33, 34, 45, or 50,
b. Visual inspection. figure 11-11) were removed from
support assembly (32), or collective lever
(1) AH threaded areas (figure 11-10) for thread (27), install bearings.
damage.
(2) All bearings in accordance with TM 55- a. Install and tape bolt (29) and washer (30) in top
1500-204-25/1 and for wear that exceeds 0.005 hole of support assembly (32). Place elbow (18) into
inch radial and 0.030 inch axial. support with slot towards bolt (29). Align elbow with
bearings (28 and 31) and press collective lever (27)
(3) All bolt holes for wear. Maximum allowable into elbow from side opposite slot. Align bolt holes in
wear is 0.005 inch. collective lever with bolt holes in elbow and install
bolts (20), washers (17 and 19) and nuts (16).
(4) All items for corrosion and mechanical
damage. Maximum allowable 0.005 inch for b. Assemble drive assembly (12), guide (10 and
corrosion and 0.010 for mechanical. Inspect for 11), and throttle tube (9). Place assembled
dents or distortions that would affect operation. components into control stick (8). Place control stick
into elbow (18). Align slots in control stick with bolt
(5) All items for cracks or broken parts. holes in elbow. Install bolts (21), washers (14 and 22)
and nuts (15).
(6) All pins for grooving.
c. Install boot (24) on elbow (18) with screws.
(7) Gears for broken teeth. Lockwire (C137) screws together. Place ring (4) on
throttle tube (9). Place throttle grip (5) on control stick
c. Fluorescent penetrant inspect to verify (8). Align holes in grip, ring, and throttle tube. Install
Suspected flaws found during visual inspection of screw (1), washers (2, 3, 5, and 6) and nut (7).
elbow (18), collective lever (27), and support
assembly (32) in accordance with TM 43-0103. NOTE
d. Magnetic particle inspect to verify suspected Vary quantity of washers (2, 3, 5, and 6)
flaws found during visual inspection of control stick under screw head to maintain 0.20 to
(8) in accordance with TM 43-0103. 0.22 inch projection through nut (7).
11-24
TM 55-1520-236-23
Figure 11-10. Gunner Collective Stick Assembly (Sheet 1 of 2)
11-25
TM 55-1520-236-23
Figure 11-10. Gunner Collective Stick Assembly (Sheet 2 of 2)
11-26
TM 55-1520-236-23
Figure 11-11. Gunner Collective Stick Adjustment
d. Install shim (49), tagged during disassembly, on lever gear, remove shim from point C and add to
key (13), pinion gear (48), washer (47), and nut (46) on point E. Continue procedure until required dimension
drive assembly (12). is obtained.
NOTE h. Adjust throttle breakaway force (paragraph 11-
25).
Check for smooth operation by rotating
grips (26) through full travel. i. Wire throttle lever (2) to support (3) to maintain
position during subsequent handling.
e. Install shim (38), tagged during disassembly,
and throttle lever assembly on shaft (39). Position
throttle lever with gear teeth facing small end of 11-24. I N S T A L L A T I O N - GUNNER
shaft. COLLECTIVE STICK (AVIM).
f. Install shaft (39) into support assembly and a. I n s t a l l c o l l e c t i v e s t i c k ( 1 , f i g u r e 1 1 - 9 ) u p
secure with washer (35), nut (36), and cotter pin (37). through console and attach support assembly (19) to
Secure throttle lever to shaft with screw (44), washer airframe with three bolts (15, 20, and 23), washers
(41 and 43), and nut (40). (16, 17, 21, and 22) and one nut (18).
g. Check mating between pinion gear (1, figure b. Connect throttle tube assembly (3) to throttle
11-11) and throttle lever gear (2). Surfaces of gear lever with bolt (14), head inboard, washers (12 and
teeth should be flush within 0.020 inch. if pinion 13), and nut (11). Place steel washer (13) under bolt
gear rides too high on lever gear, remove shim from head and stainless steel washer (12) under nut.
point E and add to point C. If pinion gear rides too low Secure nut with cotter pin (10).
11-27
TM 55-1520-236-23
c. C o n n e c t c o l l e c t i v e t u b e a s s e m b l y ( 4 ) t o transducer of the SCAS (Stability and Control
collective lever (1) with bolts (5), washers (6 and 7) Augmentation System) and a force trim magnetic
and nut (8). Place one washer under nut, and one brake connected to control linkage through a spring-
washer under bolt head. Secure nut with cotter pin Ioaded force gradient assembly. The fore-and-aft
(9). cyclic controls extend aft from the control sticks to a
jackshaft, then downward at right side of fuselage,
d. Remove wire (paragraph 11-23). then aft below the forward fuel cell, then upward to
the hydraulic cylinder which is connected on the right
11-25. ADJUSTMENT - GUNNER forward horn of the swashplate (figure 11-12). The
COLLECTIVE STICK. lateral cyclic controls are interconnected between
control sticks at right side of the fuselage, then extend
NOTE aft and to left side, then downward and aft below the
fuel cell, then upward to the hydraulic cylinder which
Steps a., b., f., and g., will be followed if is connected on the left forward horn of the
collective stick is installed in aircraft. swashplate (figure 11-13).
Premaintenance Requirements for
a. Remove left side access panel (paragraph 2-
Cyclic Control System
59).
b. D i s c o n n e c t t h r o t t l e t u b e a s s e m b l y f r o m
Conditions Requirements
throttle lever (2, figure 11-11).
Model AH-1S
c. Measure breakaway force at point B on throttle
lever (2). Use a spring scale to apply force in direction Part No. or Serial No. All
illustrated by arrows on lever.
Special Tools (T46)
NOTE
Test Equipment None
If necessary, equally add or remove
laminations of shims at points C and E Support Equipment (S2)
because tooth surfaces on pinion (1) and
lever (2) must remain flush within 0.020 Minimum Personnel Two
inch at point D. Required
d. Add or remove shims at points C and E to obtain Consumable Materials (C43), (C138)
a breakaway force of 0.50 TO 1.50 pounds. Refer to
paragraph 11-20, a. and b., for shim removal and Special Environmental None
paragraph 11-23, d., e., and f., for shim installation. Conditions
e. R e p e a t s t e p d . , t o d e t e r m i n e w h e t h e r
breakaway force is now within tolerance. If
necessary, repeat shimming procedure.
11-28. INSPECTION - CYCLIC SYSTEM.
f. Connect throttle tube assembly ,to throttle lever
(2) (paragraph 11-24, b.).
a. Inspect control system in place for secure
installation, damage, and freedom of operation
g. Install left side access panel (paragraph 2-59).
through full range of travel (figures 11-12 and 11-13).
11-26. CYCLIC SYSTEM.
11-27. DESCRIPTION - CYCLIC SYSTEM. Insure adequate clearance exists between
the air distribution ducts and the control
T h e m a i n r o t o r cyclic controls consist of tubes of the cyclic system to allow free
interconnected control sticks in pilot and gunner movement over the full range of tubes.
compartments, and two separate systems of linkage
to the swashplate. Each of the cyclic systems includes b. If required; remove components for detailed
a dual hydraulic cylinder, a servo-actuator and a inspection. Refer to paragraphs 11-40 and 11-169 for
11-28 Change 7
TM 55-1520-236-23
damage limits on bellcranks and tube assemblies. there is not more than one inch exposed threads on
Refer to paragraph 7-63 for damage limits on hydraulic control tube (11) (figure 11-12, detail C). Check bolt
cylinder assemblies. that attaches control tube (8) to hydraulic cylinder
valve (7), torque bolt finger tight and install cotter pin.
11-29. RIGGING CYCLIC SYSTEM (Pre The bolt must turn freely.
ferred Method).
a. Accomplish rigging with hydraulic power
unless otherwise stated.
Do not Interchange control tube (7, fig-
ure 11-12) and control tube (8, figure
b. Install all components of the cyclic control 11-13).
system with the following exceptions:
h. Adjust stop bolts (10, figure 11-13) for 0.005 to
(1) Leave hydraulic cylinders (4, figure 11-12,
0.015 inch clearance with bellcrank at full right and full
and 6, figure 11-13) disconnected from swashplate.
Also, leave the elevator control tube (3, figure 11-12) left control positions.
and spring (2) disconnected.
i. Install rigging fixture (T46) on pilots cyclic
(2) Leave control tube (7) disconnected from control stick
bellcrank (8) but connect to hydraulic cylinder valve
lever. (1) Remove four screws, washers, and nuts
from holes in pilots floor outboard of stick support.
(3) Leave control tube (8, figure 11-13) dis-
sconnected from bellcrank (9) but connect to hydraulic
cylinder valve lever. (2) Open clamp of rigging fixture (T46) and
place over stick with open end of damp aft. Engage
pins in mounting holes.
(4) Leave control tube (16, figure 11-12) and
transducer (13) disconnected from bellcrank (11).
j. Clamp cyclic stick in aft hole A of riggjig
(5) Leave control tube (11, figure 11-13) and fixture (T46). Hold bellcrank (8, figure 11-12) against
transducer (15) disconnected from bellcrank (13). fixed stop (9). Adjust control tube (16) and connect to
bellcrank (11).
c. Check and adjust cyclic stick friction (para-
graph 11-37). k. Push Control tube (7) upward to bottom out
piston in top of hydraulic cylinder (4) and hold lever of
d. Hold pilots cyclic stick full right. valve (6) at top of travel. Adjust control tube (7) length
to fit on bellcrank (8), then shorten two full turns and
connect to bellcrank Check exposed threads on con-
e. Adjust control tube (11) to 14.36 inches be-
trol tube (7) to ensure that not more than one inch of
tween bolt hole centers and connect to bellcrank (13).
thread is exposed (figure 11-12, detail B). Check bolt
that attaches control tube (7) to hydraulic cylinder
f. Check that aft arm of bellcrank (9) is raised to valve (6), torque bolt finger tight and install cotter pin.
its highest travel without touching aft stop bolt (10). If The bolt must turn freely.
necessary, adjust stop bolt to dear.
l. Clamp cyclic control stick in center hole N of
g. Push control tube (8) upward to bottom out
rigging fixture (T46).
piston in top of hydraulic cylinder (6) and hold lever of
valve (7) at top of travel. Adjust control tube (8) length
to fit on bellcrank with control stick full right, then m. Fabricate a work aid as shown in figure 11-14
shorten two full turns and connect tube to bellcrank. or use an 18 inch scale as a measuring instrument. Set
Check exposed threads to ensure that not more than both swashplate horns to 12.92 inches, measured
1.25 inches of thread is exposed (figure 11-13, detail from transmission flange to fewer edge of bolt holes.
A). If necessary, adjust length of control tube (11) and Keep right horn at 12.82 inches 0.06 and set left horn
repeat adjustment procedure for tube (8). Ensure that to 12.52 inches 0.06 (figure 11-15).
Change 22 11-28.1
TM 55-1520-236-23
NOTE u. Attach hydraulic cylinders adjusted in the two
preceeding steps to the swashplate. Connect spring
An alternate method of measuring the (2, figure 11-12) to bracket at outer side of right horn.
swashplate in case it bottoms out on the
swashplate support after the rigging v. Remove rigging fixture (T46) from control
has been completed is to measure from stick.
the bottom of the transmission top case
to the bottom edge of the bolt holes w. Hold control stick full forward. Position trans-
using the following dimension, 13.63 ducer (13) in retracted position, adjust rod end and
0.06 inches for the right horn and 13.33 connect on inboard side of bellcrank. Use large safety
0.06 inches for the left hand horn. washer under screw head and aluminum alloy
washers under nut and between rod end and bellcrank
n. Remove Iockwire from retaining nut (26, figure Move control stick full aft and check that transducer
11-12) and loosen nut. does not bottom out.
o. Adjust rod end (24) of extension tubs (27) to x. Hold cyclic full forward. Hold arm on magnetic
fit right swashplate horn at its measured position. Do brake (17) full aft. Adjust rod end of force gradient (14)
not attach hydraulic cylinder to swashplate at this time. and connect to arm on jackshaft (15). If there is not
enough adjustment in force gradient (14), rotate the
arm of the magnetic brake (17) one serration counter
p. Torque nut (26) 450 TO 600 inch-pounds.
clockwise.
Lockwire nut to lock (25) with Iockwire (C138).
y. Hold cyclic stick full right. Adjust and connect
Position boot (29) on cylinder (4) and exten-
lateral SCAS transducer (15, figure 11-13) in retracted
sion tube as shown in figure 11-12, detail D. Top of boot
position on inboard side of bellcrank (13). Install safety
should be13.70 inches from bottom of locknut on rod
washer and aluminum alloy washers in same manner
end. Tighten clamps (28) with boot in this position.
described in step w. above. Move cyclic stick full left
and check that transducer does not bottom Out.
r. Remove Iockwire from retaining nut (33, figure
11-13) and Ioosen nut. z. Hold cyclic stick at center position. Hold arm
of magnetic brake (27) square to beam on which brake
s. Adjust rod end (31) of extension tube to fit left is mounted. Adjust force gradient rod end bearing (20)
swashplate horn at its measured position. Torque and connection bolt at underside of forward army of
retaining nut (33) 480 TO 600 inch-pounds and lock- bellcrank (19).
wire with wire (C138).
aa. Check complete cycIic controls system for
NOTE security and safetying of components.
Any rod end bearing which exceeds the ab. Check operation by moving cyclic controls
0.80 inch maximum or 2.50 inch maxi- through full throw and ensure that there is no binding
mum dimensions should be readjusted or interference.
within these limits. Rod ends with
insufficient exposed threads to permit ac. Rig and connect synchronized elevator con-
lock (32) engagement should also be trols (paragraph 11-138).
readjusted. Final rigging adjustment
should be at the interface of the
extension tubs and hydraulic cylinder ad. Perform maintenance test flight (TM 55-1520-
236-MTF).
assembly.
t. Position bottom of boot (4) in groove provided 11-29.1. RIGGING CYCLIC SYSTEM
on base (5). Position top of boot (4) on extension tubs (ALTERNATE METHOD).
so that there is a distance of 15.16 inches from top of
boot to bottom of locknut on rod end. Tighten clamp(3) a. Accomplish rigging without hydraulic power
with boot in this position (figure 11-13, detail B). unless otherwise stated.
11-28.2 Change 22
TM 55-1520-238-23
b. Install all components of the cyclic control h. Adjust stop bolts (10) for 0.005 TO 0.015 inch
system with the following exceptions: clearance with bellcrank at full right and full left posi-
tions.
(1) Leave hydraulic cylinders (4, figure 11-12)
and (6, figure 11-13) disconnected from swashplate. i. Install rigging fixture (T46) on pilot cyclic con-
Also, leave the elevator tube assembly (3, figure trol stick.
11-12) and spring (2) disconnected.
(1) Remove four screws, washers, and nuts
(2) Leave tube assembly (7) disconnected from holes in pilot floor outboard of stick support.
from bellcrank (8) but connect to hydraulic cylinder
(2) Open damp of rigging fixture (T46) and
valve lever (6).
place over stick with open end of damp aft. Engage
pins in mounting holes.
(3) Leave tube assembly (8, figure 11-13) dis-
connected from bellcrank (9) but connect to hydraulic Clamp cyclic stick in aft A of rigging fixture
j.
cylinder valve lever (7). (T46). Hold bellcrank (8, figure 11-12) against fixed
stop (9). Adjust tube assembly (16). Coat clevis
(4) Leave tube assembly (16, figure 11-12)
threads with corrosion preventive compound (C43)
and transducer (13) disconnected from bellcrank (11). when adjusting control tube. Connect tube to bellcrank
(11).
(5) Leave tube assembly (11, figure 11-13)
and transducer (15) disconnected from bellcrank (13). k. Push tube assembly (7) upward to bottom out
piston in top of hydraulic cylinder (4) and hold lever of
c. Check and adjust cyclic stick friction (para- valve (6) at top of travel. (See detail B, figure 11-12.)
graph 11-37). Adjust tube (7) to length to fit on bellcrank (8), then
shorten two full turns and connect to bellcrank (8).
d. Hold pilot cyclic control stick full right. Check exposed threads on tube (7) to ensure that they
do not exceed one inch (detail B). Ensure that bolt
e. Adjust control tube (11, figure 11-13) to 14.36 attaches tube (7) to hydraulic cylinder valve (6) is
inches between bolt hole centers and connect to bell- tightened sufficiently to remove axial play. Back off to
crank (13). first castellation. Do not damp clevis. The bolt must
turn freely, and cotter pin must be installed.
f. Check that aft arm of bellcrank (9) is raised to
its highest travel without touching aft stop bolt (10). If l. Adjust cyclic control hydraulic cylinder
necessary, adjust stop bolt to dear. assemblies and attach to swashplate as follows:
(1) Clamp pilot cyclic control stick in center
hole N of rigging fixture (T46).
Do not interchange tube (7, figure (2) Fabricate a work aid as shown on figure
11-12), and tube (8, figure 11-13). 11-14 or use an eighteen inch scale as a measuring
instrument. Set both swashplate forward horns to
12.82 inches (figure 11-15). Measure from transmis-
g. Push tube assembly (8) upward to bottom out sion flange to lower edges of bolt holes. Maintain right
piston in top of hydraulic cylinder (6) and hold lever of horn at 12.82 inches 0.08 inch and set left horn to
valve (7) at top of travel. (See Detail A, figure 11-13). 12.52 inches 0.08 inch.
Adjust tube assembly (8) length to fit on bellcrank (9)
with control stick full right, then shorten two full turns NOTE
and connect tube to bellcrank. Check exposed threads
to ensure that not more than 1.25 inches of thread is An alternate method of measuring the
exposed. See Detail A. If necessary, adjust length of swashplate In case it bottoms out on the
tube assembly (11) and repeat adjustment procedure swashplate support after the rigging
for tube (8). Ensure that there is not more than one inch has been completed Is to measure from
exposed threads on tube assembly (11) (detail C). the bottom of the transmission top case
Ensure that nut and bolt that attaches tube assembly to the bottom edge of the bolt holes
(8) to hydraulic cylinder valve (7) is tightened suffi- using the following dimension, 13.63
ciently to remove axial play. The bolt must turn freely 0.06 inches for the right horn and 13.33
and cotter pin must be installed. 0.06 inches for the left hand horn.
Change 22 11-29
TM 55-1520-236-23
Figure 11-12. Fore-and-Aft Cyclic Controls (Sheet 1 of 2)
11-30
TM 55-1520-236-23
Figure 11-12. Fore-and-Aft Cyclic Controls (Sheet 2 of 2)
(3) Adjust hydraulic cylinder assembly (4, fig- (c) Measure exposed threads on rod end
ure 11-12) for attachment to swashplate (1) as follows: bearing (24). If lock (25) can be installed and if less
than 0.80 inch of thread is exposed, torque nut (26)
(a) Remove lockwire and loosen nut (26). 450 TO 600 inch-pounds, Iockwire nut (26) to lock(25)
with Iockwire (C138) and proceed to step (4). If there
are insufficient exposed threads to install lock (25) or
if exposed threads on rod end bearing (24) are in
When setting hydraulic cylinder valve excess of 0.80 inch, make adjustment at nut (30) as
levers to top of travel, do not cause outlined in step (3) (d) through (i).
controls below cylinder to move or mis-
rigging will occur.
(d) Thread rod end bearing (24) into exten-
(b) Ensure that swashplate (1) is at posi- sion lube (27) until 0.80 inch of threads are exposed.
tion set in step (2). Pushdown on extension tube (27) Torque nut (26) 450 TO 600 inch-pounds and Iockwire
with just enough force to hold lever of hydraulic to lock (25) with Iockwire (C138).
cylinder valve (6) at full up position as shown on detail
B. Maintain this position and adjust rod end bearing
(24) to fit on swashplate (1); then shorten one full turn (e) Loosen clamps (28) and (32). Slide
of rod end bearing to compensate for change that boot (29) up until nut (30) is exposed. Remove Iockwire
occurs when hydraulic pressure is applied. and loosen nut (30).
Change 22 11-31
TM 55-1520-236-23
Figure 11-13. Lateral Cyclic Controls (Sheet 1 of 2)
11-32 Change 9
TM 55-1520-236-23
Figure 11-13.
CAUTION swashplate (1), then shorten one full turn of extension
tube (27) to compensate for change that occurs when
When setting hydraulic cylinder valve hydraulic power is applied.
levers to top of travel, do not cause
controls below cylinder to move or (g) Measure length of exposed threads at nut
misrigging will occur. (30). Maximum acceptable exposed thread is 0.80 inch.
(f) Ensure that swashplate (1) is at position set (h) Torque nut (30) 800 TO 1000 inch-pounds
in step (2). Push down on extension tube (27) with just and Iockwire nut (30) to lock (31) with Iockwire (C138).
enough force to hold lever of hydraulic valve (6) at full
p position as shown on detail B. Maintain this position (i) Position top of boot (29) 13.70 inches from
and adjust extension tube (27) on hydraulic cylinder top of extension tube (27) as shown on detail D and
assembly (4) to length so rod end bearing (24) will fit on tighten clamp (28). Position lower end of boot (29) on
hydraulic cylinder assembly (4) and tighten clamp (32).
Change 18 11-33
TM 55-1520-236-23
Figure 11-14.
(4) Attach rod end bearing (24) elevator control enough force to hold lever of hydraulic cylinder valve
tube (3), and spring (2) to swashplate (1). Comply with (7) at full up position as shown on detail A. Maintain
procedure outlined in paragraph 7-66. this position and adjust rod end bearing (31) to fit on
swashplate (1); then shorten one full turn of rod end
(5) Adjust hydraulic cylinder assembly (6, bearing to compensate for change that occurs when
figure 11-13) for attachment to swashplate (1) as hydraulic pressure is applied.
follows:
(c) Measure length of exposed threads on rod
(a) Remove Iockwire and loosen nut (33). end bearing (31). If less than 0.80 inch of threads are
exposed, torque nut (33) 450 TO 600 inch-pounds,
Iockwire nut (33) to lock (32) with Iockwire (C138),
and proceed to step (6). If exposed threads on rod end
When setting hydraulic cylinder valve bearing (31) are in excess of 0.80 i n c h , m a k e
levers to top of travel, do not cause adjustment at nut (35) as outlined in steps (d) through
controls below cylinder to move or (1).
misrigging will occur.
(d) Thread rod end bearing (31, figure 11-13)
into extension tube (2) until 0.80 inch of threads are
(b) Ensure that swashplate (1) is at position exposed. Torque nut (33) 450 TO 600 inch-pounds
set in step (2). Push extension tube (2) down with just and Iockwire to lock (32) with Iockwire (C138).
11-34
TM 55-1520-236-23
(i) Measure length of exposed threads at nut
(35). Maximum acceptable exposed thread is 0.80
inch.
(j) T o r q u e n u t ( 3 5 ) 8 0 0 T O 1 0 0 0 i n c h -
pounds and Iockwire nut (35) to lock (37) with
Iockwire (C138).
(k) Position spring (36) on base (5). Thread
retaining nut (34) on nut (35) until top of retaining nut
(34) is flush with top of nut (35). Lockwire retaining
nut (34) to nut (35) with Iockwire (C138).
Figure 11-15.
(1) Position bottom of boot (4) in groove on
base (5). Position top of boot (4) 15.16 inches from top
of extension tube (2) as shown on detail B. Tighten
clamp (3).
(6) Attach rod end bearing (31) to swashplate
(1). Comply with procedure outlined in paragraph 7-
66.
m. Disconnect fore-and-aft SCAS actuator (10,
figure 11-12) from bellcrank (11). Hold control stick
full forward against stop. Position transducer (13) in
retracted position, adjust rod end and connect on
inboard side of bellcrank. Use large safety washer
under screw head and aluminum alloy washers
(e) Loosen clamp (3) and remove boot (4) from under nut and between rod end and bellcrank. Move
base (5). Slide boot (4) up until nut (35) is exposed. control stick full aft against its stop and check that
transducer does not bottom out. Reconnect fore and
(f) Remove Iockwire and remove retaining aft SCAS actuator (10).
nut (34) and spring (36).
n. Hold cyclic stick full forward. Hold arm on
(g) Remove Iockwire and loosen nut (35). magnetic brake (17) full aft. Adjust rod end of
force gradient (14) and connect to arm on jack-
shaft (15). If there is not enough adjustment in
force gradient (14), rotate the arm of the magnetic
brake (17) one serration counter-clockwise.
When setting hydraulic cylinder valve o. Hold cyclic stick full right against stop. Position
levers to top of travel, do not cause lateral SCAS transducer (15, figure 11-13) in its
control below cylinder to move or retracted position. Adjust rod end of transducer to fit,
misrigging will occur. then screw one-half turn to prevent bottoming
transducer. Connect transducer to inboard side of
(h) Ensure that swashplate (1) is at position bellcrank (13).
sat in step (2). Push down on extension tube (2) with
just enough force to hold lever of hydraulic cylinder p. Clamp cyclic stick in center hole N of rigging
valve (7) at full up position as shown on detail A. fixture (T46). Hold arm of magnetic brake (27) square
Maintain this position and adjust extension tube (2) within 2 degrees to structural beam on which brake is
on hydraulic cylinder assembly (6) to length so rod mounted. Adjust force gradient rod end bearing (20)
end bearing (31) will fit on swashplate (1); then and connect on bolt at underside of forward arm of
shorten one full turn of extension tube (2) to bellcrank (19). Remove rigging fixture and move cyclic
compensate for change that occurs when hydraulic stick full right and full left to ensure that magnetic
pressure is applied. brake stop is not contacted.
Change 5 11-35
TM 55-1520-236-23
Figure 11-16.
11-36
TM 55-1520-236-23
Figure 11-16.
q. Check complete cyclic controls system for mounted through gimbal bearings in a bell-shaped
security and safetying of components. support. The grip attached at top of stick is equipped
with the following switches: SAS REL, TRIGGER
r. Check operation with hydraulic power from a ACTION, TRIGGER TURRET FIRE, WING ARM FIRE,
hydraulic test stand if available; if not available, move TRIM REL, ICS-RADIO, and NIGHT VISION GOGGLE.
cyclic controls through full throw manually and Pilot cyclic stick has a mechanical advantage of 2 to 1
ensure that there is no binding or interference. ratio over the gunner cyclic stick.
s. Rig and connect elevator controls (paragraph Premaintenance Requirements for
11-138). Pilot Cyclic Stick
t. Perform maintenance test flight (TM 55-1520-
236-MTF).
Conditions Requirements
11-30. PILOT CYCLIC STICK. Model AH-1S
11-31. DESCRIPTION - PILOT CYCLIC Part No. or Serial No. All
STICK.
Special Tools None
The conventional type control stick is mounted
through the floor in front of the pilot seat. It is Test Equipment Feeler Gage
11-37
TM 55-1520-236-23
d. Remove elbow (2) from pilot cyclic stick (5) by
Conditions Requirements removing nut (4), washers (3 and 6), and bolt (7).
Remove old primer from ends of elbow with clean
Support Equipment None cloth saturated by MEK (C74).
Minimum Personnel Two e. S e p a r a t e p i l o t c y c l i c s t i c k ( 5 ) f r o m l e v e r
Required assembly (32) by removing cotter pin (29), nut (30),
washers (31 and 40), and bolt (39).
Consumable Materials (C14), (C88), (C74),
(C91), (C105), (C112) NOTE
Special Environmental None Save shims (26) located on bolts (18)
Conditions between support (17) and gimbal (22).
f. Separate support (17) from gimbal (22) by
removing two cotter pins (20), two nuts (21), and two
11-32. REMOVAL-PILOT CYCLIC STICK. washers (19). Remove bolts (18) and shims (26).
g. Remove remaining cotter pins (23), nuts (24),
a. Obtain access to area below pilot floor through and washers (25). Remove bolts (33) with shims (38)
door in panel at top of ammunition compartment. and separate lever assembly (32) from gimbal (22).
Save shims (38) for reuse during installation.
b. Disconnect lateral system tube assembly (24,
figure 11-16) and fore-and-aft tube assembly (17) h. Rotate nuts (8 and 9) counterclockwise until
from levers on lower end of control stick. clear of threads on collar (15). Remove spring tension
washers (10 and 11), spacer (12), and bell assembly
c. Disconnect electrical cable connector (27) of (13).
control stick from the receptacle.
11-34. INSPECTION - PILOT CYCLIC
STICK.
d. Detach stick support from floor by removing
four bolts (10) with nuts (13) and washers (11 and 12).
a. Inspect washers (10 and 11, figure 11-17) for
damage which will affect serviceability.
e. Lift stick assembly out of floor opening.
b. Inspect bearings (27, 37, 41 and 44) for
11-33. DISASSEMBLY - PILOT CYCLIC roughness, freedom of movement, and wear in
STICK (AVIM). excess of 0.005 inch radial and 0.030 inch axial play.
a. Identify and tag wires of cable (42, figure 11- c. Inspect lever assembly (32) and gimbal (22)
17) for sequence of installation in electrical connector using fluorescent penetrant in accordance with TM
(43); then remove connector from electrical cable 43-0103.
(42).
d. Inspect shims (26 and 38) for wear and/or
b. Remove bolt (36), washer (35), and clamp (34) damage.
attaching cable assembly to lever assembly (32).
e. Inspect grip assembly (1) for cracks. Inspect
NOTE switches for operation of detent and obvious damage.
Use care when removing grip from stick f. Inspect electrical cable (42) and electrical
because electrical wires of grip must be connector (43) for loose connections, broken
removed from inside of stick. terminals, pins and/or soldered connections. Inspect
cable for obvious damage such as chafing.
c. Remove grip assembly (1) from elbow (2) by
removing nut (45), washer (46), and screw (47), see g. Inspect elbow (2) for cracks and for elongation
detail A. of bolt holes.
11-38 Change 5
TM 55-1520-236-23
h. Inspect collar (15) for cracks and damaged
threads.
i. Inspect nuts (8 and 9) for damaged threads.
j. Inspect stick (5) for cracks.
11-35. REPAIR OR REPLACEMENT -
PILOT CYCLIC STICK (AVIM).
a. R e p l a c e c o m p o n e n t s t h a t f a i l t o m e e t
inspection requirements of paragraph 11-34.
b. Replace elbow (2, figure 11-17) as follows:
(1) Remove nut (4), washers (3 and 6) and bolt
(7).
(2) Remove elbow (2) from cyclic stick.
(3) Prime elbow with primer (C88) or (C91).
Align holes in elbow with holes in cyclic stick and
install.
(4) Install bolt (7), washers (3 and 6) and nut (4).
Change 9 11-38.1/(11-38.2 blank)
TM 55-1520-236-23
b.1. Replace sheet felt (17A) (C53.3) in bell (13) diameter holes to match holes in pilot cyclic stick (5)
if warn or damaged. and lever assembly (32, figure 11-17).
(4) Prime area of pilot cyclic stick (1, figure 11-
18) where collar (2) will be installed with primer (C88
or 91). Slide new collar onto cyclic stick (1). Position
collar (2) so that flange is 3.820 inches from center of
hole in end of cyclic stick (1).
(5) With collar (2) positioned as shown in detail
Cleaning solvent is flammable and
A, figure 11-18, drill three rivet holes 118 degrees to
toxic. Provide adequate ventila-
122 degrees apart to match with holes in pilot cyclic
tion. Avoid prolonged breathing of
stick (1). Center of rivet to be 0.20 inch from end of
solvent vapors and contact with skin
collar as shown (figure 11-18).
or eyes.
(6) I n s t a l l t h r e e MS20470AD4 or
MS20600AD4 rivets (3).
d. Replace bearings (41 and 44, figure 11-17) if
(1) Scrape old sheet felt (C53.3) out of bell rough, binding or worn beyond limits. Refer to
(13) and clean with MEK (C74). paragraph 11-35.
(2) Apply cement (C28.1) to new sheet felt 11-36. ASSEMBLY - PILOT CYCLIC
(C53.3) and install in bell (13).
STICK (AVIM).
c. Replace collar (15) as follows:
(1) If installed, remove lever assembly (32) from
end of cyclic stick (paragraph 11-38). Cleaning solvent is flammable and toxic.
Provide adequate ventilation. Avoid
(2) Remove three rivets (3, figure 11-18), then prolonged breathing of solvent vapors
slide collar (2) off pilot cyclic stick (1). and contact with skin or eyes.
(3) Inspect bushing (4). If damaged, install new
bushing as follows:
(a) Chill end of cyclic stick to minus 6 0 Do not allow solvent to enter bearings or
degrees F (minus 51 degrees C). Use suitable punch electrical components.
and mallet on bushing (4) to break the adhesive.
Remove bushing. a. Clean exposed surfaces with a clean cloth
dampened with dry cleaning solvent (C112).
(b) Ensure that old adhesive is removed from
inside cyclic stick. b. Install bell assembly (13, figure 11-17), spacer
(12), two washers (10 and 11) and two spanner nuts
(c) Mix and apply adhesive (C14) to bushing. (8 and 9) over end of pilot cyclic stick (15) onto collar
Refer to table 1-11, for adhesive, mix ratio, pot life and (15).
curing schedule.
NOTE
(d) Position slot in new bushing as shown in
detail B, figure 11-18, and install bushing into cyclic Separate wires from grip assembly (1) so
stick until flush with end of stick. that the screws is between bundles.
(e) With bushing aligned as shown in detail c. Apply unthinned primer (C88 or C91) to elbow
B, figure 11-18, drill two 0.24965 TO 0.2500 i n c h (2) and install elbow screw (47), washer (46) and
Change 9 11-39
TM 55-1520-236-23
Figure 11-17.
11-40 Change 9
TM 55-1520-236-23
Figure 11-17.
11-41
TM 55-1520-236-23
Figure 11-18.
spline nut (45) to grip assembly (1). Route electrical Install bolts (33) from inside of lever assembly (32) to
cable (42) through pilot cyclic stick (5). Apply outside of gimbal (22) and secure with washer (25),
unthinned primer to end of elbow and attach elbow to nut (24), and cotter pin (23).
pilot cyclic stick with bolt (7), washers (6 and 3) and
nut (4). f. Install bearings (27) in support (17) and install
support over bottom end of pilot cyclic stick.
d. I n s t a l l t w o b e a r i n g s ( 3 7 a n d 4 4 ) i n l e v e r
assembly (32).
g. R o u t e e l e c t r i c a l c a b l e ( 4 2 ) t h r o u g h l e v e r
e. Assemble lever assembly (32) and gimbal (22) assembly (32) while inserting pilot cyclic stick (15)
with sufficient shims (38) between bearing and into lever assembly (32) as shown on figure 11-17.
gimbal to prevent lever side play. Distribute shims on Align hole in lever assembly (32) with hole in pilot
each side so that the centerline of bore in lever is cyclic stick (5). Install bolt (39), washers (31 and 40),
concentric within 0.005 inch with center of gimbal. nut (30) and secure with cotter pin (29).
11-42
TM 55-1520-236-23
h. Align holes in support bearings (27) with b. Align holes and install four bolts through the
gimbal (22). Install bolts (18) from outside through stick support and floor. Use thin alloy washers under
bearing (27) with sufficient shims (26) between bolt heads and nuts.
support and gimbal to prevent side play and maintain
center of support (17) concentric within 0.005 inch of c. Apply sealant (C105) to fill in structure fore-
gimbal center. and-aft of stick support and form a fillet between
support and floor.
i. Secure bolts (18) with washer (19), nut (21), and
cotter pin (20). d. Connect tube assembly (12, figure 11-12).
Use one washer under bolt head and one washer
j. Attach electrical cable (42) to lever assembly under nut. Secure with cotter pin.
(32), using clamp (34), bolt (36), and washer (35).
Ensure that all slack is removed from wires in stick e. Connect tube assembly (18, figure 11-13).
and maximum distance between electrical cable (42) Use one washer under bolt head and one washer
and lever (32) is 0.050 inch and is snug against lever under nut. Secure with cotter pin.
(32).
f. Connect electrical connector (43, figure 11-17),
k. Remove masking tape from electrical cable of stick to receptacle provided.
(42). Install electrical connector (43) on electrical
cable (42) with wires of cable installed in original plug g. Check complete control system for security and
position. safetying of components.
l. Adjust pilot cyclic stick friction (paragraph 11-
37).
11-39. OPERATIONAL CHECK - PILOT
CYCLIC STICK.
11-37. ADJUSTMENT - PILOT CYCLIC
a. Check operation of pilots cyclic stick through full
STICK.
range of movement (paragraph 11-29).
a. Place support (17, figure 11-17) of pilot cyclic
b. Install access panel in top of ammunition
stick in a suitable device to hold it immovable with
compartment.
pilot cyclic stick (5) perpendicular to the support.
c. Perform maintenance test flight. Refer to TM
b. Screw lower spanner nut (9) on threads until
55-1520-236 MTF.
nut is against washers (10 and 11).
c. Adjust stick friction as follows:
(1) Adjust two lower spanner nuts (figure 11- 11-40. GUNNER CYCLIC STICK.
19) to obtain 2.0 0.25 pounds breakaway force
from neutral positions. Measure breakaway force
with a force gage (fish scale) at center of stick grip. 11-41. DESCRIPTION - GUNNER CYCLIC
STICK.
(2) H o l d l o w e r s p a n n e r n u t . T o r q u e u p p e r
spanner nut 450 TO 500 i n c h - p o u n d s , R e c h e c k The gunner cyclic control stick is mounted on gunner
breakaway torque and readjust if required. right side console. It is attached on a support through
pivot bearings which allow both fore-and-aft and
lateral movements. The grip, attached at top of stick,
is functionally identical to grip used on pilot cyclic
11-38. INSTALLATION - PILOT CYCLIC stick and is equipped with identical control switches
STICK. (figure 11-20). Because of the difference in the pilot
and gunner cyclic systems, it requires more force
a. Place pilot cyclic stick in mounting hole of pilot (1.63 TO 1 ratio) to move the gunner cyclic stick than
floor. it does to move the pilot cyclic stick.
Change 16 11-43
TM 56-1620-236-23
Figure 11-19.
Premaintenance Requirements for Conditions Requirements
Gunner Cyclic Stick
Support Equipment None
Conditions Requirements Minimum Personnel Two
Model AH-1S Required
Part No. or Serial No. All Consumable Materials (C112)
Special Tools (T48), (T61) Special Environmental None
Conditions
Test Equipment Feeler Gage
11-44
TM 55-1520-236-23
11-42. REMOVAL - GUNNER CYCLIC f. Separate bellcrank (9) from support (10) by
STICK (AVIM). removing cotter pin (17), nut (16), washers (12 and
15), and bolt (13).
a. Remove screw mounted panel from right side
of fuselage above ammunition compartment for g. Remove clamp support (29) by removing nut
access to stick. (3), washers (2 and 28), and screw (27).
b. Disconnect electrical cable plug (9, figure
11-20) of stick from receptacle in console.
11-44. INSPECTION - GUNNER CYCLIC
c. Disconnect fore-and-aft system tube assembly STICK.
(13) by removing bolt (15), washers (12 and 14), nut
(11), and cotter pin (10).
a. Inspect grip (1, figure 11-21) for cracks. No
cracks are acceptable.
d. Disconnect lateral system link (21) by removing
bolts (23), washers (20 and 22), nut (19), and cotter b. Inspect bellcrank (9), support (10), and cyclic
pin (18). control stick (31) for scratches, nicks, dents, and
corrosion. Minor mechanical damage and superficial
e. Detach boot (26) from console by removing corrosion is acceptable if polished out.
screw (28) and washer (27) on outboard side and
screw (28) and washer (27) on inboard side of stick. c. Inspect bellcrank (9), support (10) and cyclic
control stick (31) for cracks by fluorescent penetrant
f. Detach stick support from console structure by method (TM 43-0103). No cracks are acceptable.
removing three bolts (24) and washers (25), Lift stick
assembly out of console. d. Inspect switches for damage that could affect
function of the switches.
e. Inspect cable (5) for loose connectors, broken
11-43. D I S A S S E M B L Y - GUNNER
terminals, pins, and/or soldered connections to
CYCLIC STICK (AVIM).
switches in grip (1). Inspect cable wires for breaks
and/or chafing.
a. Tag wires of electrical cable (5, figure 11-21)
for identification, number and installation sequence
f. Inspect bearings (8, 11, 14, 25, and 30) for
in electrical connector (4) then remove connector
roughness and wear. Maximum acceptable wear
plug from cable assembly.
(play) is 0.005 TO 0.030 i n c h .
b. Remove clamp (18) from electrical cable (5) by
removing screw (20), washers (19 and 23) and nut
(26).
11-45. REPAIR OR REPLACEMENT -
GUNNER CYCLIC STICK (AVIM).
c. Remove clamp (37) from bracket (38), by Replace c o m p o n e n t s t h a t f a i l t o m e e t
removing screw (35), washers (36 and 39) and nut inspection requirements of paragraph 11-44.
(40), see detail C.
b. Replace defective switches or electrical cable
d. Remove grip (1) from uppper end of stick (31) by as required (paragraph 9-20 and Appendix F).
removing screw (17, figure 11-20) and apply gentle
upward pressure on grip to prevent injury to attached c. Refer to paragraph 11-165 for instructions to
cable assembly. replace bearings. If bearing (30) must be replaced,
use staking tool (T48) in place of staking tool (T61).
e. Separate stick (31, figure 11-21) from bellcrank
(9) and support (10) by removing cotter pin (21), nut d. Polish out minor corrosion and mechanical
(22), washers (7 and 24), and bolt (6). Remove bracket damage from parts in accordance with general repair
(38) from bolt. procedures in paragraph 11-158.
11-45
TM 55-1520-236-23
Figure 11-20.
11-46
TM 55-1520-236-23
Figure 11-20.
11-47
TM 55-1520-236-23
Figure 11-21.
11-48
TM 55-1520-236-23
11-46. ASSEMBLY - GUNNER CYCLIC j. Ensure that cable (5) is routed as shown in
STICK (AVIM). figure 11-21. Install connector (4) on cable (5) in same
sequence as original installation (Appendix F and
paragraph 9-22).
11-47. I N S T A L L A T I O N - GUNNER
Cleaning solvent is flammable and toxic.
Provide adequate ventilation. Avoid CYCLIC STICK (AVIM).
prolonged breathing of solvent vapors
and contact with skin or eyes. a. Place stick assembly into opening of console,
inserting electrical cable first.
CAUTION b. Align stick support to mounting holes of beam.
Install three bolts (24, figure 11-20) with thin
Do not allow solvent to enter bearings or aluminum alloy washers (25) under heads.
electrical components.
c. Connect fore-and-aft system tube assembly
(13) by installing bolt (15), washers (12 and 14), nut
a. Clean exposed surfaces by wiping with a cloth
dampened with dry cleaning solvent (C112). (11), and cotter pin (10).
b. Place one washer (12, figure 11-21) under d. Connect lateral system link (21) by installing
head of bolt (13), insert bolt through support (10) and bolt (23), washers (20 and 22), nut (19), and cotter pin
through bellcrank (9). Secure bolt with washer (15), (18).
nut (16), and cotter pin (17).
e. C o n n e c t e l e c t r i c a l c a b l e c o n n e c t o r ( 9 ) t o
c. Separate two wire bundles in cable (5) so that receptacle in console.
screw (17, figure 11-20) can be installed between the
two wire bundles without damage to cable (5, figure f. Secure boot (26) to console with screw (28) and
11-21). washer (27) on inboard side and screw (28) and
washer (27) on outboard side.
d. Route cable (5) through top of cyclic stick and
install grip (1) with holes in grip aligned with holes in 11-48. OPERATIONAL CHECK - GUNNER
cyclic stick (31). Install screw (17, figure 11-20) CYCLIC STICK.
through grip and stick. Ensure that screw is between
cable bundles (5, figure 11-21). a. Check complete control system for security and
safetying of components.
e. If removed, attach clamp support (29) to cyclic
stick with screw (27), washers (2 and 28), and nut (3). b. Check cyclic system rigging as outlined in
paragraph 11-29.
f. Install cable (5) in clamp (18) and attach clamp
to support (29) with screw (20), washers (19 and 23), c. Install access panel.
and nut (26).
d. Perform maintenance test flight (TM 55-1520-
g. P o s i t i o n b e l l c r a n k ( 9 ) w i t h s u p p o r t ( 1 0 ) 236 MTF).
between ears of cyclic stick (31). If removed, install
floating bearing (25) in one ear of cyclic stick. Align 11-49. JACK SHAFT - CYCLIC
holes in bellcrank with bearings (8 and 25) and install
CONTROLS.
bolt (6) with one washer (7) under head through cyclic
stick and bellcrank.
11-50. DESCRIPTION - JACKSHAFT -
h. Install cable (5) in clamp (37) and secure with CYCLIC CONTROLS.
screw (35), washers (36 and 39), and nut (40).
The jackshaft integrates fore-and-aft cyclic control
i. Install one washer (24) and bracket (38) on bolt input actions from the pilot and gunner cyclic sticks
(6). Install nut (22) and secure with cotter pin (21). into one output action and changes the direction of
11-49
TM 55-1520-236-23
movement from WL 54.76, station 146.50 down and e. Detach jackshaft support (8) from its attaching
slightly forward to a bellcrank at WL 37.88, station point by removing four bolts (10) and washers (9).
144.75. Supports located at stations 146.50 and
148.50 provide for attachment of the jackshaft to the f. Carefully guide outboard lever of jackshaft (1)
fuselage. The jackshaft rotates on bearings within the through the opening in right hand beam assembly
supports. and remove jackshaft from fuselage through
ammunition compartment.
Premaintenance Requirements for
Jackshaft g. Remove cotter pin (11), nut (12), washers (13
and 14) and remove support (8) from end of jackshaft.
Conditions Requirements h. Remove support (3) from bearing surface of
jackshaft and guide it off end of jackshaft over lever.
Model AH-1S
11-52. INSPECTION - JACKSHAFT -
Part No. or Serial No. All CYCLIC CONTROLS.
Special Tools (T48), (T61) a. Inspect jackshaft assembly (1, figure 11-22)
and support assemblies (3 and 8) for cracks, using
Test Equipment None fluorescent penetrant in accordance with TM 43-
0103.
Support Equipment None
b. Inspect bearings (2, 6, 15, 19, and 22) for
Minimum Personnel One roughness, freedom of movement, and wear in
Required excess of 0.005 inch radial and 0.030 inch axial play.
Consumable Materials (C31), (C36), (C88), c. Inspect plating on bearing surface of jackshaft
(C91), (C102), (C112 for wear, damage, and peeling. Minimum allowable
diameter of plated bearing surfaces is 1.560 inch.
Special Environmental None
Conditions d. Inspect plug (7) for damaged threads and worn,
peeled or damaged plating.
e. Inspect jackshaft (1) and supports (3 and 8) for
11-51. REMOVAL - JACKSHAFT -
scratches and corrosion.
CYCLIC CONTROL.
a. Remove access panels (4,5,9, and 10, figure 2- 11-53. REPAIR OR REPLACEMENT -
3) from right side of fuselage and remove access JACKSHAFT CYCLIC CONTROLS.
panels (32, 33, and 34) from bottom of fuselage.
a. Polish out all scratches and corrosion on
b. Open ammunition compartment door (8) and jackshaft (1, figure 11-22) or supports (3 and 8) which
remove access panel on aft, center bulkhead inside do not exceed 0.005 inch depth, using 180 grit or
ammunition compartment. Detach tube assembly finer sandpaper (C102). Polish to a smooth, scratch
(12, 16, and 19, figure 11-12) and force gradient (14) free finish with abrasive cloth (C36). Blend edges of
from levers of jackshaft (15). Refer to paragraph 11- repair into surrounding area. Apply chemical film
65 for procedure. coating (C31) to repaired areas. Prime repaired areas
with primer (C88 or C91).
c. Remove nut (21, figure 11-22), washers (18
and 20), and bolt (17) that attaches lower ear of b. Replace jackshaft assembly (1, figure 11-19)or
support (3) to right hand beam and lower ear of supports (3 and 8) if cracked.
support assembly.
c. Replace bearings (2, 6, and 19) when wear or
d. R e m o v e b o l t s ( 5 ) a n d w a s h e r s ( 4 ) f r o m damage exceeds limits of paragraph 11-52. Refer to
remaining two ears of support (3). paragraph 11-13 for replacement procedure.
11-50
TM 55-1520-236-23
Figure 11-22.
11-51
TM 55-1520-236-23
d. Replace bearing (15) in support (8) when wear e. Install bolt (17) with washer (18) through hole
or damage limits in paragraph 11-52, step b. (Use in bottom ear of support (3). Secure with washer (20)
replacement procedure in paragraph 11-13, except and nut (21).
use staking tool (T48) instead of staking tool (T58).
f. Align support (8) to four holes in bulkhead and
e. Replace bearing (22) in support (3) when wear install four bolts (10), washers (9) under bolt heads.
or damaged exceeds limits in paragraph 11-52.
g. Attach tube assemblies (12, 16, and 19, figure
(1) Carefully press bearing from support. 11-12) and force gradient (14) to levers of jackshaft
(15).
h. Check complete control system for security and
safetying of components.
i. Check cyclic system rigging (paragraph 11-29).
Cleaning solvent is flammable and toxic.
Provide adequate ventilation. Avoid j. Install access panels, (4,5,9, and 10, figure 2-3)
prolonged breathing of solvent vapors and access panels (32, 33, and 34). Install access
and contact with skin or eyes. panel on aft, center bulkhead inside ammunition
compartment and secure ammunition door (8).
(2) Clean inside of support with dry cleaning
solvent (C112). k. Perform maintenance test flight (TM 55-1520-
236 MTF).
(3) Apply primer (C88 or C91) to outer race of
bearing.
11-55. MAGNETIC BRAKE - CYCLIC
(4) C a r e f u l l y p r e s s n e w b e a r i n g ( 2 2 ) i n t o CONTROLS.
support while primer is wet.
f. Replace jackshaft (1) when wear and damage to 11-56. DESCRIPTION - MAGNETIC
plated bearing surface is in excess of limits in BRAKE - CYCLIC CONTROLS.
paragraph 11-52.
A magnetic brake assembly is installed in both the
g. Inspect plug (7) in end of jackshaft. If inspection fore-and-aft and lateral cyclic control system. Each
reveaIs any damage, send to next higher brake assembly is secured to the airframe structure. It
maintenance level. consists of a rotary shaft which can be mechanically
actuated and an electrically actuated magnetic brake
11-54. INSTALLATION - JACKSHAFT - that will hold the rotary shaft at any point in its travel
CYCLIC CONTROLS. when actuated by a switch on the cyclic stick (figures
11-12 and 11-13).
a. Install support (3, figure 11-22) on jackshaft (1)
and position it on plated bearing surface of jackshaft.
Premaintenance Requirements for
Magnetic Brake
b. Insert threaded end of plug (7) into support (8)
bearing. lnstall two washers (13 and 14), nut (12), and
cotter pin (11).
Conditions Requirements
c. Carefully guide outboard lever of jackshaft (1) Model AH-1S
through opening in right hand beam assembly.
Part No. or Serial No. Al I
d. Align the three holes in support (3) with holes
in right hand beam. Install one bolt (5) with one Special TOOLS None
washer (4) through bolt hole in top and in forward ear
of support (3). Test Equipment None
11-52
TM 55-1520-236-23
e. On lateral system only, unhook springs (29,
Conditions Requirements
figure 11-13) from plates (28). Detach plates (28) by
removing two bolts.
Support Equipment None
f. D e t a c h m a g n e t i c b r a k e a s s e m b l y f r o m
Minimum Personnel Two structure by removing four bolts and washers.
Required
Consumable Materials (C88), (C91), (C102),
(C112)
Cleaning solvent is flammable and toxic.
Special Environmental None Provide adequate ventilation. Avoid
Conditions prolonged breathing of solvent vapors
and contact with skin or eyes.
11-59. CLEANING - MAGNETIC BRAKE
- CYCLIC CONTROLS.
11-57. INSPECTION - MAGNETIC BRAKE
- CYCLIC CONTROL. Clean exposed surface of magnetic brake with clean
cloth dampened with dry cleaning colvent (C112). Do
a. With electrical power off, manually rotate the not allow solvent to enter bearings or electrical
rotary shaft of the magnetic brake from stop to stop. components.
Check to ensure freedom of rotation and full range of
travel. 11-60. REPAIR OR REPLACEMENT -
MAGNETIC BRAKE - CYCLIC CONTROLS.
b. Apply electrical power to actuate the magnetic
brake. Check to ensure that the rotary shaft will not a. R e m o v e m i n o r c o r r o s i o n w i t h s a n d p a p e r
rotate with brake applied. (C102). Prime repaired area with primer (C88 or C91).
If corrosion damage is severe enough to affect
c. C h e c k a t t a c h m e n t b o l t s f o r s e c u r i t y , i f
function, replace the magnetic brake assembly.
magnetic brake is attached to the fuselage.
b. Replace magnetic brake assembly if damaged
d. Inspect electrical connector for mechanical
of malfunctioning.
damage and corrosion.
11-61. INSTALLATION - MAGNETIC
BRAKE - CYCLIC CONTROLS.
11-58. REMOVAL - MAGNETIC BRAKE -
CYCLIC CONTROLS. a. P r i o r t o i n s t a l l a t i o n o f m a g n e t i c brake
assembly, check the magnetic brake assembly to
a. Turn electrical power off. make sure arm is properly located on the shaft. Mark
F on the arm must be 90 degrees from line on end of
b. Remove access panel. For the fore-and-aft shaft. See detail A, figure 11-12 and detail D, figure
system, r e m o v e p a n e l i n t o p o f a m m u n i t i o n 11-13.
compartment. For lateral system, remove panel on
right side of fuselage above ammunition b. Position magnetic brake assembly to mounting
compartment. holes of structure, and install four attaching bolts
with washers.
c. D i s c o n n e c t e l e c t r i c a l connector from
receptacle on magnetic brake. NOTE
Springs (29, figure 11-13) assist control
d. Detach force gradient from arm of magnetic stick movements by compensating for
brake by removing cotter pin, nut and washer, and weight of the actuator (12) and will
from bellcrank by removing cotter pin, nut, washer, normally be attached in end holes of plate
and bolt. (28).
11-53
TM 55-1520-236-23
(1) I n s t a l l m a g n e t i c brake (27) for the lateral 11-64. INSPECTION - FORCE GRADlENT
cyclic system on the outboard side of beam in the right - CYCLIC CONTROLS (AVIM).
side console at fuselage station 105.78 with the
electrical receptacle facing aft and the arm pointing a. Check cap (2, figure 11-23), cylinder (3), and
outboard (to right) at midtravel. Install plate (28) on shaft (8) thread condition.
two aft bolts, on outboard side of brake body. Hook
springs (29) on plate (28). b. Fluorescent penetrant inspect cylinder (3),
shaft (8), and guides (9 and 11) in accordance with TM
(2) Install magnetic brake (17, figure 11-13) for 43-0103, if cracks are suspected. Refer to paragraph
the fore-and-aft cyclic system on the underside of the 11-67 for disassembly of force gradient.
pilot floor panel inboard of right side beam and aft of
pilot control stick at fuselage station 133.76 with the c. I n s p e c t b e a r i n g ( 4 ) f o r b i n d i n g a n d / O R
electrical receptacle facing forward and the arm on FREEDOM OF MOVEMENT_
the inboard side pointing down at midtravel.
NOTE
c. Connect electrical connector to receptacle on Free length of spring used in tail rotor
magnetic brake. force gradient should be 4.50 TO 4.62
inches.
d. Install force gradient (paragraph 11-70).
d. Inspect free length of spring (10) for length of
11-62. FORCE GRADlENT - CYCLIC 4.84 to 4.96 i n c h e s .
CONTROLS.
11-65. REMOVAL - FORCE GRADIENT-
11-63. D E S C R I P T I O N - FORCE CYCLIC CONTROLS.
GRADlENT - CYCLIC CONTROLS.
a. Remove access panels. Fore-and-aft gradient,
A force gradient assembly in each of the two cyclic remove panel in top of ammunition compartment. For
controls systems performs stick centering and force lateral gradient, remove panel on right side of
trim functions. The force gradient is a link equipped fuselage above ammunition compartment.
with an internal spring and connects the magnetic
brake arm to a lever or bellcrank in the cyclic control b. Detach force gradient from arm of magnetic
system (figures 11-12 and 11-13). brake by removing cotter pin, nut, and washer.
Detach lateral gradient (21, figure 11-13) from
Premaintenance Requirements for bellcrank or fore-and-aft gradient (14, figure 11-12)
Force Gradient in Cyclic Control from jackshaft by removing cotter pin, nuts, washers,
and bolt.
Conditions REQUIREMENTS
Model AH-1S
Part No. or Serial No. All
Cleaning solvent is flammable and toxic.
Special Tools None Provide - adequate ventilation. Avoid
prolonged breathing of solvent vapors
Test Equipment None and contact with skin or eyes.
Support Equipment None
Minimum Personnel Two Do not allow solvent to enter bearings.
Required
11-66. CLEANING - FORCE GRADIENT-
Consumable Materials (C112), (C138) CYCLIC CONTROLS.
Special Environmental None Clean force gradient components with clean cloth
Conditions dampened with dry cleaning solvent (C112).
11-54
TM 55-1520-236-23
NOTE c. Install nut (6) on shaft (8) adjacent to nut (7).
Disassembly is only required for d. Hold nut (7) with wrench or other suitable
fluorescent penetrant inspection or
device and tighten nut (6) tightly against it as a jam
replacement of parts. nut.
11-67. DISASSEMBLY - FORCE e. Make certain preload on spring is still same as
GRADlENT - CYCLIC CONTROLS (AVIM). recorded in step b(1).
a. Cut Iockwire and remove cap (2, figure 11-23) f. Insert spring assembly (1) into cylinder (3).
from cylinder (3).
g. Slide center hole of cap (2) over end of spring
b. Remove spring assembly (1) from cylinder (3).
shaft (1) with thread end of cap toward cylinder (3).
c. Remove three nuts (5, 6, and 7) from shaft (8).
h. S c r e w c a p ( 2 ) i n t o c y l i n d e r ( 3 ) u n t i l a l l
noticeable end play of spring assembly (1) is removed.
d. Remove spring guides (9 and 11) and spring
(10).
i. Lockwire cap (2) to cylinder (3) with Iockwire
(C138) as shown in figure 11-23, to eliminate motion
11-68. REPAIR OR REPLACEMENT - in either direction.
FORCE GRADlENT - CYCLIC CONTROLS
(AVIM). j. Install remaining nut (5) onto shaft of spring
assembly (1) (to be used as jam nut against rod end at
Replace bearing, sleeve, and nuts as necessary. installation).
a. Fluorescent penetrant inspect housing per
1 1 - 7 0 . I N S T A L L A T I O N - FORCE
MIL-I-6866 (reference TM 55-1500-204-25/1) after GRADlENT - CYCLIC CONTROLS.
bearing removal.
a. Install rod end on threaded end of spring shaft,
b. Roll stake sleeve both sides. with jam nut in place. Final adjustment is made in-
rigging procedure.
a. Chamfer 0.030 inch depth x 45 degrees each
side of hole in housing. b. C o n n e c t c y l i n d e r e n d o f f o r c e g r a d i e n t
assembly on arm of magnetic brake with special
d. Coat sleeve ID and OD, bearing OD, and washer, nut, and cotter pin. Leave rod end of force
housing bore with wet zinc chromate primer (C91) gradient disconnected, to be adjusted and connected
during assembly. after rigging cyclic controls.
11-69. ASSEMBLY - FORCE GRADlENT c. Attach force gradient assembly (14, figure 11-
- CYCLIC CONTROLS (AVIM). 12) to jackshaft (15). Refer to paragraph 11-29 for
rigging instructions of force gradient assembly.
a. Assemble spring (10, figure 11-23) and guides
(9. and 11) on shaft (8) and install one nut (7) onto shaft d. Rig and install force gradient assembly (21,
with edge of nut adjacent to guide (11) on threaded figure 11-13) to bellcrank (19). Refer to paragraph
end of shaft. 11-29 for rigging instructions.
b. Preload spring (10) on shaft (8) as follows:
e. After final adjustment, secure rod end (fig-
ure 11-13, item 20) with jam nut (figure 11-23, item
(1) Apply a Ioad of 5.5 T0 6.5 pounds on spring
5) torqued 150 TO 200 inch-pounds.
of gradient. Measure spring length while at this load,
and record length.
11-71. TAIL ROTOR CONTROL
(2) Tighten nut (7) against guide (11) until SYSTEM .
length of spring (7) is the same as when under load
(step (1) above).
Change 5 11-55
TM 55-1520-236-23
11-72. DESCRIPTlON - TAIL ROTOR levers, servo actuator (SCAS), magnetic brake and
CONTROL SYSTEM. force gradient assembly, and a hydraulic power
cylinder which transmits control input from the
The tail rotor system consists of two sets of adjustable pedals or SCAS system to the tail rotor tube assembly
pedals connected by tube assemblies, bellcranks, at tail rotor gearbox (figure 11-24).
11-56 Change 5
TM 55-1520-236-23
Figure 11-23.
Change 5 11-56 .1/(11-56.2 blank)
TM 55-1520-236-23
Figure 11-24.
11-57
TM 55-1520-236-23
Figure 11-24.
11-58
TM 55-1520-236-23
1. Gunner control pedals 22. Lever
2. Tube assembly 23. Servo actuator (SCAS)
3. Bellcrank and support 24. Lever
4. Adjuster knob 25. Hydraulic cylinder and support
5. Tube assembly 26. Tube assembly
6. Bellcrank assembly 27. Top stop bolt
7. Tube assembly 28. Bottom stop bolt
8. Magnetic brake 29. Lever
9. Force gradient 30. Tube assembly
10. Rod end bearing 31. Bellcrank
11. Bellcrank and support 32. Tube assembly
12. Tube assembly 33. Tube assembly
13. Pilot control pedals 34. Bellcrank
14. Tube assembly 35. Crosshead
15. Bellcrank 36. Trunnion
16. Tube assembly 37. Tail rotor
17. Bellcrank 38. Guide
18. Tube assembly 39. Screw and washer
19. Lever 40. Guide
20. Tube assembly 41. Screw and washer
21. Transducer
209001-110-3A
Figure 11-24. Tail Rotor Controls (Sheet 3 of 3)
Premaintenance Requirements For 11-73. RIGGING - TAIL ROTOR
Tail Rotor Controls CONTROL SYSTEM .
Conditions Requirements a. If installed, remove access panels (12, 21, 22,
figure 2-2) and access panels (3 and 4 right, 35,45, 53,
Model AH-1P/E/F figure 2-3).
Part No. or Serial No. All b. Accomplish rigging without hydraulic power
unless otherwise stated.
Special Tools None
c. Install all fixed length tube assemblies in the
Test Equipment None anti-torque controls, b u t d o n o t c o n n e c t t u b e
assemblies (7, 18, 30, or 33, figure 11-24). Do not
Support Equipment (S2) connect transducer (21) to lever (22).
Minimum Personnel Two d. Adjust pilot and gunner pedals to approximate
Required midposition with adjuster knobs (4).
Consumable Materials (C43) e. Position pilot pedals even with each other,
Position gunner pedals even with each other. Adjust
Special Environmental N/A and install tube assembly (7). Coat clevis threads with
Conditions corrosion preventive compound (C43) when adjusting
tube assembly. Ensure that exposed threads on tube
(7) do not exceed 1.00 inch as shown on view B.
Change 12 11-59
TM 55-1520-236-23
f. Push right pedal forward against stop. Position that it does not bottom at either extreme position.
lever (24) in position shown in dashed outline in view Install transducer (21) on lever. Install servo actuator
A. Adjust and install tube assembly (18). Coat clevis (23) on lever (22).
threads with corrosion preventive compound (C43) m. Place pilot control pedals even with each
when adjusting tube assembly. Ensure that exposed other. Position arm of magnetic brake (8) square
threads on tube assembly (18) do not exceed 1.00 within 2 degrees of the beam on which brake is
inch as shown in view B. Check to ensure that right mounted. Adjust farce gradient (9) to connect to
pedal is still forward against stop. Adjust top stop bolt bellcrank (11) then extend length of rod end by two
(27) to clear support by 0.005 TO 0.015 inch as and one-half turns and install bolt from the top. Use
shown on detail A. thin aluminum alloy washer under bolt head and
standard steel washer under nut. Tighten locknut on
g. Check to ensure that right pedal is still forward rod end.
against stop. Push forward on piston rod of hydraulic
cylinder (25) to bottom valve. Measure and record n. Check complete tail rotor control system far
dimension X shown on view A. Pivot lever (24) toward security and safetying of components. Install access
position shown by solid outline in view A until panels (12, 21, and 22, figure 2-2, and 35, 45, and 53,
dimension X is decreased by 3.02 inches. Keep figure 2-3).
hydraulic cylinder (25) valve bottomed. Adjust bottom
stop bolt (28) to touch stop. o. Check operatian with hydraulic test stand (S2)
if available. If not available, move controls through
h. R e m o v e t a i l r o t o r b l a d e p i t c h l i n k s a n d full throw manually and ensure that there is no
adjust to 6.115 0.010 inch dimension. Refer to binding or interference.
paragraph 5-104 for instructions to adjust and
install tail rotor blade pitch links. p. Perform tracking check of tail rotor (paragraph
5-115).
NOTE
11-74. PEDALS.
Temporarily install tube assembly (30)
until left pedal has been pushed for- 11-75. DESCRIPTION - PEDALS.
ward against stop.
The pilot and gunner pedal installations are similar.
i. Push left pedal forward against stop and adjust The pedals pivot in support attached beneath the
crosshead to 4.074 inch dimensions from outboard floor. The pedals are connected by short links to a
face of trunnion as shown in view F. Temporarily bellcrank mounted on an adjuster which allows
disconnect tube assembly (30). Adjust tube assembly variable settings for the comfort and efficiency of
(33) to obtain 0.40 inch clearance with bellcrank (34) crew members. A protective boot covers the openings
as shown in view E. around the pedals.
j. Ensure left pedal is still forward against stop. 11-76. REMOVAL - PEDALS.
Position bellcrank (34) as noted in preceding step.
Push forward on piston rod of hydraulic cylinder (25) NOTE
to bottom valve. Adjust tube assembly (30) to fit, then This procedure is the same for both the
lengthen tube by adjusting clevis one turn. Install gunner and pilot tail rotor pedals.
tube. Ensure that exposed threads on tube (30) do not
exceed one inch as shown in view B. a. Disconnect tube assembly (1, figure 11-25)
from bellcrank (19) at front of pedal assembly by
removing cotter pin (18), nut (17), washers (3 and 16)
k. Disconnect servo actuator (23) from lever (22). and bolt (2).
Connect transducer (21) to structure but disconnect
from lever (22). Move pilot right pedal full forward b. Disconnect bellcrank links (4 and 23) from
against stop. Align transducer (21) for installation on pedals (29 and 39) by removing cotter pin (11), nut
lever and check to ensure that it does not bottom. (12), washers (10 and 40), and bolt (41).
i. Move pilot left pedal full forward against stop. c. Obtain access to area under floor. Remove
Align transducer (21) for installation on lever and cotter pin (51), nut (52), washers (45 and 50) and bolt
check to ensure that it does not bottom. If necessary, (44) that secure pedals to support (43). Remove
adjust rod end on transducer and recheck to ensure pedals upward from support.
11-60 Change 12
TM 55-1520-236-23
d. Remove nuts (46 and 48) and washers (47 and
49) from lower ends of four bolts (31 and 35) that pass
through adjuster support (37), boot retainer, floor
panel, and pedals support (43). Remove support
Keep solvent out of bearings.
below floor.
11-77. CLEANING - PEDALS.
Premaintenance Requirements for Pedals
Clean parts with dry cleaning solvent (C112). Use
Conditions Requirements care to avoid removing solid film lubrication from
shank of adjuster clevis and interior surfaces of
Model AH-1S
adjuster knob and housing.
Part No. or Serial No. All
11-78. INSPECTION - PEDALS.
Special Tools None
a. If cracks are suspected, fluorescent penetrant
Test Equipment None inspect bellcrank (19, figure 11-25), links (4 and 23),
clevis (9), pedals (29 and 39), and supports (37 and 43)
Support Equipment None in accordance with TM 43-0103.
Minimum Personnel Two b. Inspect bearings (5, 20, 21, 28 and 42) for
Required roughness, freedom of movement, and wear in
excess of 0.005 inch radial and 0.030 inch axial play.
Consumable Materials (C30), (C31), (C36),
(C43), (C88), (C91), c. I n s p e c t c l e v i s ( 9 ) a n d b e l l c r a n k ( 1 9 ) f o r
(C102), (C112) corrosion, damaged threads, and elongated holes.
Special Environmental None d. Inspect knob (32) for corrosion and damage.
Conditions
e. Inspect links (4 and 23) for corrosion and worn
or elongated bushings.
f. Inspect pedals (29 and 39) and support (37 and
e. Detach, bellcrank (19) from links (4 and 23) and 43) for corrosion and elongated holes.
adjuster clevis (9) by removing. bolts (8 and 13), nuts
(15 and 27), washers (6, 7, 22 and 25), and cotter pins 11-79. REPAIR OR REPLACEMENT -
(14 and 26). PEDALS.
f. If disassembly of adjuster is required, remove a. Replace parts which fail to meet inspection
nut (34) and retaining washer (33) and unscrew knob requirements of paragraph 11-78.
(32) from threaded end of clevis (9). Slide clevis out of
adjuster support. Handle parts with care to avoid b. Polish out all scratches and corrosion that do
damaging threads and mating surfaces coated with not exceed 0.005 inch depth, using 180 grit or finer
dry film lubricant. sandpaper (C102). Polish to a smooth, scratch free
finish with abrasive cloth (C36). Blend edges of repair
into surrounding area. Apply chemical film cpating
(C31) to repaired area. Prime repaired areas with
primer (C88 or C91).
c. Refer to paragraph 11-13 for procedure to
Cleaning solvent is flammable and toxic. replace bearing (5, 21 and 28, figure 11-25).
Provide adequate ventilation. Avoid
prolonged breathing of solvent vapors d. Replace worn or elongated bushings (24) in
and contact with skin or eyes. links (4 and 23) as follows: (AVIM)
11-61
TM 55-1520-236-23
Figure 11-25.
11-62
TM 55-1520-236-23
Figure 11-25.
11-63
TM 55-1520-236-23
(1) Press old bushing from link. and two bolts (35) through adjuster support, boot
retainer, floor panel, and pedal support. Use one
washer (30 and 36) under each bolt head and one
washer (47 and 49) under each nut (46 and 48).
d. Insert pedals (29 and 39) down through boot
Cleaning solvent is flammable and toxic. slots. Align holes in support. Install bolt (44) with one
Provide adequate ventilation. Avoid washer (45), from left side through support and both
prolonged breathing of solvent vapors pedals. Install washer (50), nut (52) and cotter pin
and contact with skin or eyes. (51 ).
(2) Clean hole in link with clean cheese cloth
e. Align a link (4 or 23) from bellcrank (19) to inner
(C30) dampened with dry cleaning solvent (C112).
side of pedal. Place one washer (40) on bolt (41), and
insert through pedal and Iink. Install safety washer
(3) Prime outer race of bushing with primer (spacer) (10), nut (12), and cotter pin (11) on inboard
(C88 or C91) and press new bushing into link (4 or 23). end of bolt. Attach link to other pedals in the same
manner.
(4) Line ream hole in bushing (24) to 0 . 2 4 9 5
TO 0.2505 inch diameter. Polish to a smooth scratch f. Align tube assembly (1) on forward end of
free finish with abrasive cloth (C36). bellcrank (19). Install bolt (2), washers (3 and 16), nut
(17) and cotter pin (18).
e. Replace bellcrank (19) or pedals (29 and 39)
when damage to bearings (20 or 42) exceeds limits of g. Check installation to ensure that all cotter pins
paragraph 11-78. are installed.
11-80. INSTALLATION - PEDALS.
11-81. OPERATIONAL CHECK - PEDALS.
NOTE
a. Adjust the position of pedals by rotating knob
This procedure is typical for either pilot or (32, figure 11-25) to set a variety of pedal positions.
gunner pedal and adjuster assemblies. Actuate the pedals in each position through full range
of travel and check for freedom of movement and any
binding.
a. Coat clevis threads with lubricant (C43) and b. Check tail rotor rigging to ensure that rigging
insert threaded end of clevis (9, figure 11-25) into h a d n o t b e e n d i s t u r b e d by pedal installation
adjuster support (37) from flared lower end. Position (paragraph 11-73).
knob (32) on opposite end, with lip engaged in
retaining groove. Screw knob on clevis threads.
Install retaining washer (33) and nut (34) on small
threaded end. 11-82. MAGNETIC BRAKE - TAIL
ROTOR CONTROLS.
b. Align pedal interconnecting bellcrank (19) in
adjuster clevis (9). Install bolt (8) from top through
clevis and bellcrank. Use aluminum alloy washers (6
and 7) under bolt head and under nut. Secure nut (15) 11-83. DESCRIPTION - MAGNETIC
with cotter pin (14). In the same manner, attach two BRAKE - TAIL ROTOR CONTROLS.
links (4 and 23) to bellcrank, using bolts (13), washers
(22 and 25), nut (27) and cotter pin (26). A magnetic brake and force gradient assembly are
connected to the linkage for force trim and control
c. P o s i t i o n p e d a l s u p p o r t ( 4 3 ) u n d e r f l o o r centering functions. The brake is secured on the right
openings, with open sides of pedal slots forward. main beam, and has an arm on its rotary shaft which
Place boot retainer (38) and adjuster assembly over can be braked and held at any point of travel by use of
floor openings. Align holes and install two bolts (31) a switch on the cyclic control stick.
11-64 Change 3
TM 55-1520-236-23
Premaintenance Requirements for
Magnetic Brake in Tail Rotor
Control System
Conditions Requirements
Model AH-1S Do not allow solvent to enter bearings or
electrical components.
Part No. or Serial No. None
Special Tools None
11-86. CLEANING - MAGNETIC BRAKE
Test Equipment None - TAIL ROTOR CONTROL.
Support Equipment None
Clean exposed surface of magnetic brake with a clean
Minimum Personnel Two cloth dampened with dry cleaning solvent (C112).
Required
Consumable Materials (C88), (C91), (C122)
11-87. REPAIR OR REPLACEMENT -
Special Environmental None MAGNETIC BRAKE - TAIL ROTOR
Conditions CONTROLS.
11-84. INSPECTION - MAGNETIC BRAKE a. Clean up minor corrosion and touch up with
primer (C88 or C91). If corrosion damage is severe
- TAIL ROTOR CONTROLS.
enough to affect function, replace the magnetic
brake.
Refer to paragraph 11-57.
b. Replace magnetic brake assembly if damaged
11-85. REMOVAL - MAGNETIC BRAKE - or malfunctioning.
TAIL ROTOR CONTROLS.
a. Turn electrical power off. 11-88. INSTALLATION - MAGNETIC
BRAKE - TAIL ROTOR CONTROLS.
a. Remove access panels.
a. P r i o r t o i n s t a l l a t i o n o f m a g n e t i c b r a k e
c. 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
assembly, check the magnetic brake assembly, check
receptacle on magnetic brake.
the magnetic brake assembly to make sure the arm is
d. Detach force gradient (9, figure 11-24) from properly located on the shaft. Mark F on the arm
arm of magnetic brake by removing cotter pin, nut must be 90 degrees from line on end of shaft (view G,
and washers, and from bellcrank (11) by removing figure 11-24).
cotter pin, nuts, washers, and bolts.
b. P o s i t i o n m a g n e t i c b r a k e a s s e m b l y ( 8 ) t o
e. Detach magnetic brake (8) assembly from mounting holes on outboard side of beam, in gunner
structure by removing four bolts and washers. right side console between walking beam and
bellcrank with the electrical receptacle facing
forward and arm on lower side pointing outboard (to
right) at midtravel. Install four attaching bolts with
thin washers.
Cleaning solvent is flammable and toxic. c. Connect electrical connector to receptacle on
Provide adequate ventilation. Avoid magnetic brake (8).
prolonged breathing of solvent vapors
and contact with skin or eyes. d. Install force gradient (paragraph 11-97).
11-65
TM 55-1520-236-23
11-89. FORCE GRADlENT - TAIL b. Detach force gradient rod end bearing
ROTOR CONTROLS. from bellcrank (11) by removing cotter pin,
washers, and bolt.
11-90. D E S C R I P T I O N - FORCE
c. Detach force gradient from arm on magnetic
GRADIENT - TAIL ROTOR CONTROLS. brake by removing cotter pin, nut and washer.
A force gradient is used in the tail rotor control system 11-93. CLEANING - FORCE GRADIENT -
for pedal centering and force trim functions. The force
TAIL ROTOR CONTROLS.
gradient is a link equipped with an internal spring and
connects the magnetic brake arm to a bellcrank of the
Refer to paragraph 11-66.
tail rotor controls. Although similar in appearance the
lateral and fore-and-aft force gradients are different
from the tail rotor force gradient and are not
11-94. DISASSEMBLY - FORCE
interchangeable.
G R A D l E N T - TAIL ROTOR CONTROLS
(AVIM).
Premaintenance Requirements for Force Refer to paragraph 11-67.
Gradient in Tail Rotor Control System
11-95. REPAIR OR REPLACEMENT -
FORCE GRADlENT - TAIL ROTOR
Conditions Requirements CONTROLS (AVIM).
Model AH-1S Replace bearing, sleeve, and nuts as necessary.
Part No. or Serial No. All a. Fluorescent penetrant inspect housing per
MIL-I-6866 (reference TM 55-1500-204-25/1) after
Special Tools None bearing removal.
Test Equipment None
b. Roll stake sleeve both sides.
Support Equipment None
c. Chamfer 0.030 inch depth x 45 degrees each
side of hole in housing.
Minimum Personnel Two
Required d. Coat sleeve ID and OD, bearing OD, and
housing bore with wet zinc chromate primer (C91)
Consumable Materials (C138)
during assembly.
Special Environmental None
Conditions 11-96. ASSEMBLY - FORCE GRADlENT
- TAIL ROTOR CONTROLS (AVIM).
a. Assemble spring (10, figure 11-23) and guides
(9 and 11) on shaft (8) and install one nut (7) onto shaft.
11-91. INSPECTION - FORCE GRADlENT with edge of nut adjacent to guide (11) on threaded
- TAIL ROTOR CONTROLS. end of shaft.
Refer to paragraph 11-64. b. Preload spring (10) on shaft (8) as follows:
(1) Apply a load of 2.5 T0 3.0 pounds on spring
11-92. REMOVAL - FORCE GRADIENT - of gradient. Measure spring length while at this load.
TAIL ROTOR CONTROLS.
(2) Tighten nut (7) against guide (11) until
a. Remove access panels as necessary for access length of spring (10) is the same as when under load
to force gradient (9, figure 11-24). (step (1) above).
11-66 Change 5
TM 55-1520-236-23
c. Install nut (6) on shaft (8) adjacent to the nut (7) e. Make certain preload on spring is still same as
installed. recorded in step b(1).
d. Hold first nut (7) with wrench or other suitable f. Insert spring assembly (1) into cylinder (3).
device and tighten nut (6) tightly against it as a
jamnut.
Change 5 11-66.1/(11-66.2 blank)
TM 55-1520-236-23
g. Slide center hole of cap (2) over end of spring disturbances yet maintains high quality
shaft (1) with thread end of cap toward cylinder (3). control/response characteristics for pilot inputs.
Rate gyros (located in sensor/amplifier unit) provide
h. S c r e w c a p ( 2 ) i n t o c y l i n d e r ( 3 ) u n t i l a l l electrical signals to airframe damping against
noticeable end play of spring assembly (1) is removed. external disturbances. A transducer mounted on the
transmission tail rotor driveshaft quill (26, figure 11-
i. Lockwire cap (2) to cylinder (3) with wire (C138) 26) and a bracket on the fifth mount monitors pylon
as shown in figure 11-23, to eliminate motion in pitch motion. Control motion transducers provide a
either direction. compensating electrical signal to prevent system
from opposing the pilot during maneuvers and to
j. Install remaining nut (5) onto shaft of spring augment control/response characteristics.
assembly (1), to be used as jam nut against rod end at
installation. 11-100. q q DESCRIPTION -
STABILITY AND CONTROL
11-97. I N S T A L L A T I O N - FORCE AUGMENTATION SYSTEM (SCAS).
GRADlENT - TAIL ROTOR CONTROLS.
The SCAS consists of the following: two circuit
a. Install rod end bearing (10, figure 11-24) in breakers, a control panel, sensor amplifier unit;
threaded end of spring shaft, with jam nut in place. three-axis rate sensor (three rate gyros in one unit);
Final adjustment is made during rigging procedure. three servo actuators; three solenoid-controlled
hydraulic valves; and three control motion
b. Attach force gradient to arm on magnetic brake transducers. The armament compensator unit
by installing cotter pin, nut, and washer. supplies signals to each sensor amplifier module
c. Rig and install force gradient to bellcrank (11) (SAM) when the guns are fired. All equipment is
(paragraph 11-73). interconnected with multi conductor cable
assemblies for transferring signal data and power
11-98. STABILITY AND CONTROL within the system. The SCAS receives 28 Vdc power
AUGMENTATION SYSTEM (SCAS). from the essential do bus through the circuit breaker
labeled SCAS PWR. When the SCAS is engaged, 28
Vdc power is also supplied by the battery so that loss
11-99. q D E S C R I P T I O N - S T A B I L I T Y of power to the essential do bus will not disengage
AND CONTROL AUGMENTATION SYSTEM SCAS. AC power is supplied by the 115 Vac essential
(SCAS). bus through the circuit breaker labeled SCAS PWR.
Hydraulic power is provided to the longitudinal and
The SCAS is a three axis stability and control lateral electrohydraulic servo actuators by the No. 2
augmentation system. It is integrated into fore and hydraulic system while the directional
aft, lateral, and directional (anti-torque) flight controls electrohydraulic servo actuator is supplied by the No.
to improve stability and handling qualities of the 1 hydraulic system. The three servo-actuator
helicopter. The system consists of electro-hydraulic assemblies include one control tube attached to one
servo actuator control tube assemblies, fore-and-aft end of each servo-actuator and a clevis attached to
cyclic, lateral cyclic, and anti-torque, control motion the other end. The control tube and clevis provide for
transducers, pitch, roll, and yaw sensor/a ampIifier the mounting of the servo actuator in series in the
unit, pylon compensator unit, pylon transducer and helicopter mechanical control systems. The internal
control panel. The sensor/amplifier unit produces piston and shaft of the actuator is hydraulically moved
electrical inputs to servo actuators. Servo actuators in and out of the actuator case to provide for
are installed as series extensible links in appropriate mecahnical displacement of helicopter controls. The
flight controls and provide compensating control internal centering and locking feature provides a solid
motions to augment stability and control of the link in the helicopter control linkage if hydraulic
helicopter. Operation of servo actuators is not felt in pressure to the actuator is lost or the channel is
pilot controls provided proper control friction is disengaged. An internal servo hydraulic valve
present. Servo actuators are limited to 12.5 percent provides for controlling hydraulic pressure to the
of the pilot control authority, and center and lock in piston in the proper direction of displacement. Servo
case of electrical and/or hydraulic failure. SCAS actuators are electro-hydraulically operated and
provides a highly damped airframe for external receive command signals from sensor amplifier unit
11-67
TM 55-1520-236-23
to hydraulically driven helicopter control system. Amplifier Unit contains rate gyros to sense helicopter
Servo actuators are limited toil 12.5 percent of total rates, power circuits to power other parts of system,
pilot control authority. Pitch and roll servo actuators and compensating networks and valve drivers to
control movement of the swashplate with no provide command signals to servo actuators. The
resultant motion of the cyclic stick as a result of sensor amplifier unit is housed in a metal case with
external forces. Yaw servo actuator moves the tail four holddown attach points. Front of the case
rotor blade pitch angle in same manner as pitch and contains two pushbutton switches, labeled GYRO
roll servo actuators move helicopter swashplate. Yaw TEST and ACTR TEST and a hinged access door held
servo actuator control authority is also limited to in place by two captive screws. Right side of case
12.5 percent of control authority available to the contains one fuse and fuseholder, one spare fuse and
pilot through control pedals. fuseholder, and one 41 pin connector, for transferring
signal data and power within system. The aft wall of
case is utilized as a common mount for three rate
Premaintenance Requirements for SCAS gyros within case. Rate signal from rate gyro and
control position signal, from control motion
transducers, and actuator feedback signal are
Conditions Requirements summed and shaped in compensating network to
Model AH-1S provide desired helicopter control response.
Part No. or Serial No. All
11-104. ~ q DESCRIPTION -
Special Tools None SENSOR AMPLIFIER UNIT (SCAS).
Test Equipment None The sensor amplifier unit (SAU) contains three sensor
amplifier modules (SAM). One SAM is used for each
Support Equipment None channel (PITCH, ROLL and YAW). They are housed in
a metal case with four holddown attach points. The
Minimum Personnel One front of each SAM contains two pushbutton switches,
Required labeled RATE TEST and ACTR TEST, and a NULL light.
Each SAM is held in place by four captive screws. The
Consumable Materials None switches isolate inputs from the rate gyros and servo
actuators in conjunction with the built-in test
Special Environmental None equipment (BITE). If, after 30 seconds, a NULL lamp is
Conditions lighted and the light extinguishes when the RATE
TEST switch is depressed, a rate gyro or
interconnecting wiring may be defective. Similarly, if
a NULL lamp is lighted, and depressing the ACTR
TEST switch causes the NULL lamp to extinguish, a
11-101. TROUBLESHOOTING AND servo actuator or interconnecting wiring may be
OPERATIONAL CHECK - (SCAS). defective. When, either No. 1 or No. 2 hydraulic
pressure is lost, the No. 1 or No. 2 hydraulic pressure
Refer to TM 11-1520-236 series manuals. switch will close. This illuminates the No. 1 HYDR
PRESS or the No. 2 HYDR PRESS caution light and
11-102. SENSOR AMPLIFIER UNIT disengages the sensor amplifier module(s) (YAW or
PITCH and ROLL) relay(s) circuit, thus disengaging
(SCAS).
the affected channel servo actuator.
11-103. q DESCRIPTION - SENSOR
AMPLIFIER UNIT (SCAS). NOTE
Sensor Amplifier Unit located in pilot compartment Refer to TM 11-1520-236 series
left rear is operationally the center of SCAS and manuals for removal, troubleshooting,
contains components and circuitry to implement testing and replacement of sensor
stabilization of the AH-1S helicopter. Sensor amplifier unit.
11-68 Change 7
TM 55-1520-236-23
11-105. ~ INSPECTION - SENSOR 11-108. @ PYLON COMPENSATION
AMPLIFIER UNIT (SCAS). UNIT (SCAS).
Inspect sensor amplifier, (4, figure 11-26) for the 11-109. q D E S C R I P T I O N - PYLON
following conditions. COMPENSATION UNIT (SCAS).
a. Loose mounting (loose mounting screws and The pylon compensation unit (PCU) (3, figure 11-26)
insufficient electrical bonding). is located aft and above SCAS sensor amplifier unit.
Only 28 Vdc is supplied to the unit from SCAS control
panel. The Pylon Compensation Unit electrically
b. Loose control channel assemblies.
detects motion of the pylon with respect to the
airframe, and operates in conjunction with SCAS to
c. Loose or inoperative NO-GO indicator lights.
provide automatic damping. Under certain conditions
of power loading, g-loading and velocity, it is possible
d. Burned fuse.
to set up a Iow frequency oscillation which causes the
pylon to lean or rock in a circular pattern opposite to
e. Account for spare fuse.
t h e d i r e c t i o n o f rotor rotation. The Pylon
Compensation Unit consists of a compensation
network and one pylon motion transducer. The
f. Loose or corroded module mounts.
transducer measures fore and aft pylon motion
relative to the airframe. The compensation network
g. Corroded or damaged connectors, internal or
provides necessary signal shaping and phasing to
external.
apply corrective signals to the roll channel of SCAS,
effectively damping the pylon suspension system to
cancel undesired motion.
11-106. E q INSPECTION - SENSOR NOTE
AMPLIFIER UNIT (SCAS).
Refer to TM 11-1520-236 series
manuals for removal and installation of
Inspect sensor amplifier (4, figure 11-27) for the
pylon compensation unit.
following conditions:
a. Loose mounting (loose mounting screws and
11-110. @ INSPECTION - PYLON
insufficient electrical bonding). COMPENSATION UNIT (SCAS).
b. Loose control channel assemblies. Inspect the pylon compensation unit (3, figure 11-26)
for the following:
c. Loose or inoperative NO-GO indicator lights.
a. Loose mounting or bonding.
d. Loose or corroded module mounts
b. Damaged or corroded connectors.
e. Corroded or damaged connectors, internal or C. Case damage.
external.
d. Proper operation. Refer to TM 11-1520-236
series manuals for procedure.
11-107. REPAIR OR REPLACEMENT - 11-111. q REPAIR OR REPLACEMENT-
SENSOR AMPLIFIER UNIT (SCAS) (AVIM). PYLON COMPENSATION UNIT (SCAS).
a. Tighten loose mounting screws or bolts. a. Tighten loose connections.
b. Replace damaged parts. Refer to TM 11-1520- b. Replace damaged parts. Refer to TM 11-1520-
236 series manuals. 236 series manuals.
11-69
TM 55-1520-236-23
Figure 11-26.
11-70
TM 55-1520-236-23
11-112. Q m ARMAMENT signals are applied to the armament compensation
UNIT (SCAS). unit and, when the M197 gun is fired, output signals
COMPENSATION
are applied to the SCAS servo actuators to provide
recoil damping. q q The ACU receives 115 Vac
11-113. ~ q DESCRIPTION -
power from the RECOIL COMP switch located on the
ARMAMENT COMPENSATION UNIT
pilot armament control panel. The magnitude of the
(SCAS).
ACU output signals can beset to either LO-MED-HI by
The armament compensation unit (ACU) (3, figure using the RECOIL COMPEN selector switch located
11-27) is located in the left side of fuselage forward of on the right side of the pilot instrument panel.
the wing. When the weapon is fired, three-axis turret
position signals are applied to the ACU to provide NOTE
weapon recoil damping of helicopter movement. The
armament compensation unit electrically interfaces Refer to TM 11-1520-236 series
the turret system with the Stability and Control manuals for removal and installation of
Augmentation System (SCAS). Turret position armament compensation unit.
Figure 11-27.
11-71
TM 55-1520-236-23
11-114. q q INSPECTION - b. Damaged or corroded connectors.
ARMAMENT COMPENSATION UNIT
(SCAS). c. Case damage.
d. Proper operation. Refer to TM 11-1520-236
Inspect the armament compensation unit for the
series manuals for procedure.
following:
a. Loose mounting or bonding.
11-119. E q REPAIR OR
b. q q Damaged or corroded connectors. REPLACEMENT - T H R E E - A X I S R A T E
SENSOR (SCAS).
c. Case damage.
a. Tighten loose connections.
d. Proper operation. Refer to TM 11-1520-236
series manuals for procedure.
b. Replace damaged parts. Refer to TM 11-1520-
236 series manuals.
11-115. la q REPAIR OR
REPLACEMENT ARMAMENT
COMPENSATION UNIT (SCAS). 11-120. CONTROL MOTION
TRANSDUCER (SCAS).
a. Tighten loose connections.
b. Replace damaged parts. (Refer to TM 11-1520-
11-121. DESCRIPTION - CONTROL
236 series manuals. MOTION TRANSDUCER (SCAS).
11-116. q q THREE-AXIS RATE Each control channel (pitch, roll and yaw) receives
signals from an individual transducer. The signal is
SENSOR (SCAS).
processed and summed with rate signals from rate
gyros to provide correction signals for instantaneous
11-117. DESCRIPTION - THREE-AXIS control of helicopter motion. Transducer signals are
RATE SENSOR. one source of control of servo actuators which allow
pilot to fly system with less effort and provide
Three-axis rate sensor (5, figure 11-27) consists of a helicopter flight stabilization. Control motion
mounting surface and holes for four hold-down transducer consists of an internal linear
screws, one cable assembly, and one connector. potentiometer, a cylindrical case, a movable shaft,
Three rate gyros within the package sense helicopter two attach points (one on case and one on shaft), and
rates in each of the three stabilized axis. Electrical an electrical connector for transferring signal data to
rate signal outputs from each of the rate gyros are the sensor amp unit.
applied to each of the sensor amplifier modules
compensation and logic networks.
11-122. REMOVAL - CONTROL MOTION
NOTE TRANSDUCER (SCAS).
Refer to TM 11-1520-236 series a. Turn all electrical power off.
manuals for removal and installation of
three-axis rate sensor. b. Remove access panels.
11-118. INSPECTION - THREE-AXIS C. Disconnect electrical connector from fore-and-
RATE SENSOR (SCAS). aft (pitch), Iateral (roll), or directional (yaw) transducer
(8, 13 or 14, figure 11-26 or 11-27). Detach cylinder
Inspect the three-axis rate sensor (5, figure 11-27), or transducer from fuselage structure by removing
for the following: bolt, washer, spacer, and washer. Detach adjustable
rod end from bellcrank by removing nut, washers, and
a. Loose mounting or bonding. screw.
11-72
TM 55-1520-236-23
1 1 - 1 2 3 . INSPECTION - CONTROL (2) Position stainless steel washer on bait.
MOTION TRANSDUCER (SCAS). Install bolt with washer through the rod end bear-
ing, then slide spacer and washer on bolt. Align
Inspect control motion transducers as follows: bolt to outboard side of bellcrank; then secure
with bolt and nut.
a. Bearings for binding corrosion and wear in
excess of 0.005 inch radial and 0.030 inch axial play. NOTE
b. Attachment for security. Attach rod end to bellcrank only after
completion of rigging. (Refer to
c. Electrical connector for condition. paragraph 11-29).
d. Threads for damage. (3) Position stainless steel washer on screw.
Position c y l i n d e r b e a r i n g o n i n b o a r d s i d e o f
11-123.1. CALIBRATION - CONTROL bracket at fuselage. Position washer between
MOTION TRANSDUCER (SCAS). bracket and bearing. T h e n i n s t a l l s c r e w w i t h
washer and tighten.
Calibrate the SCAS transducer as follows:
b. Install roll control motion transducer (15,
a. Disconnect the transducer from the aircraft figure 11-13).
wiring and airframe.
(1) A l i g n r o l l control motion transducer
b. Support the transducer in order to measure cylinder housing bearing to fuselage structure with
the position of the output shaft length per figure electrical wire inboard.
11-27.1.
(2) Position stainless steel washer on bolt.
c. Using multimeter (T-2 or T-3), measure the install bolt with washer through the rod end bear-
resistance across pins A and B. ing, then slide spacer and washer on bolt. Align
bolt to outboard side of bellcrank; then secure
d. The resistance (OHMS) at output shaft posi- with bolt and nut.
tions 1, 2 and 3 must be within the tolerance
specified in figure 11-27.1. NOTE
Attach rod end to bellcrank only after
11-124. REPAIR OR REPLACEMENT - completion of rigging (paragraph 11-
CONTROL MOTION TRANSDUCER (SCAS). 29).
(3) Position stainless steel washer on screw.
a. Replace adjustable rod end when worn or Position c y l i n d e r b e a r i n g o n i n b o a r d s i d e o f
binding. Nominal length of transducer in neutral bracket at fuselage. Position washer between
position measured between centers of cylinder bracket and bearing. T h e n i n s t a l l s c r e w w i t h
bearing and rod end bearing should be 6.18 inch. washer and tighten.
b. Tighten loose attachments. c. Install yaw control motion transducer (21,
figure 11-24).
c. Replace transducer with damage in excess of
that listed in paragraph 11-123. (1) A l i g n y a w c o n t r o l m o t i o n t r a n s d u c e r
cylinder housing bearing to fuselage structure.
11-125. INSTALLATION-CONTROL MO-
TION TRANSDUCER (SCAS).
a. Install pitch control motion transducer (13, (2) Position stainless steel washer on bolt.
figure 11-12). Install bolt with washer through the rod end bear-
ing, then slide spacer and washer on bolt. Align
(1) A l i g n p i t c h c o n t r o l m o t i o n t r a n s d u c e r
bolt to outboard side of bellcrank; then secure
cylinder housing bearing to fuselage structure with
with bolt and nut.
electricaI wire inboard.
Change 5 11-73
TM 55-1520-236-23
NOTE 11-130. ~ INSTALLATION - PYLON
Attach rod end to directional bellcrank TRANSDUCER (SCAS).
oniy after completion of r i g g i n g
(paragraph 11-73). Install transducer (5, figure 11-26) on bracket
(19), using screw (17), washers (18 and 20) and nut
(3) Position stainless steel washer on screw. (21).
Position cylinder bearing on inboard side of
bracket at fuselage. Position washer between b. Install transducer (5) on transmission tail rotor
bracket and bearing. T h e n i n s t a l l s c r e w w i t h driveshaft quill (26), using screw (22), washers (23
washer and tighten. and 24), and nut (25).
11-126. TEST PROCEDURE - CONTROL c. Remove covers from transducer plug and
MOTION TRANSDUCER (SCAS). receptacles. Engage and secure connector.
Refer to TM 11-1520-236 series manuals. d. Close and secure transmission cowling.
11-131. SOLENOID VALVE (SCAS).
11-127. ~ PYLON TRANSDUCER
(SCAS).
11-132. DESCRIPTION - SOLENOID
VALVES (SCAS).
1 1 - 1 2 8 . .q D E S C R I P T I O N - P Y L O N
TRANSDUCER (SCAS).
The three solenoid valves are two position valves
which control hydraulic pressure to servo actuators.
Pylon transducer (5, figure 11-26) is located between
In de-energized position, there is not hydraulic
pylon fifth mount and transmission tail rotor
pressure, and servo actuators are mechanically
driveshaft quill as shown in figure 11-24. The locked in center position. When solenoid valve is
transducer senses pitch motion of pylon. Output energized from the SCAS pitch, roll or yaw engage
signals of transducer are inserted into pylon switch, hydraulic pressure is applied to servo actuator
compensation unit where signals are summed, to unlock actuator and move actuator piston in
shaped, attenuated, and inserted into the roll response to command signals. Solenoid valve
channel of sensor amplifier for retardation of pylon consists of metal case, three hydraulic ports (labeled
oscillation. CYL, RET, and PRESS) to provide for hydraulic
connection to helicopter hydraulic system and servo
11-129. ~ REMOVAL - PYLON actuators in the SCAS. Two attach points are provided
TRANSDUCER (SCAS). for installation on helicopter structure. One 6 pin
electrical connector is attached to case to provide
a. Turn electrical power off. electrical connection to system.
b. Gain access to transmission. NOTE
c. Disconnect transducer plug and protect with Refer to paragraph 7-68 for removal,
cover. inspection, and installation procedures
for SCAS hydraulic solenoid valves.
d. Disconnect transducer (5, figure 11-26) from
transmission tail rotor driveshaft quill (26), by 11-133. CONTROL PANEL (SCAS).
removing screw (22), washers (23 and 24), and nut
(25).
11-134. DESCRIPTION - CONTROL
e. Disconnect transducer (5) from bracket (19) on PANEL (SCAS).
fifth mount (16) by removing screw (17), washers (18
and 20) and nut (21). Remove transducer. The SCAS control panel (15, figures 11-26 and 11-27
NOTE contains a POWER switch for applying 28 Vdc
(essential bus) and 115 Vac operating voltages to the
For inspection and repair procedures,
system. The circuits are protected by the SCAS PWR
refer to paragraph 11-123 and 11-124.
11-74 Change 5
TM 55-1520-236-23
dc and SCAS PWR ac circuit breakers. The panel also The NO-GO lights have a built-in press-to-test
contains three channel engage switches which feature for ensuring that the indicator is operational.
energize electric solenoid valves controlling hydraulic ~ This feature works only prior to channel
pressure to the system. The panel has three NO-GO engagement.
lights; one associated with each PITCH, ROLL, and
YAW channel engage switch. These lights are
illuminated during the warmup to indicate the
NOTE
presence of current in each associated channel
actuators. When engagement is made, the NO-GO
Refer to TM 11-1520-236 series
lights are locked out of the circuit and do not operate repair, and
m a n u a l s f o r removal,
as malfunction indicators. Disengaging a channel,
installation procedures.
however, restores the associated light to operation.
Change 5 11-74.1
TM 55-1520-236-23
Figure 11-27.1.
paragraph 11-124a.
11-74.2 Change 9
TM 55-1520-236-23
11-135. INSPECTION - CONTROL PANEL 11-138. R I G G I N G - ELEVATOR
(SCAS). CONTROL SYSTEM.
a. Inspect control panel for security. a. Rig cyclic controls if not previously
accomplished (paragraph 11-29).
b. With electrical power ON, check control panel
for the following: b. I f i n s t a l l e d , r e m o v e r i g h t s i d e a c c e s s ( 9 ,
figure 2-3) and tailboom access door (21, figure
(1) Indicator lights for operation. 2-2). Install all components of the elevator control
system, but leave tube assembly (18, figure 11-28)
(2) Switches for security and proper operation. disconnected from swashplate inner ring (20), and
tube (7) disconnected from elevator horn. Support
11-136. ELEVATOR CONTROL tube assembly (18) so that control linkage can be
SYSTEM. moved during rigging procedure.
11-137. DESCRIPTION - ELEVATOR c. Adjust and attach tube assembly (7) as follows:
CONTROL SYSTEM.
(1) Position elevator with trailing edge up so that
The elevator control system consists of two elevator
there is 0.055 to 0.065 inch clearance between forward
assemblies, a horn assembly and a mechanical
side of stop (4) and stop (3) on horn (detail C, figure 11-
control linkage of tube assemblies and bellcranks
28).
connected in series from the right forward
swashplate horn to the elevator horn. Movement of
(2) Pull tube assembly (7) to its extreme aft
the cyclic control stick in the fore and aft direction
position. Ensure that bellcrank (12) is dead centered
actuates the swashplate. This movement is
with control tube (11).
transmitted through the elevator control linkage and
changes the angle of attack of the elevator
(3) Adjust length of control tube (7) to fit arm on
assemblies (figure 11-28).
elevator horn and attach. Do not exceed 1.0 inch
exposed thread (detail B, figure 11-28).
Premaintenance Requirements for
d. A d j u s t a n d a t t a c h t u b e a s s e m b l y ( 1 8 ) a s
Elevator Control System Rigging
follows:
(1) Hold pilot cyclic stick full forward against
Conditions Requirements
stop.
Model AH-1S
(2) Position elevator with trailing edge down so
Part No. or Serial No. All that there is a 0.055 TO 0.065 i n c h c l e a r a n c e
between aft side of stop (4) and stop (3) on horn,
Special Tools None (detail C, figure 11-28).
Test Equipment None (3) Adjust length of tube assembly (18) to fit on
bolt at inboard side of right forward horn of
Support Equipment (S2) swashplate inner ring (20), then lengthen tube
assembly (18) by one turn of rod end to compensate
Minimum Personnel Two for hydraulic valve position.
Required
(4) Ensure that not more than one inch of
Consumable Materials None thread is exposed at rod end (detail A, figure 11-28).
Attach control tube bolt on horn of swashplate inner
Special Environmental None ring (20).
Conditions
e. Check rigging with hydraulic boost on.
Change 7 11-75
TM 55-1520-236-23
Figure 11-28.
11-76
TM 55-1520-236-23
NOTES:
1. With elevator positioned (trailing edge up) so that there is 0.055 to 0.065 clearance
between forward side of stop on horn and stop on support.
2. With elevator positioned (trailing edge down) so that there is 0.055 to 0.065 clearance
between aft side of stop on horn and stop on support.
1. Right elevator 11. Tube assembly
2. Left elevator 12. Bellcrank and support
3. Stops (on horn) 13. Tube assembly
4. Stop (on support) 14. Bellcrank and support
5. Elevator horn assembly 15. Tube assembly
6. Guide (4 reqd) 16. Lift beam
7. Tube assembly 17. Bellcrank
8. Walking beam and support 18. Tube assembly
9. Tube assembly 19. Fore-and-aft cyclic hydraulic cylinder tube
10. Walking beam and support 20. Swashplate inner ring
209001-113-2A
Figure 11-28. Elevator Control System (Sheet 2 of 2)
(1) U s i n g h y d r a u l i c t e s t s t a n d , ( S 2 ) a p p l y i. Perform maintenance test flight Refer to TM
hydraulic power to helicopter. 55-1520-236 MTF.
(2) P o s i t i o n p i l o t c y c l i c s t i c k f u l l f o r w a r d
against stop. Check that trailing edge of elevator 11-139. ELEVATOR INSTALLATION.
points to rivet R o n t a i l b o o m w i t h i n 0 . 4 0 i n c h
and that there is a 0.055 TO 0.065 inch clearance ELEVATOR
11-140. DESCRIPTION -
between stops (3 and 4) as described in step d.(2).
Adjust tube assembly (7) if necessary as described in
INSTALLATION.
step c.
The elevator installation consists of two elevator
assemblies and a horn assembly (12, figure 11-29).
(3) Move pilot cyclic stick aft. Check for a
Each elevator assembly is a horizontal airfoil section
clearance of 0.055 TO 0.065 inch between stops (3
built up on a spar tube, which is inserted into a
and 4) when bellcrank (12) passes thru dead center;
projecting end of the horn assembly and secured by a
also, that elevator trailing edge points to rivet P
single bolt. The horn assembly is mounted
within 0.4 inch bellcrank (12) is at dead center as
horizontally through the sides of the tail boom, and is
described in step c(2).
secured to the structure by supports, which serve as
bearings for rotational movement. A control arm on
(4) Position pilot cyclic stick full aft against
the horn provides attachment for elevator control
stop. Check trailing edge of elevator to ensure that it
system linkage from the fore-and-aft cyclic control
stops at rivet S within 0.4 i n c h .
system at the swashplate.
f. Move pilot cyclic stick through full range fore-
Premaintenance Requirements for Elevator
and-aft and ensure that there is no binding or
interference in the elevator control system.
Conditions Requirements
g. Disconnect hydraulic test stand.
Model AH-1S
h. Check complete elevator control system for
security and safetying of components. Install ac- Part No. or Serial No. All
cess panel (9, figure 2-3) and tailboom access door
(21, figure 2-2). Special Tools None
Change 5 11-77
TM 55-1520-236-23
(2) Remove nuts (15 and 25), washers (16 and
Conditions Requirements
26), bolts (7 and 20), and washers (8 and 21).
Test Equipment Dial Indicator (3) Remove bolts (11) and washers (10).
Remove upper half of support assembly (9), shim (6)
Support Equipment None and shims (17).
Minimum Personnel Two (4) Remove upper half of support assembly
Required in the same manner outlined in the preceding step.
Consumable Materials (C31), (C41), (C37), (5) Remove bolts (13) and washers (14).
(C88), (C91), (C110) Remove lower half of support assembly (9) and shim
(6).
Special Environmental None
Conditions (6) Remove lower half of support assembly
in the same manner outlined in the preceding step.
11-141. REMOVAL - ELEVATORS AND (7) Move horn assembly (12) to the right
HORN ASSEMBLY. through bracket (5) as far as possible, rotating the
control arm as necessary to allow passage of end lug
NOTE through bracket. Lower left side of horn assembly and
move horn assembly inboard and toward access door
while removing opposite end of horn and lug through
Perform inspection of installed elevators
bracket. Remove horn assembly.
and elevator control system prior to
removal (paragraph 11-1 42).
11-142. INSPECTION - ELEVATORS AND
a. Remove retaining bolt (2, figure 11 -29) and ELEVATOR CONTROL SYSTEM.
washer (3). Move elevator (1) outboard until spar tube
(4) is clear of horn assembly (12). a. Inspect installed elevators and elevator control
system as follows:
b. Remove opposite elevator in the same manner.
(1) I n s p e c t e l e v a t o r s a n d e l e v a t o r c o n t r o l
c. Remove horn assembly (12) as follows: system for secure installation, damage and freedom
of operation through full throw.
(1) Remove cotter pin (31), nut (32), washers
(33 and 35) and bolt (36). Disconnect tube assembly (2) I f d a m a g e is detected during
(34) from horn assembly (12). accomplishment of step (1), make detailed inspection
as outlined in step b.
NOTE
(3) Inspect elevator support brackets (5, figure 11-
If horn assembly is to be reinstalled on 29) for loose rivets. Apply enough pressure to elevator
the same helicopter, index shims (23 and at outboard end to provide normal deflection. Inspect
27) for reinstallation in the same rivets visually and by hand contact for signs of move-
location. Support assemblies (9 and 22) ment. No loose or cocked rivets are acceptable. Re-
are different pert numbers and must be quest assistance of next higher maintenance level if
reinstalled in the same location. any loose or cocked rivets are found.
NOTE
b. Inspect elevators and elevator control system
Support assemblies (9 and 22) have components after removal as follows:
bearing material bonded to the surfaces
that contact the horn assembly. Handle (1) Inspect both elevators (1, figure 11-29) for
support assemblies carefully to avoid scratches, dents, nicks, cracks, tears and holes. Refer
damage. to paragraph 2-330 for damage limits.
11-78 Change 7
TM 55-1520-236-23
Figure 11-29. Elevator Installation (Sheet 1 of 2)
11-79
TM 55-1520-236-23
Figure 11-29. Elevator Installation (Sheet 2 of 2)
(2) Inspect support assemblies (9 and 22, b. Repair elevators with corrosion or mechanical
figure 11-29) for mechanical and corrosion damage. damage that is within reparable limits. Refer to para-
See figure 11-33 for damage Iimits. Inspect support graph 2-331 for repair instructions.
assemblies for damaged and/or loose bearing
material. Damaged, loose or excessively worn bearing c. Polish out mechanical and corrosion damage
material is not acceptable. on horn assembly (12, figure 11-29) that is within Iimits
shown on figure 11-32. Polish to a smooth, scratch free
(3) Clean elevator horn with solvent (C112). finish with crocus cloth (C37). Blend edges of repair
Inspect horn assembly (12, figure 11-29) for mechani- into surrounding area. Apply chemical film coating
cal and corrosion damage. See figure 11-33 for (C31) to repair areas. Prime repaired areas with primer
damage Iimits. Inspect horn assembly bearing in
accordance with instructions in paragraph 11-164.
lnspect horn assembly (12, figure 11-29) for cracks by d. Replace faulty bearing in horn assembly (12,
fluorescent penetrant method (TM 43-0103). No
figure 11-33). Refer to paragraph 11-184 for proce-
sacks are acceptable.
dure.
(4) Inspect elevator control system tubes and
links shown on figure 11-28 for mechanical and corro- 11-144. INSTALLATION ELEVATORS AND
sion damage. See figure 11-30 for damage Iimits. HORN ASSEMBLY.
(5) Inspect elevator control system walking a. Insert horn assembly (12, figure 11-23)
beams, supports, and bellcranks shown on figure through access opening in tailboom with control arm
11-28 for mechanical and corrosion damage. See fig- toward left aide of tailboom. Rotate control arm to
ure 11-33 for damage limits. approximate vertical position and insert lug of horn
through support bracket (5) on left aide of tailboom.
(6) Inspect all bearings in the elevator control Move horn assembly outboard as far as possible.
system shown on figure 11-28 m accordance with Raise opposite end of horn assembly and rotate con-
instructions in paragraph 11-164. trol arm downward as necessary to allow lug at horn
assembly to pass through support brackets (5) on right
11-143. REPAIR OR REPLACEMENT
ELEVATORS, HORN ASSEMBLY AND
SUPPORT ASSEMBLIES. b. Position lower shim (23) and support assem-
bly (9) on support bracket (5). Install bolts (13) and thin
a. Replace components that do not meet inspec- aluminum washers (14). Install shim (23) and support
tion requirements of paragraph 11-142. assembly (22) in the same manner.
11-80 Change 22
TM 55-1520-236-23
c. Position upper shim (6) and support assembly h. Measure amount of force required to rotate horn
(9) on bracket (5). Install bolts (11) and thin aluminum assembly (12), Use a force gage (fish scale) with a 0 TO
washers (10). Install upper shim (6) and support 50 pound range. Attach gage at bearing (30) and pull
assembly (22) in the same manner. perpendicular to control arm. Force required should be
13 TO 16 pounds. Adjust thickness of shims (17) until
d. Move horn assembly (12) from side to side and force required to rotate horn is 13 TO 16 pounds with
measure movement between support assembly (9) and nuts (15) torqued 50 TO 70 inch-pounds.
horn assembly (12). If lateral movement is not 0.005 TO
0.030 inch, add or remove shims (6 and 23) to obtain i. Torque nuts (25) that were installed in step g, 50
movement within limits. TO 70 inch-pounds.
e. Coat spar tube (4) of elevator (1) with corrosion j. Measure amount of force required to rotate horn
preventive compound (C41). Insert spar tube (4) of assembly as outlined in step h. The force required
elevator (1) in horn assembly (12). Align holes of should now be 26 TO 32 pounds. Adjust thickness of
elevator fitting with horn assembly lug and install bolt shims (27) until force required to rotate horn is 26 TO 32
(2) and aluminum washers (3), torque bolt (2) 100 TO pounds with nuts (25) torqued 50 TO 70 inch-pounds.
140 inch-pounds. Install opposite elevator in the same
manner. k. Install two bolts (11) and thin aluminum washers
(10). Install two bolts (18) and thin aluminum washers
f. Check clearance between elevators and (19).
tailboom. If there is not adequate clearance on both
sides, move shim sets (6 and 23) as required to obtain l. Position control tube (34) on horn assembly (12).
equal clearance after removing the elevator. Install bolt (36), steel washers (35 and 33), nut (32), and
cotter pin (31).
g. Remove two bolts (11) and washers (10). install
two shims (17), bolts (7), thin aluminum washers (8), m. Install elevator in accordance with paragraph
thin aluminum washers (16), and nuts (15). Torque nuts 11-144e. Check elevator rigging (paragraph 11-138).
(15) 50 TO 70 inch-pounds. Install shims (27) in the
same manner but do not torque nuts (25) at this time.
SECTION Il. FLIGHT CONTROL COMPONENTS
11-145. FLIGHT CONTROL COMPONENTS. Premaintenance Requirements for
Control Tubes - Cyclic, Collective
11-146. DESCRIPTION - FLIGHT CONTROL Anti-torque and Synchronized
COMPONENTS. Elevator System
The flight control components covered in this section are Conditions Requirements
the control tubes, links, bellcranks, levers, walking
beams, and supports illustrated in figure 11-31. Model AH-1S
11-147. FLIGHT CONTROL TUBES AND LINKS. Part No. or Serial No. All
11-148. DESCRIPTION - FLIGHT CONTROL Special Tools None
TUBES AND LINKS.
Test Equipment Force Gage
The flight control system tube assemblies and links (Fish Scale)
(figure 11-31) are used in all the flight control systems.
Fixed length tube assemblies are used as much as Support Equipment None
possible, but adjustable lengths are required in some
locations to rig the controls. Minimum Personnel Required Two
Consumable Materials (C31), (C36)
(C88), (C102)
Special Environmental Conditions None
Change 18 11-81
TM 55-1520-236-23
ALL DIMENSIONS ARE IN INCHES UNLESS OTHERWISE NOTED
TYPE OF DAMAGE MAXIMUM DEPTH AND REPAIR AREAS ALLOWED
CRACKS ALLOWED NONE
MECHANICAL AND CORROSION DAMAGE ALLOWED OTHER THAN DENTS
PART TUBE WALL CIRCUMFRENCIAL WIDTH OF REPAIRED AREA
NUMBER DIAMETER THICKNESS .25 IN 25 PERCENT 50 PERCENT
209-001 -063-5 .875 .035
Before Repair .002 .0015 .001
After Repair .0035 .003 .002
209-001-063-25 .750 .049
Before Repair .0025 .002 .002
After Repair .005 .004 .003
Remaining P/N Diameter to .058
to be added be added
later. later.
Before Repair .003 .002 .002
After Repair .006 .004 .004
NOTES:
Rework parts by smoothing out scratches, nicks or corrosion with 400 grit sandpaper (Cl 02),
and finish to original surface condition. Finish in a longitudinal direction.
209001-175-1
Figure 11-30. Damage Limits - Fixed Length Flight Control Tubes and Links (Typical) (Sheet 1 of 3)
11-82
TM 55-1520-236-23
TYPE OF DAMAGE MAXIMUM DEPTHS AND REPAIR AREAS ALLOWED
CRACKS None None
NICKS, SCRATCHES,
DENTS AND CORROSION
(AFTER CLEAN UP) None 0.007
MAXIMUM AREA PER
FULL DEPTH REPAIR None 0.10 Sq. In.
NUMBER OF REPAIRS None Two
EDGE CHAMFER None 0.02 x 0.02
THREAD DAMAGE: N/A
DEPTH: One-third of thread
LENGTH: One-fourth inch
NUMBER: Two
BEARING/RADIAL Maximum acceptable radial play
WEAR is 0.006
BEARING/AXIAL Maximum acceptable axial play
WEAR is 0.015
ALL DIMENSIONS ARE IN INCHES UNLESS OTHERWISE NOTED
209001-175-2
Figure 11-30. Damage Limits - Fixed Length Flight Control Tubes and Links (Typical) (Sheet 2 of 3)
11-83
TM 55-1520-236-23
TYPE OF DAMAGE MAXIMUM DEPTHS AND REPAIR AREAS ALLOWED
CRACKS ALLOWED None
NICKS, SCRATCHES, 0.005
SHARP DENTS
CORROSION
AFTER REPAIR 0.005
MAXIMUM AREAR PER FULL
DEPTH REPAIR 0.10 Sq. In.
NUMBER OF REPAIRS One Per Segment
EDGE CHAMFER 0.020 x 0 . 0 2 0
THREAD DAMAGE:
DEPTH: One-third of thread
LENGTH: One-quarter inch
NUMBER: Two
RADIAL WEAR/ELONGATION 0.005
OF CLEWS HOLE
(DIMENSION A)
ALL DIMENSIONS ARE IN INCHES UNLESS OTHERWISE NOTED
209001-175-3
Figure 11-30. Damage Limits - Fixed Length Flight Control Tubes and Links (Typical) (Sheet 3 of 3)
11-84
TM 55-1520-236-23
Figure 11-31. Control System Linkage Installation (Sheet 1 of 7)
11-85
TM 55-1520-236-23
Figure 11-31. Control System Linkage Installation (Sheet 2 of 7)
11-86
TM 55-1520-236-23
Figure 11-31. Control System Linkage Installation (Sheet 3 of 7)
11-87
TM 55-7520-236-23
Figure 11-31. Control System Linkage Installation (Sheet 4 of 7)
11-88 Change 12
TM 55-1520-236-23
Figure 11-31. Control System Linkage Installation (Sheet 5 of 7)
11-89
TM 55-1520-236-23
Figure 11-31. Control System Linkage Installation (Sheet 6 of 7)
11-90 Change 10
TM 55-1520-236-23
Figure 11-31. Control System Linkage Installation (Sheet 7 of 7)
11-91
TM 55-1520-236-23
11-149. REMOVAL - FLIGHT CONTROL TUBES additional bearing inspection information.
AND LINKS. d. If any evidence is noted in steps a. through h. that a
part is cracked, make fluorescent penetrant inspection in
NOTE accordance with TM 43-0103. No cracks are acceptable.
Parts of control system can be removed sep- NOTE
arately as need occurs, or completely, in
practical sequence. Take precautions When chafing strips become worn through, you
against accidental movement of linkage may rotate control tube 180 (on straight tubes).
while disconnected. Do not turn end for end or change tube length. If
this is not possible, you should replace the tube
NOTE when the inspection limitations for the tube have
been exceeded.
Elevator Control tube (186, figure 11-31) may
be removed by first removing the four e. Inspection criteria for control tubes not listed in fig-
guides (6, figure 11-28) and sliding tube out ure 11-30:
or in through access panel under the eleva-
tor. (1) Inspect tube portion for scratches and score
marks as follows:
a. Remove access covers as required. (a) Maximum allowable dents when scratches
and scores are less than 45 degrees to lengthwise center
b. Remove components as required to gain access to line of tube is 0.010 inch.
flight control tubes or links. Refer to chapter that pertains to
obstructing component for removal procedures. (b) Maximum allowable depth when scratches
and score marks are more than 45 degrees to center line of
c. Remove control tubes and/or links as required. tube is 0.005 inch.
11-150. INSPECTION - FLIGHT CONTROL TUBES (2) Inspect tube portion for corrosion damage.
AND LINKS. Maximum allowable depth is 0.005 inch before repair and
0.010 inch after repair.
a. Inspect all fixed length control tubes for dents,
scratches, corrosion, friction wear, nicks and abrasions. (3) Maximum allowable width of repair area at any
See figure 11-30. given section of tube is one-third of tube circumference.
NOTE (4) No thread damage is acceptable. No repair to
any surface is acceptable if the repair will affect threads.
A smooth dent is one that does not contain a
scratch and/or a nick. (5) Inspect clevises and rod ends for nicks, scratch-
es and corrosion. Maximum allowable depth of mechanical
(1) The maximum allowable depth of a smooth dent damage is 0.010 inch. Maximum allowable corrosion dam-
is equal to the wall thickness of the tube body. See figure age is 0.005 inch before repair and 0.010 after repair.
11-30.
(6) Inspect bolt holes for wear. Maximum allowable
(2) The maximum allowable width of a smooth dent wear is 0.005 inch.
is equal to 20 percent of the outer tube diameter. See fig-
ure 11-30. (7) Inspect area on surfaces surrounding bolt holes
for mechanical and corrosion damage. Maximum allowable
b. Scratches, nicks, and/or abrasions maybe grouped repair of mechanical and/or corrosion damage within dis-
together and reworked, provided repair areas do not tance of one diameter from edge of hole is 25 percent of
exceed the limits shown in figure 11-30. area.
c. Inspect all rod end bearings, anti-torque pedal con- (8) Inspect bearings for wear and/or damage in
netting link bearing, and bearings installed in bellcranks excess of limits. Refer to paragraph 11-162.
(paragraph 11-164). Refer to TM 55-1500-204-25/1 for
11-92 Change 19
TM 55-1520-236-23
11-151. REPAIR OR REPLACEMENT - 11-152. I N S T A L L A T I O N - FLIGHT
FLIGHT CONTROL TUBES AND LINKS. CONTROL TUBES AND LINKS.
a. Replace all parts that fail to meet inspection a. Install bellcranks, levers, walking beams and
requirements of paragraph 11-150. Polish out all supports if these parts were removed. Refer to
minor corrosion and mechanical damage that does paragraph 11-159 and 11-160.
not exceed damage limits. Do not remove more
material than necessary to blend repair smoothly into b. Install fixed length tubes and links. See figure
surrounding surface. Use fine to medium grades of 11-34. Ensure that cotter pins are installed where
sandpaper (C102) or abrasive cloth (C36). Do not use applicable. See figure 11-31, detail A for typical
grinding wheels. Polish out mechanical damage only installations.
deep enough to remove traces of damage. Polish out
corrosion damage to twice the depth of the deepest c. Adjust (rig) and install adjustable length tubes
pit. and links. Refer to paragraphs 11-7, 11-29, 11-55,
and 11-38 as applicable.
b. Touch up repair area on aluminum parts with
chemical film (C31) and primer (C88 or C91). Touch d. Install components that were removed to gain
up repair area on steel parts with primer (C88 or C91). access to flight control tubes and links.
c. Refer to paragraph 11-165 if bearings are worn e. Ensure that all safety devices (cotter pins and
beyond acceptable limits. Iockwire) are installed in the flight control system
being repaired.
d. Replace worn bushings in pedal connecting
links (119 and 129, figure 11-31). Refer to paragraph
11-97.
Change 5 11-92.1/(11-92.2 blank)
TM 55-1520-236-23
f. Move controls through full throw and ensure 11-156. REMOVAL - BELLCRANKS,
that there is no binding or interference. LEVERS, W A L K I N G B E A M S , A N D
SUPPORTS.
g. Install access panels.
NOTE
11-153. FUNCTIONAL CHECK - FLIGHT
CONTROL TUBES AND LINKS. Parts of control system can be removed
separately as need occurs or completely,
Perform maintenance test flight. in practical sequence. Take precautions
against accidental movement of linkage
11-154. BELLCRANKS, LEVERS, while disconnected.
WALKING BEAMS, AND SUPPORTS.
a. Remove access covers as required.
NOTE
b. Remove flight control tubes and links as
Refer to paragraph 11-167 for
required (paragraph 11-149).
maintenance instructions for cyclic and
collective power cylinder (hydraulic
c. Disconnect cyclic force gradient if required
cylinder assembly) supports.
(paragraph 11-65).
11-155. DESCRIPTION BELLCRANKS,
LEVERS, WALKING BEAMS AND d. Disconnect tail rotor force gradient if required
SUPPORTS (figure 11-31). (paragraph 11-92).
Bellcranks, levers and walking beams are utilized in e. D i s c o n n e c t S C A S m o t i o n t r a n s d u c e r s i f
all control systems to change direction of movement required (paragraph 11-122).
and amount of motion in the control system. Supports
provide for attachment of the flight controls to the f. Disconnect springs (32, figure 11-31) from
airframe. lateral bellcrank (32) and spring (67) from longitudinal
idler crank (59) if required.
Premaintenance Requirements for
Bellcranks, Levers, Walking Beams, and
g. Disconnect droop compensator tube assembly
supports
(12). Refer to paragraph 4-85.
Conditions Requirements
h. Remove SCAS servo actuators (46, 77, and
Model AH-IS 143). Refer to paragraph 7-73.
Part No. or Serial No. Al I i. Remove Iockwire, cotter pins, nuts, washers,
and bolts that attach bellcranks, levers, and walking
Special Tools None beams to supports. Remove bellcranks, levers, and
walking beams.
Test Equipment Force Gage
(Fish Scale)
Support Equipment None
Minimum Personnel Two Lateral and collective supports (5 and 40)
Required and tail rotor and fore-and-aft supports
(75, 110, and 116) use some common
Consumable Materials (C31), (C36), (C88), hardware for airframe attachment.
(C91), (C99), (C138), Immobilize both systems if either
(C102) support is removed.
Special Environmental None
Conditions j. Remove collective support (5), lateral support
(40), fore-and-aft support (75), and tail rotor support
Change 3 11-93
TM 55-1520-236-23
(111 or 116) by removing bolts, (44, 93, 118, and c. Polish out minor corrosion and mechanical
112), washers (42, 43, 89, 91, 92, 113, 114, and 117), damage that does not exceed inspection limits. Do not
and nuts (41, 88, and 115). remove more material than necessary to blend repair
smoothly into surrounding surface. Use fine to
k. Remove idler crank support (64) by removing medium grade of sandpaper (C102) or abrasive cloth
three bolts (66) and washers (65). (C36). Do not use grinding wheels. Polish out
mechanical damage only deep enough to remove
l. Separate idler crank (60) from support by traces of damage. Polish out corrosion damage to
removing cotter pin (63), nut (62), washers (59 and twice the depth of the deepest pit.
61), and bolt (58).
d. Touch up repair area on aluminum parts with
NOTE chemical film (C31) and primer (C88 or C91), Touch
up repair area on steel parts with primer (C88 or C91).
Lateral and fore-and-aft support (49 and
80) have nuts on aft bolts. Tail rotor e. Refer to paragraph 11-165 for instructions to
supports (111 and 124) have a nut on replace bearings.
lower bolt (58).
11-159. INSTALLATION - BELLCRANKS,
m. Remove remaining supports by removing bolts LEVERS, WALKING BEAMS, AND
and washers. SUPPORTS.
11-157, INSPECTION - BELLCRANKS, a. Install bellcranks, levers, walking beams and
LEVERS, WALKING BEAMS, AND supports that are removed. See figure 11-31, detail A
SUPPORTS. for typical installations.
a. Inspect bearings for wear and/or damage. b. Attach lateral and collective supports (5 and
Refer to paragraph 11-164 for limits. 40) to airframe with bolts (44), washers (42 and 43),
and nuts (41). Place one washer under bolt head and
b. Inspect all parts for mechanical and corrosion one washer under nut.
damage. See figures 11-33 through 11-35 for limits.
c. Inspect bolt holes (bushings) for wear.
Maximum acceptable elongation is 0.005 inch.
Washers (91) must be installed between
tail rotor control support (90) and
d. Inspect area on surfaces surrounding bolt
airframe. Failure to do so will cause
holes for mechanical and corrosion damage.
binding in tail rotor controls.
Maximum acceptable repair or mechanical and/or
corrosion damage within distance of one diameter
c. Attach fore-and-aft and tail rotor supports (75
from edge of hole is 25 percent of area.
and 90) to airframe with bolts (93), washers (89, 91,
e. Inspect all threaded areas for damaged and 92), and nuts (88). Place washers (91) between
tail rotor support and airframe. Place one washer
threads.
under bolt head and one under nut.
NOTE
11-158, REPAIR OR REPLACEMENT
BELLCRANKS, LEVERS, WALKING BEAMS, Lateral and collective supports (5 and 40)
AND SUPPORTS, and tail rotor and fore-and-aft supports
(75, 111, and 116) use common
a. Replace damaged threaded inserts (paragraph hardware for airframe attachment.
11-13).
d. Install idler crank (60) in support (64) with bolt
b. Replace bushings that are worn beyond (58), washers (59 and 61), and nut (62). Place one
acceptable limits. washer under bolt head and one washer under nut.
11-94
TM 55-1520-236-23
TYPE OF DAMAGE MAXIMUM DEPTH AND REPAIR AREAS ALLOWED
CRACKS None None None
MECHANICAL DAMAGE 0.005 0.015 0.030
CORROSION DAMAGE
Before Repair 0.0025 0.0075 0.015
After Repair 0.005 0.015 0.030
MAXIMUM AREA PER 0.1 Sq. In. 0.5 Sq. In. 1.0 Sq. In.
FULL DEPTH REPAIR
NUMBER OF REPAIRS One Per Area One Per Area One Per Area
EDGE CHAMFER 0.02 0.04 0.06
BORE DAMAGE 0.002 for one-fourth circumference
THREAD DAMAGE Length 0.25
Depth 0.005
Number Three
ALL DIMENSIONS ARE IN INCHES UNLESS OTHERWISE NOTED
209001-124B
Figure 11-32. Damage Limits - Anti-Torque System (Sheet 1 of 7)
11-95
TM 55-1520-236-23
TYPE OF DAMAGE MAXIMUM DEPTHS AND REPAIR AREAS ALLOWED
CRACKS None None None
MECHANICAL DAMAGE 0.005 0.015 0.030
CORROSION DAMAGE
Before Repair 0.0025 0.0075 0.015
After Repair 0.005 0.015 0.030
MAXIMUM AREA PER
FULL DEPTH REPAIR 0.1 Sq. In. 0.05 Sq. In. 1.0 Sq. In.
NUMBERS OF REPAIRS 1 Per Area 1 Per Area 1 Per Area
EDGE CHAMFER 0.02 0.04 0.06
BORE DAMAGE 0.002 for 1/4 Circumference
ALL DIMENSIONS IN INCHES UNLESS OTHERWISE NOTED. 209001-127B
Figure 11-32. Damage Limits - Anti-Torque System (Sheet 2 of 7)
11-96
TM 55-1520-236-23
TYPE OF DAMAGE MAXIMUM DEPTHS AND REPAIR AREAS ALLOWED
CRACKS None
MECHANICAL DAMAGE 0.030
CORROSION DAMAGE
Before Repair 0.015
After Repair 0.030
MAXIMUM AREA PER 1.0 Sq. In.
FULL DEPTH REPAIR
NUMBER OF REPAIRS 1 Per Area
EDGE CHAMFER 0.06
BORE DAMAGE 0.002 for 1/4 Circumference
ALL DIMENSIONS ARE IN INCHES UNLESS OTHERWISE NOTED. 209001-126B
Figure 11-32. Damage Limits - Anti-Torque System (Sheet 3 of 7)
11-97
TM 55-1520-236-23
TYPE OF DAMAGE MAXIMUM DEPTH AND REPAIR AREAS ALLOWED
CRACKS None None None
MECHANICAL DAMAGE 0.005 0.015 0.030
CORROSION DAMAGE
Before Repair 0.0025 0.0075 0,015
After Repair 0.005 0.015 0.030
MAXIMUM AREA PER 0.1 Sq. In. 0.5 Sq. In. 1.0 Sq. In.
FULL DEPTH REPAIR
NUMBER OF REPAIRS One Per Area One Per Area One Per Area
EDGE CHAMFER 0.02 0.04 0.06
BORE DAMAGE 0.002 for one-fourth circumference
ALL DIMENSIONS ARE IN INCHES UNLESS OTHERWISE NOTED 209001-125B
Figure 11-32. Damage Limits - Anti-Torque System (Sheet 4 of 7)
11-98
TM 55-1520-236-23
Figure 11-32. Damage Limits - Anti-Torque System (Sheet 5 of 7)
11-99
TM 55-1520-236-23
WALKING BEAM
209-001-761
TYPE OF DAMAGE MAXIMUM DEPTHS AND REPAIR AREAS ALLOWED
CRACKS None
MECHANICAL DAMAGE 0.010
CORROSION DAMAGE
Before Repair 0.005
After Repair 0.010
MAXIMUM AREA PER Not Critical
FULL DEPTH REPAIR
NUMBER OF REPAIRS Not Critical
BORE DAMAGE 0.002 for one-fourth circumference
ALL DIMENSIONS ARE IN INCHES UNLESS OTHERWISE NOTED
209001-137A
Figure 11-32. Damage Limits Anti-Torque System (Sheet 6 of 7)
11-100
TM 55-1520-236-23
MAXIMUM DEPTHS
TYPE OF DAMAGE AND REPAIR AREAS ALLOWED
CRACKS NONE
MECHANICAL DAMAGE 0.020
CORROSION DAMAGE
Before repair 0.010
After reapair 0.020
MAXIMUM AREA PER FULL
DEPTH REPAIR Not Critical
NUMBER OF REPAIRS Not Critical
BORE DAMAGE 0.002 for 1/4 of circumference
ALL DIMENSIONS ARE IN INCHES UNLESS OTHERWISE NOTED
209001-138A
Figure 11-32. Damage Limits - Anti-Torque System (Sheet 7 of 7)
11-101
TM 66-1520-236-23
Figure 11-33. Damage Limits - Elevator Control System (Sheet 1 of 2)
11-102 Change 16
TM 55-1520-236-23
TYPE OF DAMAGE MAXIMUM DEPTHS AND REPAIR AREAS ALLOWED
CRACKS None
MECHANICAL DAMAGE 0.030
CORROSION DAMAGE
Before Repair 0.015
After Repair 0.030
MAXIMUM AREA PER 1.0 Sq. In
FULL DEPTH REPAIR
NUMBER OF REPAIRS 1 Per area
EDGE CHAMFER 0.06
BORE DAMAGE 0.002 for 1/4 Circumference
ALL DIMENSIONS ARE IN INCHES UNLESS OTHERWISE NOTED.
209001-128B
Figure 11-33. Damage Limits - Elevator Control System (Sheet 2 of 2)
11-103
TM 55-1520-236-23
209-001-115
Figure 11-34. Damage Limits - Collective Control System (Sheet 1 of 6)
11-104
TM 55-1520-236-23
MAXIMUM DEPTHS
TYPE OF DAMAGE AND REPAIR AREAS ALLOWED
CRACKS NONE NONE NONE
MECHANICAL DAMAGE 0.005 0.015 0.030
CORROSION DAMAGE
Before repair 0.0025 0.0075 0.015
After repair 0.005 0.015 0.030
MAXIMUM AREA PER FULL
DEPTH REPAIR 0.1 Sq. In. 0.5 Sq. In. 1.0 Sq. In.
NUMBER OF REPAIRS One per area
EDGE CHAMFER 0.02 0.04 0.06
BORE DAMAGE 0.0C2 for 1/4 of circumference
ALL DIMENSIONS ARE IN INCHES UNLESS OTHERWISE NOTED
209001-143A
Figure 11-34. Damage Limits - Collective Control System (Sheet 2 of 6)
11-105
TM 55-1520-236-23
MAXIMUM DEPTHS
TYPE OF DAMAGE AND REPAIR AREAS ALLOWED
CRACKS NONE NONE
MECHANICAL DAMAGE 0.005 0.030
CORROSION DAMAGE
Before repair 0.0025 0.015
After repair 0.005 0.030
MAXIMUM AREA PER FULL
DEPTH REPAIR 0.1 Sq. In. 1.0 Sq. In.
NUMBER OF REPAIRS One par area
EDGE CHAMFER 0.2 0.6
BORE DAMAGE 0.2 for 1/4 of circumference
* NO THREAD DAMAGE IS ACCEPTABLE.
ALL DIMENSIONS ARE IN INCHES UNLESS OTHERWISE NOTED
209001-139A
Figure 11-34. Damage Limits - Collective Control System (Sheet 3 of 6)
11-106
TM 55-1520-236-23
Figure 11-34. Damage Limits - Collective Control System (Sheet 4 of 6)
11-107
TM 55-1520-236-23
Figure 11-34. Damage Limits -Collective Control System (Sheet 5 of 6)
11-108
TM 55-1520-236-23
Figure 11-34. Damage Limits - Collective Control System (Sheet 6 of 6)
11-109
TM 66-1520-236-23
Figure 11-36. Damage Limits - Cyclic Control System (Sheet 1 of 5)
11-110
TM 55-1520-236-23
Figure 11-35. Damage Limits - Cyclic Control System (Sheet 2 of 5)
11-111
TM 55-1520-236-23
Figure 11-35. Damage Limits - Cyclic Control System (Sheet 3 of 5)
11-112
TM 55-1520-236-23
Figure 11-35. Damage Limits - Cyclic Control System (Sheet 4 of 5)
11-113
TM 55-1520-236-23
Figure 11-35. Damage Limits - Cyclic Control System (Sheet 5 of 5)
11-114
TM 55-1520-236-23
Secure nut with cotter pin (63). Attach support to r. Move controls through full throw and ensure
airframe with bolts (66) and washers (65). Attach that there is no binding or interference.
longest hook of spring (23, figure 11-12) to idler crank
and attach opposite end to fuselage. s. Install access panels.
e. I n s t a l l r e m a i n i n g s u p p o r t s w i t h b o l t s a n d 11-160. OPERATIONAL CHECK -
washers. BELLCRANKS, CONTROL TUBES, AND
NOTE LINKS.
Lateral and fore-and-aft supports (49 and
80, figure 11-31) require nuts on aft Perform maintenance test flight.
bolts. Tail rotor supports (111 and 124)
require a nut on lower bolt. 11-161. BEARINGS - CYCLIC,
COLLECTIVE, ANTI-TORQUE, AND
f. I n s t a l l l a t e r a l b e l l c r a n k ( 4 5 ) , f o r e - a n d - a f t SYNCHRONIZED ELEVATOR SYSTEMS.
bellcrank (76), tail rotor bellcrank (119), and collective
bellcrank (6) in supports with bolts (8, 57, and 94) and 11-162. DESCRIPTION - BEARINGS -
washers (7, 56, and 95). Secure bolts to supports with CYCLIC, COLLECTIVE, ANTI-TORQUE, AND
Iockwire (C138). SYNCHRONIZED ELEVATOR SYSTEMS.
g. I n s t a l l r e m a i n i n g b e l l c r a n k s , l e v e r s , a n d Bearings are installed in force gradient rod ends,
walking beams in supports with bolts, washers, and bellcranks, levers, and other components of the
nuts. Install one washer under bolt head and one control systems. Inspect and replace in accordance
washer under nut. with this paragraph and with TM 55-1 500-204-25/1.
h. Connect spring (67) to longitudinal idler crank Premaintenance Requirements for
(60) and springs (32) to lateral bellcrank (33). Bearings - Cyclic, Collective
Anti-Torque and Synchronized
Elevator Systems
i. Connect tail rotor force gradient (paragraph 11-
97). Conditions Requirements
j. Connect cyclic force gradient (paragraph 11-
Model AH-1S
87).
Part No. or Serial No. AlI
k. Connect SCAS transducers (paragraph 11-96).
Special Tools (T61)
l. Connect droop compensator control tube (12)
(paragraph 4-112).
Test Equipment None
m. Install SCAS servo actuators (46, 77, and 143)
Support Equipment Drill Press,
(paragraph 7-74).
Arbor Press,
Roll Staking
n. Install dual hydraulic cylinders (paragraph 7-
Tool
63).
Minimum Personnel Two
o. Install flight control tubes and links (paragraph
Required
11-152).
Consumable Materials (C30), (C31), (C74),
p. Install components that were removed to gain
(C75), (C79), (C88),
access to flight controls.
(C96), (C102)
q. Ensure that all safetying devices (cotter pins
Special Environmental None
and Iockwire) are installed in the flight control system
Conditions
being repaired.
11-115
TM 55-1520-236-23
11-163. REMOVAL - BEARINGS - NOTE
CYCLIC, COLLECTIVE, ANTI-TORQUE, AND
SYNCHRONIZED ELEVATOR SYSTEMS. Repair consists of replacing faulty
bearings or the part containing the
a. Remove the flight control system part the bearing.
bearing is installed in . Refer to paragraph 11-149 or
11-156 as applicable. a. Replace rod end bearings (figure 11-36, detail
C) as the unit. If the rod end bearing is bonded to the
b. Refer to paragraph 11-165 for procedures to part, replace the entire part.
remove bearing from flight control system parts.
b. Do not replace individual bearings that have
been installed in figure 11-36, detail A. This type
11-164. INSPECTION - B E A R I N G S - bearing has a chamfered outer race. Parent metal of
CYCLIC, COLLECTIVE, ANTI-TORQUE, AND the part the bearing is installed in is forced over the
SYNCHRONIZED ELEVATOR SYSTEMS. bearing chamfer by segment staking or roll staking.
When bearings that have been installed by this
a. I n s p e c t bearings visually for obvious method fail to pass inspection, replace the part
mechanical damage, c o r r o s i o n a n d f o r s e c u r e containing the bearing.
installation.
b. Rotate bearings and check for binding and c. Bearings which have been roll staked by
roughness. Binding or roughness that can be forcing the bearing outer race or bearing sleeve over
detected by feel is cause to replace the affected the chamfer at the part containing the bearing as
bearing. shown on figure 11-36, detail B, can be replaced as
follows:
c. I n s p e c t b e a r i n g s f o r w e a r . Maximum
acceptable wear (looseness) is as follows: (1) Place housing over suitable support with
clearance for bearing. Press on outer race to remove
(1) Force gradient rod ends: bearing. Refer to TM 55-1500-204-25/1.
0.012 inch radial
0.030 inch axial
(2) Pivot bearings in bellcranks, levers, walking Cleaning solvent is flammable and toxic,
beams, and pedals. Provide adequate ventilation. Avoid
prolonged breathing of solvent vapors
0.005 inch radial and contact with skin or eyes.
0.030 inch axial (2) Clean housing with cheesecloth (C30) and
MEK (C74).
(3) Rod end bearings on dual hydraulic cylinder
and control tube assemblies and bearings other than (3) Inspect housing bore for damage. Maximum
pivots in bellcranks, levers, walking beams, pedal acceptable bore damage is 0.002 inch deep for one-
links, stick assemblies, jackshaft, and elevator horn: fourth of circumference.
0.012 inch radial (4) Remove burrs and light scoring from bore
and from chamfer with 320 grit or finer sandpaper
0.030 inch axial (C102).
11-165. REPAIR - BEARINGS - CYCLIC, (5) Inspect housing by fluorescent penetrant
COLLECTIVE, ANTI-TORQUE AND method. Refer to TM 43-0103. Clean with
SYNCHRONIZED ELEVATOR SYSTEMS. cheesecloth (C30) and naphtha (C75).
11-116
TM 55-1520-236-23
(6) A p p l y c h e m i c a l f i l m ( C 3 1 ) t o h o l e i n (b) Inspect bearing for cocking. The bearing
housing. Allow to dry one to three minutes. Rinse must be square to the housing surface.
with water. Dry with cloth or force dry.
(c) Rotate bearing and check for binding and
roughness by feel.
(d) Inspect for looseness between race and
Avoid excessive application of primer.
housing. There must be no evidence of bearing
Do not allow primer to enter bearing.
walking or looseness.
(7) Apply one coat of primer (C88 or C91) to
(e) Inspect housing by dye penetrant method.
housing hole and bearing outer race just prior to
Refer to TM 43-0103.
installation.
11-166. INSTALLATION - BEARINGS -
CYCLIC, COLLECTIVE, ANTI-TORQUE, AND
If extreme interference fit occurs at SYNCHRONIZED ELEVATOR SYSTEMS.
beginning of press operation, stop and
determine cause before proceeding. Do a. Install bearing in or on next higher assembly
not install bearing with extreme part as applicable (paragraph 11-165).
interference fit as it will cause bearing to
bind. b. After bearing is assembled on next higher
assembly part, install the part in the helicopter. Refer
(8) P r e s s b e a r i n g i n t o h o u s i n g h o l e w h i l e to paragraph 11-144, 11-152, or 11-159 as
primer is still wet. Ensure bearing is started square applicable.
and not cocked.
11-167. POWER CYLINDER SUPPORTS -
LATERAL CYCLIC, FORWARD AND AFT
CYCLIC, AND COLLECTIVE SYSTEMS.
Use steady hand pressure on drill during
roll staking procedure. Excessive 11-168. D E S C R I P T I O N - P O W E R
pressure may result in reduction of the CYLINDER SUPPORTS, LATERAL CYCLIC,
outer lip metal thickness adjacent to the FORWARD-AND-AFT CYCLIC, A N D
0.008 inch dimension on figure 11-36, COLLECTIVE SYSTEMS .
detail B.
a. The lateral cyclic and collective controls power
cylinder support (13, figure 11-37) is mounted at the
(9) R o l l o r r i n g s t a k e p r e g r o o v e d b e a r i n g s . left side of the transmission bay. It is the supporting
Use tool set (T-61 or T-61.1) to stake bearings. For member for the two control power cylinders-
rolI staked bearings, attach tool set to a stand- (hydraulic cylinder assemblies) named above.
t y p e d r i l l p r e s s . Operate drill press 250 to 350
rpm. Support bearing on lower part of tool and b. THE FORWARD AND AFT CYCLIC POWER
roll stake outer lip of bearing race over housing. CYLINDER SUPPORT (3, figure 11-38) is mounted at
Apply reasonably steady hand pressure on drill the right side of the transmission bay. It is the
press for a minimum of ten seconds to allow stak- supporting member for the forward and aft control
ing tool to flow metal out. Apply oil (C79) sparing- power cylinder (hydraulic cylinder assembly).
ly and cautiously to staking tool rolls. Remove all
oil immediately after staking. Refer to TM 11-169. REMOVAL - POWER CYLINDER
55-1500-322-24 for complete bearing replacement. SUPPORTS, LATERAL CYCLIC, FORE-AND-
AFT CYCLIC, AND COLLECTIVE SYSTEMS.
(10) Inspect installed bearing as follows:
a. Remove lateral cyclic and collective controls
(a) I n s p e c t f o r g a p b e t w e e n c h a m f e r o n power cylinder support (13, figure 11-39) as follows:
housing and lip on bearing race. Maximum
acceptable gap is 0.008 inch as shown in figure 11- (1) Remove lateral cyclic and collective power
36, detail B. cylinder assemblies (paragraph 7-55).
Change 5 11-117
TM 55-1520-236-23
Figure 11-36. Flight Control System Bearings
11-118
TM 55-1520-236-23
Figure 11-37. Lateral Cyclic and Collective Controls
Power Cylinder Support installation
11-119
TM 55-1520-236-23
Figure 11-38. Fore-And-Aft Cyclic Controls Power
Cylinder Support Installation
(2) Remove nuts (6), washers (5 and 12) and (3) Remove nuts (5), washers (2 and 4), and
four bolts (11) that attach support to lift beam. four bolts (1) that attach support (3) to lift beam.
(3) Remove nuts (7), washers (8 and 9), and two (4) Remove nuts (6), washers (7 and 8), and two
bolts (10). bolts (9) that attach support to bulkhead fitting.
(4) Remove nuts (1), washers (2 and 3) and two (5) Remove support (3).
bolts (4) that attach support to airframe.
1 1 - 1 7 0 . I N S P E C T I O N - P O W E R
(5) Remove support (13). CYLINDER SUPPORTS, LATERAL CYCLIC,
FORE-AND-AFT CYCLIC, AND COLLECTIVE
SYSTEMS.
b. Remove fore-and-aft cyclic controls power
cylinder support (3, figure 11-38) as follows: a. Inspect supports for damage in excess of limits
shown on figure 11-39.
(1) Remove fore-and-aft cyclic power cylinder
assembly (paragraph 7-55). b. Inspect four washers (14 and 15, figure 11-37)
and (10, figure 11-38) at each cylinder installation
(2) Remove System No. 2 hydraulic pump point (total of twelve washers on both supports) for
paragraph 7-23). secure bonding to the supports.
11-120
TM 55-1520-236-23
Figure 11-39. Damage Limits - Power Cylinder Supports (Sheet 1 of 2)
11-121
TM 55-1520-236-23
Figure 11-39. Damage Limits - Power Cylinder Supports (Sheet 2 of 2)
11-122
TM 55-1520-236-23
11-171. REPAIR - POWER CYLINDER countersunk side against head, and one washer (5)
SUPPORTS, LATERAL CYCLIC, FORE-AND- under nut. Do not tighten.
AFT CYCLIC, AND COLLECTIVE SYSTEMS.
(2) A t t a c h s u p p o r t ( 1 3 ) t o f o r w a r d c a r r y -
a. Polish out mechanical and corrosion damage through fitting with two bolts (10), washers (8 and 9),
that is within limits shown on figure 11-39 with and nuts (7). Place one washer (9) under head with
abrasive paper (C102). countersunk side against head, and one washer (8)
under nut. Attach support to aft bulkhead with bolts
b. Touch up repair area with chemical film (C31) (4), washers (2 and 3), and nuts (1). Place one washer
and primer (C88 or C91). (3) under head with countersunk side against head,
and one washer (2) under nut (1).
(3) Torque nuts (6) 120 TO 145 i n c h - p o u n d s .
Torque nuts (7) 200 TO 250 inch-pounds. Torque
nuts (1) 200 TO 250 inch-pounds.
Cleaning solvent is flammable and toxic. (4) Install lateral cyclic and collective power
Provide adequate ventilation. Avoid cylinder assemblies (paragraph 7-66).
prolonged breathing of solvent vapors
and contact with skin or eyes.
b. Install forward and aft cyclic controls power
cylinder support (3, figure 11-38) as follows:
c. (AVIM) Replace missing washers (14 and 15,
figure 11-37) and (10, figure 11-38). Clean old
(1) Attach power cylinder support (3) to lift
adhesive with sandpaper (102). Clean mating
beam with four bolts (1), washers (2 and 4), and nuts
surface of washer and support with MEK (C74). Bond
(5). Place one washer (2) under bolt head with
washer to support with adhesive (C8). Refer to table
countersunk side against head, and one washer (4)
1-11, for adhesive, mix ratio, pot life, and curing
under nut. Do not tighten.
schedule.
(2) Attach support to forward carry-through
fitting with two bolts (9), washers (7 and 8), and nuts
(6). Place one washer (8) under bolt head with
11-172. I N S T A L L A T I O N - POWER countersunk side against head, and one washer (7)
CYLINDER SUPPORTS, LATERAL CYCLIC, under nut (6).
FORE-AND-AFT CYCLIC, AND COLLECTIVE
SYSTEMS. (3) Torque nuts (5) 120 TO 145 i n c h - p o u n d s .
Torque nuts (6) 200 TO 250 inch-pounds.
a. Install lateral cyclic and collective controls
power cylinder support (13, figure 11-37) as follows: (4) I n s t a l l S y s t e m N o . 2 h y d r a u l i c p u m p
(paragraph 7-23).
(1) Attach power cylinder support (13) to lift
beam with four bolts (11), washers (12 and 5) and (5) Install fore-and-aft cyclic power cylinder
nuts (6). Place one washer (12) under bolt head with assembly (paragraph 7-66).
Change 12 11-123/(11-124 blank)
TM 55-1520-236-23
CHAPTER 12
UTILITY SYSTEMS
SECTION I. FIRE DETECTION SYSTEM
12-1. FIRE DETECTION SYSTEM - rapidly when heated causing an internal relay of the
ENGINE. control unit to activate and illuminate the FIRE light.
The system is powered by the 28 Vdc essential bus
12-2. DESCRIPTION - ENGINE FIRE and protected by the FIRE DET , FIRE DETR
DETECTION SYSTEM . circuit breaker (8). The FIRE DET TEST
switch provides a means of testing the fire detection
The fire detection system consists of a control unit system. Pressing the FIRE DET TEST switch to TEST
(10, figure 12-1), a FIRE indicator light (2), a fire places a low resistance across the heat sensing
detector test switch (9), and a heat sensing element element, simulating a fire condition, thus causing the
(6). The FIRE light will illuminate when the engine FIRE light to illuminate.
compartment temperature reaches approximately
480 degrees F (249 degrees C). The heat sensing
element exhibits high electrical resistance at normal 12-3. TROUBLESHOOTING ENGINE FIRE
ambient temperature, but the resistance drops DETECTION SYSTEM. Refer to table 12-1.
NOTE
Before you use this table, be sure you
have performed all normal operational
checks. If you have a malfunction which
is not listed in this table, notify the next
higher level of maintenance.
Table 12-1. Troubleshooting - Engine Fire Detection System
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
FIRE light fails to illuminate when FIRE DET TEST switch is depressed to TEST.
STEP 1. Ensure that voltage is present at pins A & H of control unit.
If voltage is not present, check wiring (paragraph F-9) and/or replace circuit breaker (paragraph
9-23).
If voltage is present, go to step 2.
STEP 2. Ensure that proper resistance is present at terminal 1 of FIRE DET TEST switch.
If resistance is not present, check wiring (paragraph F-9) and/or replace 8R2 resistor (paragraph
9-16).
If resistance is present, go to step 3.
12-1
TM 55-1520-236-23
Table 12-1. Troubleshooting - Engine Fire Detection System (Cont)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
STEP 3. Ensure that proper resistance is present at pin 2 of FIRE DET TEST switch.
If resistance is not present, replace switch (paragraph 9-16).
If resistance is present, go to step 4.
STEP 4. Ensure that approximately 245 ohms are present at terminal C of control unit.
If 245 ohms are not present, check wiring (paragraph F-9) and/or replace heat sensing element
(paragraphs 12-5 and 12-8).
If 245 ohms are present, go to step 5.
STEP 5. Ensure that 28 Vdc is present at pin 52 of NVG PC (Night vision goggle printed circuit) board.
If voltage is not present, check wiring (paragraph F-9) and/or replace control unit (paragraph
9-16).
If voltage is present, go to step 6.
STEP 6. Ensure that 28 Vdc is present at pin 51 of NVG PC board.
If voltage is not present, replace NVG PC board. If voltage is present, go to step 7.
STEP 7. Ensure that 28 Vdc is present at terminal 1 of FIRE light.
If voltage is not present, check wiring (paragraph F-9). If voltage is present, replace bulb
(paragraph 9-16).
12-4. TESTING ENGINE FIRE 12-5. REMOVAL ENGINE FIRE
DETECTION SYTEM. DETECTION SYSTEM.
a . Position BAT BATTERY switch to
a. Position BAT SWITCH to ON Position
OFF.
BATTERY switch to RUN or START
b. Close Fire Det FIRE DTR circuit b. Disconnect heat sensing element (6, figure
12-1) from connectors (5) at aft firewall. Cover
breaker (8, figure 12-1).
openings with tape (C127).
c. Depress FIRE DET TEST switch (9) to TEST.
FIRE light (2) should illuminate. If light does not c. Remove heat sensing element (6) from 16
illuminate, troubleshoot system (paragraph 12-3), quick release clamps. Remove heat sensing element.
12-2
TM 55-1520-236-23
Figure 12-1. Engine Fire Detection System
12-3
TM 55-1520-236-23
d. Remove control unit (10) as follows: b. Replace cable assembly clamps (7) if broken,
cracked, or unserviceable.
(1) Disconnect cable connector from control
unit. c. Replace control unit (10) if case is cracked or
damaged.
(2) Disconnect control unit ground cable.
(3) Remove four screws, washers, and nuts, 12-8. INSTALLATION - ENGINE FIRE
securing control unit. Remove control unit. DETECTION SYSTEM.
12-6. INSPECTION - ENGINE FIRE a . Route heat sensing element (6, figure 12-1) to
DETECTION SYSTEM. position.
a. Inspect cable assembly (4, figure 12-1) and b. C o n n e c t h e a t s e n s i n g e l e m e n t ( 6 ) t o
heat sensing element (6) for damage and wear. connectors (5).
b. Inspect cable assembly clamps (7) for cracks c. Secure heat sensing element (6) with 16 quick
and serviceability. release clamps.
12-7. REPAIR OR REPLACEMENT - d. Install control unit (10) with four screws,
ENGINE FIRE DETECTION SYSTEM. washers, and nuts.
a. Replace cable assembly (4, figure 12-1) and e. Connect cable connector to control unit (10)
heat sensing element (6) if damaged or worn. and secure ground cable to structure.
SECTION Il. RAIN REMOVAL SYSTEM
12-9. RAIN REMOVAL SYSTEM.
NOTE
A rain removal system incorporated in
the environmental control system is used
in lieu of windshield wipers. Refer to
Chapter 13.
SECTION Ill. DEFROSTER SYSTEM
12-10. DEFROSTER.
NOTE
A defroster system is incorporated in the
environmental control system. Refer to
chapter 13.
12-4
TM 55-1520-236-23
SECTION IV. LOW G WARNING SYSTEM
12-11. LOW G WARNING SYSTEM (MWO 12-13. TROUBLESHOOTING - LOW G
55-1520-236-50-9 INCORPORATED). WARNING SYSTEM. Refer to table 12-2 and fig-
ure F-12.2 (MWO 55-1520-236-50-9 Incorporated).
12-12. DESCRIPTION - LOW G WARNING
SYSTEM. NOTE
The low G warning system alerts the pilot that the Before using this table, assure that all
helicopter is approaching high main rotor flapping normal operational checks have been
angles resulting from low G maneuvers. The warning performed. If a malfunction exists and Is
system consists of a low G warning assembly 8A10 not listed in this table, notify the next
(7, figure 12-2), accelerometer 8A11 (2), low G warn- higher level of maintenance.
ing Iight/switch 8DS25 (1), counter 8M1 (4), relays
8K1 and 8K2 (5), terminal board 8TB15 (6), and circuit
breaker 8CB15 (3).
Figure 12-2. Low G Warning System
Change 16 12-5
TM 55-1520-236-23
Table 12-2. Troubleshooting - LOW G Warning System
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
LOW G warning light fails to illuminate and warning audio is absent when 8DS25 is pressed to test.
STEP 1. Ensure that 28 Vdc is present at pin L of 8A10P1 and P27B22.
If voltage is not present, check wire W219A22 and/or replace circuit breaker 8CB15.
If voltage is present, go to step 2.
STEP 2. Ensure that near zero resistance to ground is present at pin K of 8A10P1 with 8DS25 pressed.
If resistance is not near zero, check continuity of W216A22 from 8A101-K to 4A1J1-F, W216B22 from
4A1P-F to splice, W216C22 from splice to 8DS25-A-COM, and W217A22 from 8DS25-A-N-O to splice,
and W217B22N from splice to ground.
If continuity check is good, go to step 3.
STEP 3. Ensure near zero resistance is present between 8DS25-A-COM and 8DS25-A-N.O. When switch is
pressed.
If resistance is not new zero, replace 8DS25.
If resistance check is good, replace 8A10.
LOW G warning light fails to illuminate, but warning audio is present when 8DS25 is pressed.
STEP 1. Ensure continuity between 8A10P1-E and ground (bulb resistance expected).
If circuit Is open, check wires W216A22, W208A22, W208B22, W210A22, W210B22, W214A22, W214B22,
W214C22, W214D22, W215A22N, W215B22N and/or replace 8K1 or 8K2.
If circuit Is shorted, substitute relays 8K1 and 8K2 and/or check all wires listed above except W215A22N
and W215B22N.
If continuity check is good, replace 8A10.
LOW G warning light fails to dim when FLT INSTR LT switch is switched on (press 8DSD25 to illuminate light).
STEP 1, Ensure 28 Vdc on 8XK1-X1 and continuity to ground on 8XK1-X2.
If circuits check good, replace 8K1.
LOW G warning light fails to illuminate when FLT INSTR LT switch is on and 8DS25 is pressed.
STEP 1. Remove 8K1 and measure resistance between 8XK1-B1 and B3.
12-6 Change 16
TM 55-1520-236-23
Table 12-2. Troubleshooting - LOW G Warning System - Continued
If circuit reads approximately 161 ohms, replace 8K1.
If circuit is open, repair wiring and/or replace 8R20.
LOW G warning light fails to reduce to NVG level when NVG mode is selected (Press 8DS25 to test light).
STEP 1. Remove 8K2, select NVG mode, check for approximately 28 Vdc at 8XK2-X1 and continuity to ground
on 8XK2-X2.
If voltage is present on X1 and ground is good on X2, replace 8K2.
If voltage is missing, troubleshoot NVG system.
If ground on 8XK2-X2 is missing, repair circuit.
LOW G warning light totally extinguishes when NVG mode is selected.
STEP 1. Remove 8K2 and measure resistance between 8XK2-B1 and B3.
If circuit reads approximately 911 ohms, replace 8K2.
If circuit reads open or in error, repair wiring and/or replace 8R21.
LOW G warning audio not present when warning light is on.
STEP 1. Press LOW G warning light and check for audio in pilot and gunner positions.
If audio is missing in both positions, replace 8A10.
If audio is missing in pilot position only, repair wire W121B22 between 8A10P1-C and 2301TB1-1 and/or
refer to TM 11-1520-236-20 for repair of the pilot ICS.
If audio is missing in gunner position only, repair wire W122B22 between 8A10P1-D and 2301TB2-1 and/or
refer to TM 11-1520-236-20 for repair of the gunner ICS.
If any single audio is missing and the preceding corrective actions did not correct the problem, replace
8A10.
Counter does not register LOW G warning signals.
STEP 1. Disconnect 8A10P1 and measure continuity of wire W220A22 between 8A10P1-M and positive (+)
terminal of 8M1. Measure continuity to ground of wire W221A22N between the negative (-) terminal of 8M1
and helicopter ground.
If wiring check is good, replace 8M1 and/or 8A10 as required.
LOW G warning system does not generate warning signals.
Change 16 12-7
TM 55-1520-236-23
Table 12-2. Troubleshooting - LOW G Warning System - Continued
STEP 1. Disconnect 8A10P1 and8A11 P1 and check continuity of the following circuits:
From To
8A10P1 Wire 8A11P1
Pin No. Pin
C W191A22 F
A W190A22 ORN E
W W190A22 WHT c
V W190A22 BLU D
H W194A22 WHT A
B W194A22 BLU B
Shield W195A22N Ground
Shield W196A22N Ground
If wiring check is good, replace 8A11 and/or 8A10 as required.
12-14. TESTING - LOW G WARNING (1) Disconnect connector (1).
SYSTEM.
(2) Remove screws (4) and washers (3) securing
a. Ensure LOW G circuit breaker 8CB15 (3, figure LOW G warning assembly (2). Remove LOW G warning
12-2) is closed. assembly (2).
b. Position BAT SWITCH to ON . Position d. Open right engine air inlet/transmission access
BATTERY switch to RUN or START door.
c. Depress LOW G Iight/switch (1). Warning light e. Remove accelerometer (1, figure 12-4) as follows:
should illuminate and warning audio should be heard in
the pilot and gunner headsets. If test results are not (1) Disconnect connector (2).
achieved, troubleshoot system (paragraph 12-13).
(2) Remove screws (3) and washers (4) securing
12-15. REMOVAL - LOW G WARNING accelerometer (1) to forward bulkhead. Remove ac-
SYSTEM. celerometer (1).
a. Position BAT , BATTERY switch to f. Gain access to pilot compartment.
OFF.
g. Remove LOW G warning light/switch (2, figure
b. Open ammunition bay door to access LOW G 12-5) as follows:
warning assembly (2, figure 12-3).
(1) Loosen clamp securing LOW G warning
c. Remove LOW G warning assembly as follows: Iighth/switch (2) in instrument panel (3).
12-8 Change 16
TM 55-1520-236-23
Figure 12-3.
Change 16 12-9
TM 55-1520-236-23
Figure 12-4.
12-10 Change 16
TM 55-1520-236-23
(2) Extract LOW G warning Iight/switch (2) from in- NOTE
strument panel (3) between pilot clock (1) and HSI cent
(4). Ensure bonding strip (5) is positioned be-
tween airframe and LOW G warning
(3) Unsolder wires as required. assembly (2) in accordance with TM 55-
1500-323-23.
h. Remove control panels on pilot left console to ac-
cess counter (1, figure 12-6). (2) Position LOW G warning assembly (2, figure
12-3) on the bottom of the pilot floor panel under the left
heel rest.
l. Remove counter (1) as follows:
(3) Install bonding strip (5), washers (3) and
(1) Remove screws (2) and washers (3) securing
screws (4).
counter (1) to bottom of console.
(4) Connect connector (1).
(2) Tag and remove wires attached to counter (1).
b. Install accelerometer 8A11 as follows:
(3) Remove counter (l).
(1) Open right engine air inlet/transmission access
12-16. INSPECTION - LOW G WARNING
door.
SYSTEM.
(2) Position accelerometer (1, figure 12-4) on for-
a. Inspect LOW G warning assembly 8A10, ac-
ward transmission compartment panel.
celerometer 8A11, LOW G warning Iight/switch 8DS25,
and counter 8M1, for dents or damage that would impair
normal operation of the units. (3) Install screws (3) and washers (4).
b. Inspect connectors for bent, recessed or corroded (4) Connect connector (2).
pins.
c. Install LOW G warning Iight/switch 8DS25 as fol-
c. Inspect cable assembly, terminal board, and relays lows :
for damage and serviceability.
(1) Pull wires through clamp and instrument panel
12-17. REPAIR OR REPLACEMENT - LOW hole.
G WARNING SYSTEM.
(2) Connect wires to LOW G warning Iight/switch
a. Repair or replace connectors, wiring and terminal (2, figure 12-5).
boards that fail to meet minimum serviceability stand-
ards. (3) Install LOW G warning Iight/switch (2) in instru-
ment panel (3) between pilot clock (1) and HSI cent (4).
b. R e p l a c e L O W G w a r n i n g a s s e m b l y , a c -
celerometer, LOW G warning Iight/switch, and counter if (4) Secure clamp.
inspection requirements are not satisfied.
d. Install counter 8M1 as follows:
12-18. INSTALLATION - LOW G WARNING
SYSTEM. (1) Position counter (1, figure 12-6) in pilot left con-
sole (4).
a. Install LOW G warning assembly 8A10 as follows:
(2) Install screws (2) and washers (3).
(1) Open ammunition bay door.
(3) Observe polarity and install wires on counter
(1).
(4) Replace panels removed for access.
Change 16 12-11
TM 55-1520-236-23
Figure 12-5.
12-12 Change 16
TM 55-1520-236-23
Figure 12-6.
Change 16 12-13/(12-14 blank)
TM 55-1520-236-23
CHAPTER 13
ENVIRONMENTAL CONTROL SYSTEM
SECTION I. HEATING SYSTEM
13-1. E N V I R O N M E N T A L CONTROL b. Cool air is provided by the environmental
SYSTEM. control unit when the HTR/OFF/RAIN RMV switch is
at HTR and the ECS COOL/WARM selector is at a
13-2. DESCRIPTION - ENVIRONMENTAL COOL setting (figure 13-1). Air for the ECU is bled
CONTROL SYSTEM. from the engine compressor through a venturi which
restricts the flow. Bleed air pressure is reduced to 35
The environmental control system (ECS) (figure 13-1) psi at the pressure regulator and shutoff valve. In the
provides ventilating air at ambient temperature, or at ECU, bleed air is cooled almost to ram air temperature
controlled temperatures, to air distribution ducts and in the heat exchanger, and further cooling is
outlets in pilot and gunner compartments. Air is accomplished in the reheater-condenser by
drawn in through a screen on the pylon fairing and recirculating cold turbine discharge air. The bleed air
delivered to the distribution ducts by a transmission- is then expanded through the turbine to complete the
driven blower operating continuously when the cooling cycle. Air flows from the ECU past a control-
engine is running. Heating and cooling at controlled sensor which is manually set by the temperature
settings is provided by an environmental control unit selector and regulates output air temperature.
(ECU) using bleed air from the engine compressor
(figure 13-2). The ECU will provide comfort in ambient c. Heated air is provided by the ECU when the
air temperatures from -65 degrees F (-54 degrees C) temperature selector is turned to a WARM setting
to 125 degrees F (52 degrees C). A rain removal while the ECS switch is at HTR. Interconnections to
subsystem also uses engine bleed air to clear the the control/sensor, temperature control valve, and
windshield of moisture or ice. vent air control valve regulate output air temperature
to the air distribution ducts. A thermal probe
13-3. M O D E S O F O P E R A T I O N - (overheat) switch in the duct protects against
ENVIRONMENTAL CONTROL SYSTEM. excessive heat in event of malfunction and would
cause the ECU to cycle off and on until trouble is
a. Airflow to crew compartments is controlled by corrected.
a HEAT OR VENT AIR PULL control knob on the pilot
instrument panel. Each crew seat also has a manual 13-4. TROUBLESHOOTING -
valve controlling airflow through seat cushions. The ENVIRONMENTAL CONTROL SYSTEM.
gunner instrument panel has two butterfly valve
outlets. Defog and ventilation outlets on the pilot Accomplish troubleshooting of the environmental
pedestal have manual control handles. control system according to table 13-1.
13-1
TM 55-1520-236-23
NOTE
Before using this table, ensure all normal
operational c h e c k s h a v e b e e n
performed. If a malfunction occurs
which is not listed in this table, notify the
next higher level of maintenance.
Table 13-1. Troubleshooting ECU
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. No airflow from outlets with HEAT OR VENT AIR PULL control full out.
STEP 1. Check position of flapper valve lever on air distribution valve.
Adjust control cable connection to obtain valve opening.
STEP 2. Place ECS switch to OFF. Check for airflow.
If no airflow and shaft driven blower is operating, replace vent air control valve (paragraph
13-66).
STEP 3. Place ECS switch to HTR. If no airflow, check pressure regulator and shutoff valve for valve stroked
open and escaping air from relief valve. If no such signs, disconnect electrical connector from valve, check for
28 Vdc at pin 3 and for ground at pin 6.
If no power or ground, check and repair wiring circuit.
If power and ground are correct, replace valve (paragraphs 13-39 and 13-44).
2. Airflow from outlets does not become cool when ECS switch is positioned at HTR and temperature selector is
positioned COOL.
STEP 1. Disconnect electrical connector from control/sensor. Connect ohmmeter (set at highest resistance)
to pins F and G of electrical plug. Rotate temperature selector, observing change in resistance. If meter
shows no change, replace temperature selector. Reconnect control/sensor.
STEP 2. Disconnect regulated supply air line from magnetic actuator (figure 13-4) on temperature control
valve of ECU.
If valve closes (goes to cold condition), replace magnetic actuator (paragraph 13-29).
If magnetic actuator is operative and valve remains open, replace valve (paragraph 13-22).
3. Airflow does not become warmer when ECS switch is at HTR and temperature selector turned to WARM.
STEP 1. If all preceding checks have been made, replace control/sensor (paragraph 13-15).
STEP 2. If all preceding checks have been made and all components found operative, replace environmental
control unit (paragraph 13-8).
13-2
TM 55-1520-236-23
Figure 13-1.
13-3
TM 55-1520-236-23
13-5. ENVIRONMENTAL CONTROL 13-10. INSTALLATION -
UNIT. ENVIRONMENTAL CONTROL UNIT.
13-6. DESCRIPTION - ENVIRONMENTAL a. Position ECU in hydraulic compartment and
CONTROL UNIT. align ducts.
The environmental control unit (ECU) is the heating
b. Secure ECU to bulkhead with bolts (22 and 24,
and cooling unit for the pilot and gunner, The
figure 13-1), washers (23 and 25) and spacers (26).
environmental control system (ECS) is basically
Do not tighten mounting bolts.
composed of a heat exchanger, a reheater-
condenser, an expansion turbine, and a jet pump
c. Connect ducts and tubes (1, 5, 10, 12, and 18,
(figure 13-2).
figure 13-2) to ECU.
13-7. INSPECTION - ENVIRONMENTAL d. Connect electrical plugs to control/sensor (9)
CONTROL UNIT. and magnetic actuator (2).
a. Refer to table 13-1 for functional check. e. Tighten mounting bolts.
NOTE
b. ECU for visible damage or evidence of leakage.
Ensure minimum clearance between
c. ECU for security of attachment. ECU and hydraulic compartment floor is
0.06 inches. Where clearance cannot be
d. Check to see if interference exists between obtained, request assistance from next
turbine housing o f t h e E C U a n d h y d r a u l i c higher maintenance level.
compartment floor. Clearance minimum is 0.06 inch.
When minimum is exceeded request assistance from f. Connect the fitting connecting bleed air duct (1)
next higher maintenance level. to ECU. Torque fitting to 17 foot-pounds and Iockwire.
13-8. REPAIR OR REPLACEMENT - 13-11. TEMPERATURE CONTROL/
ENVIRONMENTAL CONTROL UNIT. SENSOR.
a. Replace ECU if ECU fails to meet inspection 13-12. DESCRIPTION - TEMPERATURE
requirements. CONTROL/SENSOR.
b. Replace if damaged or leakage is evident. The temperature control/sensor (9, figure 13-2) is
manually set by positioning the rheostat on the pilot
c. Tighten hardware if not securely attached. ECS control panel, marked COOL WARM. It regulates
the output temperature.
13-9. REMOVAL - ENVIRONMENTAL 13-13. INSPECTION - TEMPERATURE
CONTROL UNIT. CONTROL/SENSOR.
a. Open hydraulic compartment doors on left and
Visually inspect for cracks, dents, and external
right side.
damage.
b. Disconnect ducts and tubes (1, 5, 10, 12, and
18, figure 13-2) to ECU. 13-14. REMOVAL - TEMPERATURE
CONTROL/SENSOR
c. Disconnect electrical plugs from
control/sensor (9) and magnetic actuator (2). a. Disconnect electrical wiring from control/
sensor (9, figure 13-2).
d. R e m o v e b o l t s ( 2 2 a n d 2 4 , f i g u r e 1 3 - 1 ) ,
washers (23 and 25), and spacers (26) attaching ECU b. Remove screws (20) and washers (21). Then
to bulkhead in cockpit behind pilot headrest and remove control/sensor (9) and gasket (22) from duct
remove ECU. (10).
13-4 Change 3
TM 55-1520-236-23
209704-1D
Figure 13-2. Environmental Control Unit
13-5
TM 55-1520-236-23
13-15. REPAIR OR REPLACEMENT - 13-19. INSPECTION - TEMPERATURE
TEMPERATURE CONTROL/SENSOR. CONTROL VALVE.
(AVIM)
a. All threads on parts for damage, crossing,
Replace temperature control/sensor if it does not cracks, or breakage.
meet inspection requirements.
b. Check all valve parts for excessive wear or
13-16. INSTALLATION - TEMPERATURE damage.
CONTROL/SENSOR.
13-20. TESTING - TEMPERATURE
a. Position temperature control/sensor (9, figure CONTROL VALVE. (AVIM)
13-2) and gasket (22) on duct (10). Install
control/sensor (9), using washers (21) and screws Refer to figures 13-4 and 13-5.
(20).
NOTE
b. Connect electrical plug to control/sensor (9).
Perform all tests on helicopter if possible.
13-17. TEMPERATURE CONTROL Equipment required for testing the
VALVE - ECU. temperature control valve is listed in
premaintenance requirements.
13-18. DESCRIPTION - TEMPERATURE
CONTROL VALVE. a. Connect a pressure gage (T7) to the test port (4,
figure 13-4). Plug opposite port.
Output air from the ECU is supplied to the magnetic
actuator on the temperature control valve. This b. Connect a controlled pressure of 15 TO 16
enables the magnetic actuator to control the psig to the magnetic actuator inlet (1).
temperature control valve and allow the correct
amount of hot bleed air to bypass the turbine. The hot c. Connect a pneumatic source of 32 TO 38 psig
bleed air is mixed with conditioned air to maintain the with maximum flow of 14.5 TO 15.5 Ibs per minute
desired temperature in the cabin. to valve air flow inlet (7).
Premaintenance Requirements for
Temperature Control Valve d. Connect a variable source of 28 Vdc (S12) to
pins L and M of the magnetic actuator (2). Slowly
Conditions Requirements increase current until the valve starts to open and a
flow is observed. The actuation pressure on the gage
Model AH-1S should read 4 TO 6 psig.
Part No. or Serial No. Al I e. Slowly increase current until valve strokes full
open. The actuation pressure on the gage should read
Special Tools None 14 psig minimum.
Test Equipment (T7) f. Remove voltage supply from magnetic actuator
(2).
Support Equipment (S12) (S15)
g. Increase inlet pressure. Check for excessive
Minimum Personnel One leakage. Check valve seat for damage or obstruction
Required causing excessive leakage.
Consumable Materials (C112) (C26) (123) NOTE
(C79) (C80) (C17)
A small amount of leakage is acceptable.
Special Environmental None
Conditions h. Decrease inlet pressure to zero and disconnect
pressure source from magnetic actuator inlet (1).
13-6
TM 55-1520-236-23
Figure 13-3.
13-7
TM 55-1520-236-23
Figure 13-4.
13-8
TM 55-1520-236-23
Figure 13-5.
13-9
TM 55-1520-236-23
i. Disconnect pressure gage (T7) from test port (4). 13-24. MAGNETIC ACTUATOR.
j. Disconnect pneumatic source from airflow inlet 13-25. DESCRIPTION - MAGNETIC
(7). ACTUATOR .
k. Replace the temperature control valve if it does The magnetic actuator is attached to the upper part of
not operate within limits noted above. temperature control valve. As the electrical power to
the magnetic actuator is increased, the valve will start
to open and allow the passage of air.
13-21. REMOVAL - TEMPERATURE
CONTROL VALVE.
13-26. INSPECTION - MAGNETIC
a. D i s c o n n e c t e l e c t r i c a l p l u g f r o m m a g n e t i c
ACTUATOR.
actuator (2, figure 1 3-4).
Inspect for damage and security.
b, Remove attaching hardware and disconnect
duct at inlet air port (7).
13-27. R E M O V A L - MAGNETIC
ACTUATOR (figure 13-4).
c. Remove attaching hardware and disconnect
a. Disconnect electrical connector on magnetic
duct at outlet air flow port (5),
actuator.
d. Disconnect tube at regulated pressure supply
b. Disconnect tube at magnetic actuator inlet (1,
port (1).
figure 13-4).
e. Remove screw (12) and washer (13) attaching
c. Remove screws (11) and washers (10).
valve to bracket. Remove valve from helicopter.
d. Remove magnetic actuator from temperature
13-22. REPAIR OR REPLACEMENT - control valve.
TEMPERATURE CONTROL VALVE. (AVIM)
a. Replace valve if damaged, crossed, cracked or 13-28. C L E A N I N G - MAGNETIC
broken threads are found. ACTUATOR.
b. Replace valve if excessive leakage is detected
or seat is damaged,
13-23. INSTALLATION - TEMPERATURE
CONTROL VALVE. Cleaning solvent is flammable and toxic.
Provide adequate ventilation. Avoid
a. Position valve and secure to bracket with prolonged breathing of solvent vapors
screws (12, figure 13-4) and washers (13). and contact with skin or eyes.
b. Connect tube to magnetic actuator inlet port a. Clean magnetic actuator with a clean lint-free
(1). cloth moistened with solvent (C112).
c. Position duct to inlet airport (7) and secure with b. Dry with a clean lint-free cloth.
attaching hardware.
d. Position duct to outlet air port (5) and secure 13-29. REPAIR OR REPLACEMENT -
with attaching hardware. MAGNETIC ACTUATOR.
e. Connect electrical plug to magnetic actuator Replace magnetic actuator if it is damaged or fails to
(1). meet inspection requirements.
13-10
TM 55-1520-236-23
13-30. INSTALLATION - MAGNETIC removing housing assembly (8), with nozzle (9), and
ACTUATOR (FIGURE 13-4). hose (6).
a. Position magnetic actuator on temperature (2) If housing assembly (8), nozzle (9), or hose
control valve and secure with washers (10) and (6) requires replacement, remove retainer (10); cut
screws (11). out adhesive between housing assembly (8), nozzle
(9), and hose (6). Separate parts.
b. Connect tube at magnetic actuator inlet (1).
(3) Remove packing (11) from cooling turbine
c. 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 t o m a g n e t i c (12). Replace packing regardless of condition.
actuator.
13-31. ECU COOLING TURBINE.
13-32. DESCRIPTION - ECU COOLING
TURBINE.
Cleaning solvent is flammable and toxic.
Provide adequate ventilation. Avoid
The cooling turbine is an integral part of the ECU. The
prolonged breathing of solvent vapors
purpose of the cooling turbine is to take the cool high-
and contact with skin or eyes.
pressure bleed air leaving the reheater-condenser
and expand it, causing its temperature to be reduced
(4) Wash all parts with solvent (C112) and dry
by the extraction of energy from the air. The shaft
parts with compressed air.
energy produced in the turbine is transmitted through
the common shaft to a fan which, in turn, loads the
(5) If housing assembly (8) and nozzle (9) are
turbine and induces ram air across the heat
separated, cut out adhesive residue on mating
exchanger. The cooling turbine consists of a straight
surfaces. Inspect housing assembly and nozzle for
bladed radial inflow turbine wheel mounted on a
cracks. Inspect duct of housing assembly for loose
common shaft with an axial flow fan. The rotating
cement joints.
assembly is supported on ball bearings and is
lubricated by wool-felt wicks leading to the shaft from
(6) Loosen couplings (19) and disconnect valve
a cotton-packed oil sump.
(23) with couplings and sleeve (20).
13-33. INSPECTION - ECU COOLING (7) Remove screw (17) and washer (16) and
TURBINE. duct assembly (18) from cooling turbine (12) and
remove packing (15). Replace packing (15) regardless
a. Inspect for unusual noises while operating. of condition.
b. Inspect for binding rotating assembly, rough (8) Remove bolts (13) washers (14), and cooling
operation, or binding bearings and rubbing of turbine turbine (12).
blades in scroll.
(9) Remove washer (21).
c. Do not perform any maintenance on the ECU
cooling turbine except the inspection.
13-34. REMOVAL - ECU COOLING
TURBINE.
a. Remove environmental control unit (ECU) (6, Cleaning solvent is flammable and toxic.
figure 13-1) (paragraph 13-9). Provide adequate ventilation. Avoid
prolonged breathing of solvent vapors
b. Remove cooling turbine. and contact with skin or eyes.
(1) Remove housing assembly (8, figure 13-6) (10) Wipe exterior surfaces of turbine with a
and nozzle (9) by loosening clamps (5) and (7) and clean, lint-free cloth moistened with solvent (C112).
13-11
TM 55-1520-236-23
Figure 13-6.
13-12
TM 55-1520-236-23
Figure 13-6.1.
Change 12 13-12.1
TM 55-1520-236-23
(11) Install moisture and dust seal protective cap (14) Install protective plug (NAS816-123) in tur-
over impeller outlet. Also place masking tape (Cl 23) bine inlet port.
over impeller inlet.
(12) Install moisture and dust seal protective cap 13.34.1. INSPECTION HEAT EXCHANGER
(P/N FC300) (FSCM 1581) over turbine outlet. DUCTS.
(13) Install protective cap (26) over turbine inlet. inspect for damage or leaks in ducts. No deterioration,
cracks, or loose bonded joints allowed.
13-12.2 Change 12
TM 55-1520-236-23
13-34.2. REPAIR OR REPLACEMENT - HEAT a. Install washer (21, figure 13-6) in outlet of duct
EXCHANGER DUCTS. assembly (4), position turbine (12) against washer (21)
and align bolt holes. Install bolts (13) and washers (14).
Repair minor damage to polycarbonate plastic items as
follows:
a. Stop drill cracks with a No. 30 drill. b. Apply lubricating oil (C79 or C80) on packing (11),
and install packing on groove or turbine scroll.
b. Fabricate a patch from material (C86.1). Form
the material to nest over the damaged area with a 0.75
inch overlap. c. Mix adhesive and activator (C17), and apply to
joining surfaces of hose (6), housing assembly (8), and
C . Lightly sand the mating surfaces of the part to be nozzle (9); then install hose (6) on housing assembly
repaired and the patch with 300 grit sandpaper (8). Insert nozzle (9) into housing assembly (8). Position
(C102). Wipe clean areas with a clean cloth. Do not housing assembly (8) and nozzle (9) on turbine scroll.
use solvents. Install retainer (10). Position hose (6) on duct assembly
d. Mix adhesive (C17.1) and apply to repair patch (4). Install clamps (5 and 7) to secure hose (6) on duct
mating surface. Place patch on repair and apply 5 to 20 assembly (4) and housing assembly (8). Tighten upper
psi pressure during cure cycle of 7 days at 70 to 80F, or clamp (5) on hose but snug lower clamp (7) lightly to
two hours at 160F. prevent squeezing out adhesive, Check that nozzle (9)
e. After cure of adhesive, apply a coat of Iexcote is aligned in turbine scroll.
(C72.1). d. Install sleeve (20) over each end of tube (23).
13-35. REPAIR OR REPLACEMENT - ECU Position duct and sleeves in place and install couplings
COOLING TURBINE. (1 and 19).
Replace ECU cooling turbine if it fails to meet e. Install packing (15) in groove of turbine scroll.
inspection requirements. f. Insert duct assembly (18) in turbine scroll and
install screw (17) and washer (16).
13-35.1. LUBRICATION - ECU COOLING
TURBINE.
a. Remove filler plug (figure 13-6.1). 13-37. PRESSURE REGULATING AND
SHUTOFF VALVE.
b. Add approximately 50CC of lubricating oil (C79 or
C80).
13-38. DESCRIPTION - PRESSURE
c. Allow two minutes for oil wicks to become REGULATING AND SHUTOFF VALVE.
saturated.
The pressure regulating and shutoff valve is located in
d. Remove drain plug. Allow excess oil to drain out. the engine compartment and limits the flow of bleed air
to the ECU. It also acts as an ON-OFF valve for the
ECS.
Do not over lubricate. Excessive lubri- Premaintenance Requirements for Pressure
cation may cause damage to turbine. Regulating and Shutoff Valve
Excess oil must be drained before
operation. Excess oil drained from tur- Condition Requirements
bine must not be reused. Model AH-1P/E/F
Part No. or Serial No. All
e. I n s e r t w i r e s i n t o h o u s i n g i f p r o t r u d i n g .
Wires are utilized for functional test of turbine. Special Tools None
f. Install drain plug and filler plug and safety with Test Equipment (T7)
Iockwire (C137). Support Equiment (S12) (S15)
13-36. INSTALLATION - ECU COOLING Minimum Personnel Two
TURBINE. Required
NOTE Consumable Materials (C112)
Refer to paragraph 13-35.1 for Special Environmental None
lubrication instructions prior to Conditions
installation.
Change 12 13-13
TM 55-1520-236-23
13-39. REMOVAL - PRESSURE c. Disconnect duct at air flow outlet (6).
REGULATING AND SHUTOFF VALVE.
d. Disconnect tube at air flow inlet (7).
a. Open engine cowling on left side, and disconnect
electrical plug from solenoid (2, figure 13-7.) e. Remove screws (10), washers (11), and nuts (12),
holding bracket (9) to structure and remove valve (5).
b. Disconnect supply pressure tube at supply inlet
port (1).
Figure 13-7.
13-14 Change 11
TM 55-1520-236-23
13-40. C L E A N I N G - PRESSURE c. Apply 28 Vdc power (S12) to pins 3 and 6 to
REGULATING AND SHUTOFF VALVE. energize solenoid (2). Confirm that solenoid shifts
position by audible click when the power is applied.
d. Increase inlet pressure to 20 p s i g .
e. If valve fails to stroke open, replace solenoid (2).
Cleaning solvent is flammable and toxic. f. Actuator head pressure should be between 7
Provide adequate ventilation. Avoid and 8 psig. Relief valve (3) should relieve at 7 TO 8
prolonged breathing of solvent vapors psig. If pressure exceeds 8 psig or no valve action is
and contact with skin or eyes. seen, replace relief valve.
a. Clean pressure regulator and shutoff valve g. Set downstream flow control gate to flow
with solvent (C112). maximum of 14.5 TO 15.5 Ibs per minute at 35 psig
during test.
b. Wipe dry with a clean lint-free cloth.
h. Reduce inlet pressure to 40 psig. Valve should
regulate to 32 TO 38 psig. If valve fails to regulate,
13-41. I N S P E C T I O N - PRESSURE replace vaIve.
REGULATING AND SHUTOFF VALVE.
i. De-energize solenoid (2). Valve should close.
a. Visually inspect all threaded parts for crossed,
broken, or cracked threads. j. Energize solenoid (2). Valve should open and
regulate 32 TO 38 psig.
b. Inspect for excessive wear or damage and
leaking. k. De-energize solenoid (2) and increase inlet
pressure. Check for leakage. Check valve seat for
13-42. REPAIR OR REPLACEMENT - damage or obstruction causing excessive leakage.
PRESSURE REGULATING AND SHUTOFF
VALVE. NOTE
a. Replace valve if damaged, cracked, crossed, or Some leakage is acceptable.
broken threads are found.
l. Decrease inlet pressure to zero and disconnect
b. Replace valve if excessive leakage is detected from valve.
or seat is damaged. (Refer to troubleshooting chart,
table 13-1, for operational check). m. Disconnect pressure gage.
13-43. T E S T I N G - PRESSURE n. Disconnect electrical power source.
REGULATING AND SHUTOFF VALVE
(FIGURES 13-7 and 13-8). (AVIM) o. Replace pressure regulating and shutoff valve
if it fails to meet the inspection requirements.
NOTE
13-44. INSTALLATION - PRESSURE
Perform all tests on helicopter if possible. REGULATING AND SHUTOFF VALVE.
Equipment required for testing the
pressure regulating and shutoff valve is a. Secure valve to structure with bracket (9, figure
listed in the premaintenance 13-7), using screws (10), washers (11), and nuts (12).
requirements.
b. Position tube to airflow outlet (6) and secure
a. Connect regulated air to supply inlet (1, figure with attaching hardware.
13-7).
c. Position duct to supply inlet (1) and secure with
b. Connect pressure gage (T7) to test port (8). attaching hardware.
13-15
TM 55-1520-236-23
Figure 13-8.
13-16
TM 55-1520-236-23
d. Connect electrical plug to solenoid on valve (2). actuating the solenoid valve to shut off the flow of
bleed air to the ECU.
e. Install engine cowling on left side of helicopter.
13-44.1. AIR DISTRIBUTION
13-47. REMOVAL - THERMAL PROBE
PRESSURE REGULATOR VALVE SWITCH.
SOLENOID FILTER.
a. Remove electrical wiring.
13-44.2. DESCRIPTION - A I R
DISTRIBUTION PRESSURE REGULATOR b. Remove thermal switch (27, figure 13-1) and
VALVE SOLENOID FILTER. packing (28) from duct.
The solenoid filter is located in the supply pressure
port of solenoid valve. The purpose of the filter is to 13-48. INSPECTION - THERMAL PROBE
filter supply air to the pressure solenoid. SWITCH.
13-44.3. REMOVAL - AIR DISTRIBU- Inspect thermal switch for corrosion and condition.
TION PRESSURE REGULATOR VALVE
SOLENOID FILTER. 13-49. REPAIR OR REPLACEMENT -
Remove the pressure supply line and remove filter
THERMAL PROBE SWITCH.
Replace switch if it fails to meet inspection or operational
assembly from solenoid.
requirements. Switch opens at 225 degrees F 8
degrees F, switch closes at 260 degrees F 6 degrees F.
13-44.4. C L E A N I N G - AIR
DISTRIBUTION PRESSURE REGULATOR 13-50. INSTALLATION - THERMAL
VALVE SOLENOID FILTER. PROBE SWITCH.
Disassemble filter and clean with solvent (C112). Dry a. Place packing (28, figure 13-1) on thermal
with compressed air. probe switch (27) and install switch in duct.
13-44.5 INSPECTION - AIR b. Connect electrical wiring.
DISTRIBUTION PRESSURE REGULATOR
VALVE SOLENOID FILTER.
13-51. AMBlENT AIR BLOWER.
Inspect filter for cleanliness and deformation
Reassemble filter. 13-52. DESCRIPTION - AMBlENT AIR
BLOWER.
13-44.6. INSTALLATION - AIR
A continuously operated transmission drive blower
DISTRIBUTION PRESSURE REGULATOR
(4, figure 13-1) is mounted on a pad provided on the
VALVE SOLENOID FILTER. forward side of the transmission.
Install filter assembly into solenoid and connect air
supply line. Premaintenance Requirements for Blower
13-45. THERMAL PROBE SWITCH. Condition Requirements
13-46. DESCRIPTION - THERMAL Model AH-1E, F, & P
PROBE SWITCH.
Part No. or Serial No. All
A thermal probe switch is installed in a duct in the
outlet side of the ECU to prevent excessively hot air Special Tools None
from entering the distribution system. If excessive
heat reaches the overheat switch, the switch opens, Test Equipment None
Change 16 13-17
TM 55-1520-236-23
Figure 13-9.
Support Equipment None c. Remove eight attaching bolts (3, figure 13-9),
washers (4), and remove inlet adapter (14).
Minimum Personnel Two
d. Cut Iockwire and remove bolt (17) and washer
Required
(16).
Consumable Materials (C36) (C88) (C91) (C112) e. Separate housing (6) from transmission pad by
(C138) cutting Iockwire and removing bolts (10) and washers
(9).
Special Environmental None
Conditions 13-54. DISASSEMBLY - AMBlENT AIR
BLOWER.
a. Move impeller (13, figure 13-9) forward to clear
13-53. REMOVAL - AMBlENT AIR
housing (6) then remove housing and gasket (8).
BLOWER.
a. Open hydraulic compartment door on right side b. Remove impeller and separate impeller fitting
of helicopter and remove right side transmission (15) from impeller (13) by removing nuts (1), washers
cowling to gain access to blower area. (2), and bolts (5).
b. Remove intake and exhaust ducts by removing c. Remove bolts (12) and washers (11) and
clamps and hardware. separate adapter (7) from housing (6).
13-18 Change 3
TM 55-1520-236-23
13-55. CLEANING - AMBlENT AIR
BLOWER.
Cleaning solvent is flammable and toxic.
Provide adequate ventilation. Avoid
prolonged breathing of solvent vapors
and contact with skin or eyes.
a. Clean disassembled parts with solvent (C112).
b. Dry with a clean lint-free cloth.
13-56. INSPECTION - AMBlENT AIR
BLOWER.
Inspect blower assembly components as follows:
(figure 13-9).
a. Adapters. Inspect adapters (7 and 14) for
cracks or breaks in material and for corrosion
damage.
Change 3 13-18.1/(13-18.2 blank)
TM 55-1520-236-23
b. Housing. Inspect blower housing (6) for 13-58. ASSEMBLY - AMBlENT AIR
dents and deformity, cracks, and corrosion damage. BLOWER.
c. Impeller Fitting. Inspect impeller fitting (15) a. Attach impeller fitting (15, figure 13-9) to
for cracks, damaged internal splines, and corrosion impeller (13) with four bolts (5), aluminum washers
damage. (2) and nuts (1).
d. Impeller. Inspect impeller (13) for deformity, b. Attach adapter (7) to housing (6) with bolts (12)
broken welds, cracked or damaged blades, and and aluminum washers (11).
corrosion damage.
13-57. REPAIR OR REPLACEMENT -
AMBlENT AIR BLOWER. 13-59. INSTALLATION - AMBlENT AIR
BLOWER.
a. Adapters.
a. Position impeller (13) in opening in firewall.
(1) R e p l a c e adapter (7 and 14, figure 13-9) if
cracked.
b. Place gasket (8) and housing (6) on transmission
pad; install six bolts (10) with aluminum washers (9).
(2) C l e a n u p m i n o r c o r r o s i o n d a m a g e w i t h
Torque bolts (10) 15 TO 20 inch-pounds. Secure bolts
abrasive cloth (C36), and touch up with primer (C88 or
with Iockwire (C137).
C91). If corrosion damage is severe enough to affect
function, replace the adapter.
c. Position impeller (13) in housing (6),
b. Housing.
d. Place washer (16) under head of bolt (17), and
(1) Replace blower housing (6) if cracked install bolt through fitting (15). Torque bolt (17) 80 T0
100 inch-pounds and Iockwire to shank of bolt (5).
(2) Clean up minor corrosion damage with Use Iockwire (C138).
abrasive cloth (C36), and touch up with primer (C88 or
C91). If corrosion damage is severe enough to affect
function, replace the housing. e. Install intake and exhaust ducts with clamps
and attaching hardware.
c. Impeller Fitting.
f. C l o s e h y d r a u l i c compartment door and
transmission cowling.
(1) Replace impeller fitting (15) if cracked or for
damaged internal splines.
13-60. VENT AIR CONTROL VALVE.
(2) Clean up minor corrosion damage with
abrasive cloth (C36) and touch up with primer (C88 or
C91). If corrosion damage is severe enough to affect
function, replace the impeller fitting. 13-61. D E S C R I P T I O N - V E N T A I R
CONTROL VALVE.
d. Impeller.
The vent air control valve located between the
(1) Replace impeller (13) with deformed or transmission-driven blower and the ducts
cracked blades, or broken welds. distributing air to the crew compartment is an on-off
valve. When the ECS is functioning, the valve is
(2) Clean up minor corrosion damage with normally closed. Lack of bleed air pressure against
abrasive cloth (C36) and touch up with primer (C88 or the valve permits the valve to open, allowing the
C91). If corrosion damage is severe enough to affect transmission driven blower to force ambient air into
function, replace the impeller fitting. the crew compartment (figure 13-1).
Change 7 13-19
TM 55-1520-236-23
Premaintenance Requirements for h. Remove coupling (17) from valve (11).
Vent Air Control
i. Loosen nut (2) and remove regulator (4) from
Condition Requirements union (1). Remove union from valve (11).
13-63. DISASSEMBLY - VENT AIR
Model AH-1S
CONTROL VALVE.
Part No. or Serial No. All
a. Remove nuts (12, figure 13-11), screws (1),
washers (11), and cover (3).
Special Tools None
b. R e m o v e c o t t e r p i n ( 2 7 ; a n d p i n ( 2 4 ) t o
Test Equipment (T18)
disconnect links (22 and 25) from rod end connector
(8).
Support Equipment (S12) (S14) (S15)
c. Remove diaphragm (6) with assembled plate (5)
Minimum Personnel Two
and rod end connector (8). Remove spring (9).
Required
d. Remove screw (4), rod end connector (8), plate
Consumable Materials (C17) (C63) (C73)
(5), and cup (7).
(C112) (C124)
e. R e m o v e l i n k s ( 2 2 a n d 2 5 ) f r o m b u t t e r f l y
Special Environmental None
assembly (20).
Conditions
f. Remove screws (19), stiffener (18), and
butterfly assembly (20).
13-62. REMOVAL - VENT AIR CONTROL
VALVE. g. Slide shaft (21) out of body and remove spacer
(19), bearing (15), special washer (16), and spacer
a. Remove hydraulic compartment access door (18) from both sides of body assembly (10).
located on right side of helicopter and aft of pilot door.
13-64. CLEANING - VENT AIR CONTROL
b. Disconnect hose assembly (3, figure 13-10) VALVE.
from regulator (4), loosen nut on opposite end of hose
assembly (3), and rotate tube away from regulator. a. Clean bearings (15, figure 13-11) with a clean,
lint-free cloth.
c. Remove screw (6), washer (7), and nuts (8).
Slide clamp (9) up on flex duct (5) until it is clear of
bracket (10).
Cleaning solvent is flammable and toxic.
d. Remove screw (19), washer (20), and nut (21).
Provide adequate ventilation. Avoid
Slide clamp (18) upon coupling (17).
prolonged breathing of solvent vapors
and contact with skin or eyes.
e. Use a round-edged probe to separate coupling
(17) from duct assembly (22) and flex duct (5) from
b. Clean all parts except bearings with solvent
valve (11).
(C112). Dry parts with filtered compressed air at 2 0
TO 25 psig. Do not spin or dry bearings with
f. Remove screw (14), washer (15), and nut (16). compressed air.
Slide clamp (12) off bracket (13). Lift valve (11),
regulator (4), and coupling (17) out of the 1 3 - 6 5 . INSPECTION - VENT AIR
compartment. CONTROL VALVE.
g. Cover open ends of hose assembly (3) and a. Inspect cover assembly (3, figure 3-11) for
ducts (5 and 22) to prevent entry of foreign material. damaged threads in port.
13-20
TM 55-1520-236-23
Figure 13-10.
Change 2 13-21
TM 55-1520-236-23
Figure 13-11.
13-22
TM 55-1520-236-23
b. Inspect rod and connector (8) for damaged b. Slide shaft (21) partially into body (10) and
threads and for wear. Minimum diameter is 0 . 3 7 0 position spacer (17), special washer (16), bearing
inch. (15), and spacer (14) on shaft in sequence illustrated.
Install spacer (14) with the beveled side toward
c. Inspect plate (5) and cup (7) for distortion. Also bearing (15). Position these parts in boss of body (10)
check diameter of cup. Maximum outside diameter is and install corresponding bearing spacers and
2.312 inches. washer on opposite side.
d. Inspect diaphragm (6) for tears, cracks, and c. Install links (22 and 25) on butterfly assembly
distortion. (20) with pin (23) and cotter pin (26).
e. Inspect spring (9) for deformation and for free d. Position butterfly assembly on shaft (21) in
length of 3.06 inch. Check spring tension. The weight same relative position illustrated so that it will be on
required to compress the spring to 2.25 inches must the correct side of stop (13) when assembly is
be 10.4 TO 12.4 pounds. The weight required to complete. Secure butterfly assembly to shaft (21)
compress the spring to 0.95 inch must be 26.6 TO with stiffener (18) and three screws (19). Move the
32.6 pounds. butterfly assembly manually to ensure that it moves
freely through full range of travel.
f. Inspect holes in links (22 and 25) for wear.
Manufacturing tolerance is 0 . 1 2 4 5 T O 0 . 1 2 5 5 . e. Assemble rod end connector (8), cup (7),
Center to center dimension is 0.745 TO 0.755 inch. diaphragm (6), plate (5), and screw (4) in same relative
No distortion is allowed. positions illustrated. Install screw (4) snug but do not
torque.
g. Inspect stiffener (18) for deformation.
h. Inspect butterfly (20) for distortion and wear. f. Make trial installation of parts assembled in
Minimum diameter is 4.893 inches. Minimum preceding step. Align holes in diaphragm with holes
dimension across flats is 4.770 inches. in body (10) and insert three screws (1) to maintain
alignment. Rotate rod end connector (8) so that it will
i. Inspect shaft (21) for deformation and for align with links (22 and 25) and tighten screw (4).
damaged threads. Check diameter. Minimum Remove diaphragm (6) and attached parts from body
diameter is 0.3740 i n c h . assembly.
j. I n s p e c t b o d y a s s e m b l y ( 1 0 ) f o r d a m a g e d g. Position spring (9) in body assembly (10) and
bushings. No scoring is allowed. Inspect stop (13) for install diaphragm (6) with attached parts, Secure
secure installation. links (22 and 25) to rod end connector (8) with pin (24)
and cotter pin (27). Check diaphragm to ensure that
k. Inspect bearings (15) for galling and scoring. the holes line up with the holes in the body without
None aIlowed. twisting the diaphragm. Position cover assembly (3)
on body assembly with threaded boss oriented with
l. Inspect identification plate (2) for legibility and the body assembly (10) and stop (13) as illustrated.
secure attachment. Install screws (1), washers (11), and nuts (12).
13-66. REPAIR OR REPLACEMENT -
VENT AIR CONTROL VALVE.
13-68. TESTING - VENT AIR CONTROL
Do not attempt to repair any parts of the control valve. VALVE (FIGURES 13-11 AND 13-12).
Replace any parts which fail to pass inspections
described in paragraph 13-65. a. If the test set-up shown on figure 13-12 is not
available, perform functional check on helicopter
13-67. ASSEMBLY - VENT AIR CONTROL after installation, paragraph 13-69.
VALVE.
b. If the test set-up shown on figure 13-12 is
a. L u b r i c a t e b e a r i n g s ( 1 5 , f i g u r e 3 - 1 1 ) w i t h available, install the vent air control valve as
lubricant (C73). illustrated.
13-23
TM 55-1520-236-23
Figure 13-12.
c. A d j u s t p r e s s u r e a t a c t u a t i o n a i r s u p p l y g. If the vent air control valve fails to pass the
regulator (T18) to apply 7.0 0.5 psig pressure to the tests in steps b. through f., forward the assembly to
vent air control valve. The butterfly assembly should next higher level of maintenance.
move to full closed.
13-69. INSTALLATION - VENT AIR
d. Decrease pressure to vent air control valve to CONTROL VALVE.
zero. The butterfly assembly (20), figure 13-11)
should move to full open. a. Thread nut (2, figure 13-10) on union (1),
Lubricate two packings (23) lightly with hydraulic
e. Repeat steps c. and d. except apply 25 1 . 0 fluid (C63) or other suitable lubricant and position
psig pressure to the vent air control valve. The packings on union (1). Install union (1) on valve (11)
butterfly assembly (20) should be full open while and install regulator (4) on union (1). Do not tighten
pressure is applied and full closed when pressure is nut (2) at this time.
removed.
b. Apply a light coat of adhesive (C17) to lower
f. Adjust pressure at the actuation air supply flange of valve (11). Position coupling (17) on valve.
regulator (T18) to apply 7.0 0.5 psig pressure to the Install clamp (12) with screw (14), thin aluminum
vent air control valve and maintain pressure to keep washer (15), and nut (16) but do not tighten at this
butterfly assembly (20) closed. Adjust air flow time.
regulator to increase pressure until reading on the
water manometer (S14) is 27.0 inches. Check the c. Place clamp (18) on duct (22) and place clamp
flowmeter. and record the leakage rate across the (9) on flex duct (5).
butterfly assembly. If the leakage rate is more than
five cubic feet per minute, remove the vent air control d. Position valve (11) in the right side of the
valve from the test set-up and remove one special hydraulic compartment with the boss (24)
washer (16, figure 13-11). Reassemble the vent air uppermost as illustrated. Slide clamp (12) over
control valve and repeat the tests. bracket (13).
U.S. OOVCRNM8NT l RINTINO OWICSI lSO~.SC409WlS10
13-24 Change 2
TM 55-1520-236-23
e. Apply a light coat of adhesive (C17) to upper 13-73. INSPECTION - VENTILATING
flange of valve (11). Position flex duct (5) on valve (11)
DUCTS.
and slide clamp (9) into position on the flex duct and
also on bracket (10). Install screw (6), thin aluminum a. Ducting and insulation for damage, chafing, or
washer (7), and nut (8), but do not tighten at this time. leakage.
f. Attach tube assembly (3) to regulator (4). Turn b. Clamps and connections for security and for
the regulator or union (1) and/or rotate valve (11), if leakage around clamps.
required to obtain alignment with hose assembly (3).
Tighten nuts at each end of hose assembly (3) and c. Intake screen for obstruction.
also nut (2).
g. Check clamps (9, 12, and 18) to ensure that 13-74. REPAIR OR REPLACEMENT -
they are properly positioned on the ducts and valve VENTILATING DUCTS.
and that the two upper clamps are positioned properly
on the brackets. Tighten the nuts and screws on each a. Replace damaged or leaking ducts.
of the three clamps.
b. C l e a n i n t a k e screen if clogged, using
h. If the helicopter is operational, perform a compressed air.
functional check of the vent air control valve.
NOTE c. T i g h t e n c l a m p s o r c o n n e c t i o n i f l o o s e o r
leaking.
The vent air control valve is normally
open and is closed by bleed air pressure. d. Repair insulation if torn or damaged.
(1) Ground run the helicopter. Position the
HTR/RAIN RMV (ECU) switch to OFF. Open one of the 13-75. INSTALLATION - VENTILATING
air outlet nozzles in the pilot compartment. There DUCTS.
should be a flow of air at ambient temperature. Move
the ECU COOL/WARM selector to full WARM and
check temperature of air flowing from outlet by feel.
Move temperature selector to full COOL and check
temperature of air flowing from outlet. The When instalIing ducts, insure that adequate
temperature should not change. clearance exists between the ducts and the
cyclic control tubes to allow free movement
(2) Position the HTR OFF, RAIN RMV (ECU) over the full travel range of the tubes.
switch to HTR. Repeat the check of the temperature of
air flow from outlet nozzle with the temperature
selector at full WARM and at full COOL as outlined in
step (1). The vent air control valve should be closed a. P o s i t i o n d u c t s a n d s e c u r e w i t h h a r d w a r e
and the temperature of the air should change when and/or clamps.
the temperature selector is changed.
b. Install insulation and secure with tape (C122).
13-70. VENTILATING DUCTS.
13-71. DESCRIPTION - VENTILATING 13-76. AIR CONTROL VALVE.
DUCTS.
13-77. DESCRIPTION - AIR CONTROL
The ducts transport air from the inlet duct into the
VALVE.
cabin and are of two types, rigid and flexible. They are
attached to components by couplings and clamps An air control valve (figure 13-1) is operated by a
(figure 13-1). cable control from the pilot instrument panel. The
13-72. R E M O V A L - VENTILATING valve regulates the amount of air entering the
DUCTS. distribution system. When fully closed, all air to crew
compartment is shut off, except to pilot seat cushion.
Remove insulation, attaching hardware and /or When cabin air is desired, the control should be full
clamps and remove components. out and air control valve full open.
Change 9 13-25
TM 55-1520-236-23
13-78. REMOVAL - AIR CONTROL approximately perpendicular to surface of duct. With
VALVE. control full out, lever on valve should be
approximately horizontal to surface of duct.
a. Remove cotter pin, washer, and pin from clevis
end of control cable at control valve and duct 13-81. AIR OUTLET VALVES.
assembly.
13-82. DESCRIPTION - AIR OUTLET
b. R e m o v e s c r e w s , w a s h e r s , a n d n u t s f r o m VALVES.
clamps, brackets, and supports securing heat or vent
air pull control (16, figure 13-1) to fuselage and The outlet valves (7, 12, and 15, figure 13-1) are
ducting. located in gunner and pilot compartments or at left
and right sides of instrument panels. The air outlet
c. Loosen locknut from control valve housing. valves are adjustable to direct flow and/or amount of
Remove control from helicopter. conditioned air, as desired. The defog outlets (7,
figure 13-1) are located in the pilot compartment at
13-79. INSPECTION - AIR CONTROL right and left sides of instrument panel console. The
VALVE. defog outlets consist of a tab slider mounted to
plenum assembly. Adjustment of slider directs
a. Inspect control valve (10, figure 13-1) for conditioned air to defog canopy.
locking in all positions. Lock should hold a load of 8 13-83. REMOVAL - AIR OUTLET VALVES.
pounds without slippage. Apply 8 pounds pressure
using a force gage (fish scale). Remove attaching screws and washers and remove
air outlet valves.
b. Inspect control, housing, cable, and clevis for
damage and corrosion. 13-84. INSPECTION - AIR OUTLET
VALVES.
c. Inspect valve in duct assembly for freedom of
operation and range of travel. a. Inspect air outlet valves (7, 12, and 15, figure
13-1) for condition and operation.
d. Control valve assembly is nonrepairable and
must be replaced if it fails to meet inspection b. Inspect defog outlets slider tab and plenum for
requirements. wear and damage.
13-80. INSTALLATION - AIR CONTROL c. inspect connecting ducts for serviceability.
VALVE. 13-85. REPAIR OR REPLACEMENT - AIR
OUTLET VALVES.
a. Route heat or vent air pull control (16, figure
13-1) through instrument panel opening through
Replace valves that do not meet inspection
fuselage structure to air control valve and duct
requirements.
assembly.
13-86. INSTALLATION - AIR OUTLET
b. Secure assembly with previously removed
VALVE.
screws, washers, clamps, brackets, and supports.
a. Position air outlet valves on connecting ducts.
c. Attach clevis end of heat or vent air pull control
(16) to lever on air control valve and duct assembly.
b. Install attaching screws and washers.
Secure with pin, washers, and cotter pin.
13-87. RAIN REMOVAL SYSTEM.
d. Check heat or vent air pull control (16) for
freedom of movement and locking in intermediate 13-88. DESCRIPTION - RAIN REMOVAL
position. SYSTEM (FIGURE 13-13).
e. With heat or vent air pull control (16) pushed The rain removal system consists of a series of tubes
full in, check that lever on valve and duct assembly is from the engine compressor section to the nozzle next
13-26
TM 55-1520-236-23
to lower windshield where it is vented. This nozzle pro- 13-93. REPAIR OR REPLACEMENT -
vides air to force moisture from the outer surface of RAIN REMOVAL MANIFOLD.
windshield in a standard pattern (figure 13-15). Seven
small nozzles are grouped together and distribute the Replace rain removal manifold assembly if damaged.
air from the nozzle assembly. A selector switch on the No repairs are acceptable.
pilot instrument panel allows bleed air to flow through
the tubes and out the vent to the windshield. A drain 13-94. INSTALLATION - RAIN REMOVAL
valve (16) is provided to prevent the collection of MANIFOLD.
moisture in tube system.
a. I f n o t p r e v i o u s l y a c c o m p l i s h e d , r e m o v e
components listed in paragraph 13-91, a.
13-89. RAIN REMOVAL MANIFOLD.
b. Position rain removal manifold (4, figure 13-
13-90. DESCRIPTION - RAIN REMOVAL 13) in helicopter and position duct assembly (22) on
MANIFOLD. the manifold. Tighten nut (23).
c. Hold rain removal manifold next to helicop-
There are seven small nozzles which are grouped
ter structure and instalI four screws (6) and
together in line and direct the flow of air from the
washers (7).
manifold assembly to the windshield.
d. Position bleed air tube on left end of manifold
and tighten ring (10), Iockwire ring (10) with Iockwire
13-91. REMOVAL - (C137).
RAIN REMOVAL
MANIFOLD.
e. I n s t a l l t u b e ( 1 2 ) o n l e f t e n d o f m a n i f o l d
a. Remove the following components from the assembly.
gunner instrument panel.
f. Install the following components in the gunner
instrument panel.
(1) Gyro horizon
(2) Airspeed indicator (1) Gyro horizon
(2) Airspeed Indicator
(3) Tow control set
(4) Mu ARC 14 Radio (3) Tow control set
(4) ~ ~ ARC 14 Radio
~ Doppler Navigation Set
b. D i s c o n n e c t t u b e ( 1 2 , f i g u r e 1 3 - 1 3 ) f r o m ~ Doppler Navigation Set
manifold assembly (4).
g. P e r f o r m f u n c t i o n a l c h e c k o f c o m p o n e n t s
c. Remove Iockwire (11), loosen ring (10), and installed in step f.
disconnect bleed air tube from manifold.
h. Perform operational check of rain removal
d. Remove four screws (6) and washers (7). system.
Separate manifold from helicopter structure.
13-95. TEMPERATURE CONTROL
e. Loosen nut (23) and remove duct assembly (22) VALVE.
from manifold. Remove manifold from helicopter,
13-96. DESCRIPTION - TEMPERATURE
13-92. INSPECTION - RAIN REMOVAL CONTROL VALVE.
MANIFOLD.
A windshield clearing temperature control valve (18),
Inspect manifold assembly (4, figure 13-13) for figure 13-13) is located at F.S. 46 and W.L. 67.00 in
cleanliness and damage. the ambient air line to the manifold. The valve is
Change 11 13-27
TM 55-1520-236-23
Figure 13-13.
13-28
TM 55-1520-236-23
actuated by bleed air pressure and controlled by a 13-101. R A I N R E M O V A L T H E R M A L
solenoid. The valve is normally open to supply SWITCH.
ambient air to the manifold (4). A thermal switch (5),
imbedded in the windshield, controls valve operation. 13-102. DESCRIPTION - RAIN REMOVAL
When the system is turned on, the valve closes. The THERMAL SWITCH.
valve remains closed and bleed air is supplied to the
nozzle assembly until the thermal switch opens at A thermal switch mounted in the windshield (figure
125 degrees F (52 degrees C), de-energizing the 13-14) provides thermal protection to the windshield.
valve solenoid. The valve then opens and supplies When rain removal air exceeds preset limits, the
ambient air to the manifold. The cooler ambient air switch opens and actuates temperature control valve
mixes with bleed air flow as it is distributed through (18, figure 13-13) to prevent overheating the
nozzles to the windshield. windshield.
13-97. REMOVAL - TEMPERATURE
CONTROL VALVE. 13-103. INSPECTION - RAIN REMOVAL
THERMAL SWITCH.
a. Disconnect electrical plug at temperature
control valve (18, figure 13-13). Switch should open at 125 5 degrees F (52 3
b. Disconnect one end of tube (12) at temperature degrees C) and close at 100 5 degrees F (38 3
control valve (18). degrees C).
c. Remove screws (20) and washers (19).
13-104. REMOVAL - RAIN REMOVAL
d. Remove nuts (21), washers (24), screws (17), THERMAL SWITCH (FIGURE 13-14).
and clamps (14 and 25) from each end of temperature
valve. Remove temperature control valve from ducts Press thermal switch (figure 13-14) from windshield
(13 and 22) and helicopter. and disconnect wiring.
13-98. INSPECTION - TEMPERATURE 13-105. INSTALLATION - RAIN
CONTROL VALVE. REMOVAL THERMAL SWITCH.
a. Inspect temperature control valve for damage.
a. Scrape old sealant from windshield and clean
area by using crocus cloth (C37) and damp cloth to
b. Apply 12 Vdc power (S12) to determine if part
remove old adhesive from windshield.
is operating properly.
b. P r e p a r e adhesive (C14) according to
13-99. REPAIR OR REPLACEMENT - manufacturers instructions.
TEMPERATURE CONTROL VALVE.
NOTE
Replace temperature control valve if damaged or
inoperative. No repairs are acceptable.
Pot life of adhesive at room temperature
- is approximately 30 minutes.
13-100. INSTALLATION
TEMPERATURE CONTROL VALVE.
c. Apply light coat of adhesive (C14) to mating sur-
a. Install washers (19, figure 13-13) and screws face of thermoswitch and windshield and press ther-
(20) to attach temperature control valve (18) to moswitch into opening in windshield. Allow adhesive
structure. to cure in accordance with table 1-11.
b. Slip end of ducts (13 and 22) over ends of
NOTE
temperature control valve and install clamp (14),
screws (17), washers (24), and nuts (21).
Remove any adhesive accidentally ap-
c. Connect one end of tube (12) to temperature plied to outside surface of thermo-
control valve. switch.
d. Connect electrical plug to temperature control
valve (18). d. Connect electrical wiring (Appendix F).
Change 12 13-29
TM 55-1520-236-23
13-108. REMOVAL - RAIN REMOVAL
TUBING.
a. Remove panel on left side of helicopter below
windshield.
b. Remove panels (28, 30, 32, 33, 36, and 37,
figure 2-3) in order to gain access to tubing.
c. Remove attaching hardware and/or clamps
and couplings, and remove components.
13-109. INSPECTION - RAIN REMOVAL
TUBING.
Inspect tubing for security, damage, and leaks
(fgure 13-1).
b. Inspect couplings for leakage and security.
Figure 13-14.
c. Check drain valve (16, figure 13-13) for proper
operation.
13-110. REPAIR OR REPLACEMENT -
RAIN REMOVAL TUBING.
a. Tighten couplings if loose or leaking.
b. Replace drain valve (16, figure 13-13) if
damaged or inoperative.
c. Replace tubing if damaged.
13-111. INSTALLATION - RAIN
REMOVAL TUBING:
a. Install hardware and/or clamps and couplings
to attach tubing.
b. Install panels (28,30,32,33,36, and 37,figure
2-3).
c. Install panel left side of helicopter below
windshield.
13-106. RAIN REMOVAL TUBING. 13-112. RAIN REMOVAL VALVE.
13-107. DESCRIPTION - RAIN REMOVAL 13-113. DESCRIPTION - RAIN REMOVAL
TUBING. VALVE.
A series of tubes is located from the engine The rain removal valve (9, figure 13-1) serves to route
compressor section to the rain removal manifold a portion of engine bleed air to the helicopter
assembly. Also, a drain tube is provided to prevent the windshield rain removal nozzle. When the pilot ECS
collection of moisture in tube system. switch is positioned to RAIN RMV, the solenoid
13-30 Change 12
TM 55-1520-236-23
Figure 13-15.
13-31
TM 55-1520-236-23
actuated pilot valve allows a small amount of bleed air 13-115. FUNCTIONAL TEST - RAIN
to vent through a series of flow-control orifices to REMOVAL VALVE.
atmosphere. This creates a pressure imbalance
which causes line pressure to lift the poppet
assembly off the seat inside the body. This allows NOTE
bleed air to flow to the rain removal nozzle located at
the base of the windshield. If there are any malfunctions during this
test, refer to Troubleshooting Chart,
13-114. ADJUSTMENT RAIN paragraph 13-116.
REMOVAL VALVE.
Premaintenance Requirements for Inspection
and Adjustment of Rain Removal Valve a. Attach solenoid leads to a source of 18-30 Vdc
electrical power (S12) that is controlled by a switch.
Condition Requirements
Model AH-1S
b. Cap one of the open ports on the valve body and
All attach a source of 100 psig compressed air (S15) to
Part No. or Serial No.
the opposite port. Turn the air pressure on and
(T76) (T2) regulate to 100 psig.
Special Tools
Test Equipment None
c. Cycle the valve ten times and record time
Support Equipment (S12)(S15) required to open and close. The tolerance is 0.5 to
2.0 seconds. After last actuation, measure leakage at
Minimum Personnel Two
the normally closed port. Maximum allowable
Required leakage is 0.05 pounds per minute.
Consumable Materials (C32) (C36) (C37)
(C59) (C112) (C137)
Special Environmental None
13-116. TROUBLESHOOTING - RAIN
Conditions
REMOVAL VALVE.
NOTE
Before using this table, ensure all normal
operational checks have been
performed. If a malfunction occurs
which is not listed in this table, notify the
next higher maintenance level.
Table 13-2. Troubleshooting Rain Removal Valve
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. Valve does not open when energized.
STEP 1. Perform solenoid coil resistance test. Refer to paragraph 13-120 b.
If resistance is not within limits, replace solenoid (paragraph 13-123).
13-32
TM 55-1520-236-23
Table 13-2. Troubleshooting Rain Removal Valve (Cont)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
2. Valve does not open or close within allowable time limits (0.5 to 2.0 s e c o n d s ) .
STEP 1. Check for excessive friction on Teflon lip seal or roughness on sliding surfaces (paragraph 13-120).
Disassemble the valve, polish out burrs, relubricate, and reassemble (paragraph 13-121).
3. Valve leaks excessively in closed position.
STEP 1. Inspect poppet assembly seat seal to determine if damaged or worn (figure 13-17).
If surface of seat seal is slightly damaged, dress off surface. If damage is deep, replace the poppet
assembly (paragraph 13-121).
STEP 2. Inspect seal lip in valve body to determine if pitted or scratched (figure 13-17).
If seal lip is pitted or scratched, replace valve body (paragraph 13-123).
13-117. REMOVAL - RAIN REMOVAL d. Remove adapter (6), packing (7), spacer (8),
VALVE. gasket (9), and cap (11). Remove packing (12) from cap
(11).
a. Remove left panel (5, figure 2-3).
e. Remove spring (13) and poppet (16). Remove
b. Disconnect electrical connector to solenoid seal (14) from poppet.
assembly (1, figure 13-16) from valve adapter (6).
c. Disconnect lines and remove the valve.
13-119. CLEANING - RAIN REMOVAL
VALVE.
13-118. D I S A S S E M B L Y RAIN
REMOVAL VALVE.
a. Index adapter (6, figure 13-16), gasket (9), cap
(11), and body (17) with indelible ink marker so that
these parts can be reassembled in the same relative Cleaning solvent is flammable and toxic.
position. Provide adequate ventilation. Avoid
prolonged breathing of solvent vapors
b. Remove Iockwire and remove solenoid (1), and contact with skin or eyes.
spring (2), and armature (3).
a. Clean disassembled parts with solvent (C112).
c. H o l d n u t s ( 1 9 ) a n d r e m o v e b o l t s ( 4 ) a n d
washers (5 and 18). b. Dry with a clean lint-free cloth.
Change 7 13-33
TM 55-1520-236-23
Figure 13-16.
13-34
TM 55-1520-236-23
13-120. INSPECTION - RAIN REMOVAL h. Inspect body (17) for damaged threads. Inspect
VALVE. the sliding surfaces for scoring or scratches. Check
seat surface (7, figure 13-17) for radius of 0.020 o r
a. Use a strong light and magnifying glass to more which would require replacement of the body.
perform visual inspections in the following steps. Replace seat surface if nicked or pitted.
b. Inspect solenoid (1, figure 13-16) for evidence i. Inspect spring rate for springs (1 and 5) for rate
of leakage and deterioration at seams. Inspect within limits shown.
electrical wires and threads for damage. Check
electrical resistance of the solenoid with a multi meter j. Inspect armature to poppet bore (2) for wear in
(T2). Attach a lead from multimeter (T2) to each excess of tolerance shown.
solenoid wire. Read resistance on RX1 scale. If the
reading does not fall between 35 and 38 o h m s , k. Inspect poppet to body bore (6) for wear in
replace solenoid. excess of tolerance shown.
c. Inspect adapter (6) for damaged threads,
13-121. REPAIR OR REPLACEMENT -
corrosion, mechanical damage, and distortion.
RAIN REMOVAL VALVE.
d. Inspect spacer (8), cap (11), spring (2), and
a. Install packings (7 and 12, figure 13-15) and
spring (13) for corrosion, mechanical damage and
Teflon lip seal (14) when the valve is assembled.
distortion. Inspect orifice (10) for damage and for
secure installation in cap.
b. Replace all parts which fail to pass inspections
described in paragraph 13-120.
NOTE
The seat seal referred to in step e. is c. Polish out minor damage on the seat seal on
installed in the poppet with a sleeve poppet (16, figure 13-16). If the seat seal is nicked or
guide and then the lip of the poppet is damaged, replace the entire poppet (16).
spin-formed to retain these parts. See
the sectional view of the poppet on figure d. Polish out minor scoring, nicks, and burrs on
13-17 adjacent to index (7). The area outside areas. Work area until surface is smooth but
between the poppet and the sleeve guide do not alter concentricity. Use abrasive cloth (C36) on
is sealed pressure tight with high aluminum parts and then touch up with chemical film
temperature epoxy. The seat seal cannot (C31). Use crocus cloth (C37) on other parts.
be removed and replaced without
destroying the holding lip, but minor
damage can be dressed out. Refer to 13-122. FUNCTIONAL TEST - RAIN
paragraph 13-121. REMOVAL VALVE.
e. Inspect poppet (16, figure 13-16) for nicks in Refer to paragraph 13-115.
grooves of seal (14). Inspect sliding surface for galling
and scoring. Inspect orifice (15) for damage and 13-123. ASSEMBLY - RAIN REMOVAL
secure installation in poppet. Inspect seat seal in the VALVE.
end of poppet that contacts seat surface in body bore
(7, figure 13-17) for scratches and nicks. a. Position tool (T76) on poppet (figure 13-18).
f. Inspect gasket (9, figure 13-16) for breaks and b. Lubricate Teflon lip seal with a thin film of
distortion in the thin wall sections adjacent to bolt silicone grease (C59) and position on tool with open
holes. Inspect the pilot seat surface (3, figure 13-17) end facing down as illustrated. Slide the seal down
for radius of 0.007 inch or more which would require the tapered wall of the tool and into the groove on the
replacement. Replace gasket if nicks or scratches are poppet.
found in the seat surface.
c. Allow the Teflon lip seal to stabilize for five
g. Inspect armature (3, figure 13-16) at taper and minutes, and then use a round toothpick, or similar
seat area for roughness and wear. non-metallic blunt-ended rod, to work the lip of the
13-35
TM 55-1520-236-23
Figure 13-17.
13-36
TM 55-1520-236-23
Figure 13-17.
seal out until it extends past the surface of the poppet g. Lubricate packing (7) and sliding surface of
equally on all sides. armature (3) with silicone grease (C59) and install
packing in adapter (6). Install armature (3), spring (2)
d. Lubricate sliding surfaces of poppet (16, figure and solenoid (1). Lockwire solenoid from drilled hole
13-16) and body (17) with a thin film of grease (C59). in lug near leads to one of drilled head bolts (4) with
Slide poppet into position in body and place spring Iockwire (C137).
(13) on top of poppet.
e. Lubricate packing (12) with grease (C59) and
install packing on cap (11).
13-124. I N S T A L L A T I O N - RAIN
f. Observe index marks made on adapter (6), REMOVAL VALVE.
gasket (9), cap (11), and body (17) at time of
disassembly and install these parts with the index a. Install electrical connector to the valve.
mark aligned and with spacers (8) in place. Install
bolts (4), washers (5 and 18) and nuts (19). Hold nuts b. Connect lines to the valve.
and tighten bolts evenly in small increments until a
torque of 15 2 inch-pounds is applied to each bolt. c. Install left panel (9, figure 2-3).
SECTION Il. AIR COOLING SYSTEMS
13-125. AMBlENT AND 13-126. DESCRIPTION - AMBIENT AND
CONDITIONED COOLING. CONDITIONED COOLING (Section l).
13-37
TM 55-1520-236-23
Figure 13-18.
13-38
TM 55-1520-236-23
CHAPTER 14
HOISTS AND WINCHES
(Not Applicable)
14-1/(14-2 blank)
TM 55-1520-236-23
CHAPTER 15
AUXILIARY POWER PLANTS
(Not Applicable)
15-1 /(15-2 blank)
TM 55-1520-236-23
CHAPTER 16
MISSION EQUIPMENT
16-1. GENERAL. 16-6. ~~ MAINTENANCE - PILOT REFLEX
SIGHT.
This chapter contains maintenance instructions for
the fire control subsystems and the armament Refer to TM 9-1090-203 series manuals for
subsystems. additional information and maintenance procedures.
Refer to paragraph F-6 in this manual for airframe
16-2. FIRE CONTROL SUBSYSTEMS. armament electrical equipment list, and paragraph F-
9 (turret system) for airframe wiring diagrams.
16-3. DESCRIPTION- FIRE CONTROL
SUBSYSTEMS. 16-7 @ H E A D U P D I S P L A Y .
a. The fire control subsystems provide a means 16-8. ~ DESCRIPTION - HEAD UP
for accurately acquiring and tracking targets, and for DISPLAY.
firing of the turret subsystem. 2.75 inch folding fin
aerial rockets and TOW missile subsystem. The fire The pilot Head Up Display is located above the pilot
control subsystems include the following: instrument panel. It provides illuminated symbology
for pilot use when firing the wing stores or turret
weaponry during fixed forward mode of fire, display
q a Pilot reflex sight
navigation information, range to target, and TOW
Helmet sight subsystem
launch window.
Stabilized telescopic sight unit
Airborne laser tracker or FLIR missile tracker
16-9. M A I N T E N A N C E - HEAD UP
Airborne laser tracker DISPLAY.
Head up Display
Fire control computer Refer to TM 9-1270-220-13 and TM 9-1270-220-
Air data subsystem 13P manuals for additional information and
Gunner controls and indicators maintenance procedures. Refer to paragraph F-6 in
Pilot controls and indicators this manual for airframe armament electrical
Interface control unit equipment list, and paragraph F-9 (turret system) for
Rocket management subsystem airframe wiring diagrams.
b. Refer to chapter 9 in this manual for further 16-9.1. _ FLIR CONTROL PANEL.
information and maintenance data on all fire control
subsystems except as indicated in paragraphs 16-4 16-9.2. m DESCRIPTION - FLIR
through 16-9 below.
CONTROL PANEL.
16-4. ~W PlLOT REFLEX SIGHT. The FLIR control panel (FCP) is mounted inboard of
16-5. ~g DESCRIPTION - PILOT REFLEX the lower left gunner console. The FCP provides
SIGHT. controls and indicators necessary to operate FLIR
system and provides indicators for display of the FLIR
The pilot reflex sight assembly M73 is located above subsystem status and BIT results.
the pilot instrument panel. It provides an illuminated,
projected reticle image for pilot use when firing the
16-9.3. MAINTENANCE - FLIR CONTROL
wing stores, or turret weaponry during fixed forward
PANEL.
mode of fire. q For the wing stores, the pilot reads
ballistic data cards for information used to adjust the Refer to TM 9-1425-473-20 for additional
elevation/depression knob, q or estimates range to information and maintenance procedures. Refer to
adjust elevation using short medium or long range paragraph F-6 in this manual for airframe armament
witch. For turret weaponry, the range potentiometer electrical equipment list and paragraph F-9 for
.s used to obtain correct gun elevation. airframe wiring diagrams.
Change 15 16-1
TM 55-1520-236-23
1 6 - 1 0 . H E L M E T SIGHT SUBSYSTEM. 16-16. ~ M A I N T E N A N C E - T U R R E T
WEAPONS SUBSYSTEM M28A3.
16-11. DESCRIPTION - HELMET SIGHT
SUBSYSTEM. Refer to TM 9-1090-203 series manuals for
additional information amd maintenance procedures.
a. The helmet sight subsystem (HSS) M136 is Refer to paragraph 9-414 in this manual for airframe
interfaced with the turret weapons subsystem and armament system circuitry information and airframe
the telescopic sight unit (TSU) through the interface electrical component maintenance procedures. Refer
control unit (IFCU) to provide a hands-off sighting to paragraph F-6 for airframe armament electrical
system. This system enables the gunner or pilot to equipment list, and paragraph F-9 for subsystem
aim the turret weapons, and allows the gunner or airframe wiring diagrams.
pilot to quickly acquire a target for the TSU.
b. T h e H S S c o n s i s t s o f t w o h e l m e t s i g h t
assemblies, one each for pilot and gunner, mounted
on the SPH-4 helmets; two linkage assemblies, one
each for pilot and gunner, mounted to the cockpit left
canopy side frame; and an electronic interface 16-17. ~~ DESCRIPTION - TURRET
assembly mounted on the rear cockpit bulkhead. WEAPON SUBSYSTEM M97E1.
The turret weapon subystem M97E1 provides high
16-12. MAINTENANCE - HELMET SIGHT
performance capability to sight, position, feed, and
SUBSYSTEM.
fire the M197 20mm automatic gun. The subsystem
consists of a pilot control panel, gunner control panel,
Refer to TM 9-1270-212-14 manual for additional
turret assembly, 20mm automatic gun, 20mm
information and maintenance procedures. Refer to
ammunition feed system and electronic components.
paragraph ~ 9-414 or ~ 9-498 in this manual
S i g h t i n g i s a c c o m p l i s h e d u s i n g t h e m b pilots
for airframe armament system circuitry information
reflex sight or the q Head Up Display. All necessary
and maintenance procedures. Refer to paragraph F-6
electrical disconnects are installed forward of the
for airframe armament electrical equipment list, and
ammunition compartment, two on each side of the
paragraph F-9 for airframe wiring diagrams.
turret. The turret weapon subsystem interfaces with
the M136 helmet sight subsystem (HSS) and the
16-13. ARMAMENT SUBSYSTEMS. stabilized telescopic sight unit (TSU) of the M65TOW
missile subsystem for sight functions.
16-14. TURRET WEAPONS
SUBSYSTEM.
16-15. q DESCRIPTION - Turret
Weapons Subsystem M28A3.
The turret weapons subsystem M28A3 is an
electrohydraulic dual weapon system providing rapid 16-18. ~~ MAINTENANCE - TURRET
and voluminous fire power. The turret weapons WEAPON SUBSYSTEM M97E1.
subsystem consists of a pilot control panel, gunner
control panel, turret assembly, M134 7.62mm Removal and installation instructions for the turret
machine gun, 40mm grenade launcher, ammunition assembly are given below. Refer to TM 9-1090-206
feed system, electronic components, and a pilot reflex series manuals for additional information and
sight. All necessary electrical and hydraulic maintenance procedures. Refer to paragraph 9-444
disconnects are installed on a shelf in the forward in this manual for airframe armament system
ammunition compartment. The turret weapons circuitry information and airframe component
subsystem interfaces with the M136 helmet sight maintenance procedures. Refer to paragraph F-6 for
subsystem (HSS) and the turret control portion of the airframe armament electrical equipment list, and
stabilized telescopic sight unit (TSU) of the M65 TOW paragraph F-9 for subsystem airframe wiring
missile subsystem. diagrams.
16-2 Change 15
TM 55-1520-236-23
16-18.1 MILES/AGES - INSTALLATION,
MAINTENANCE, AND REPAIR OF
MILES/AGES.
Refer to TM 9-1270-223-20.
16-19. q q REMOVAL - TURRET
ASSEMBLY.
Premaintenance Requirements for
Maintenance of Turret Assembly
Conditions Requirements
Model AH-1E, F,& P
Part No. or Serial No. All
Special Tools T65, T71
Test Equipment None
Support Equipment None
Minimum Personnel
Required Two
Consumable Materials Chalk
Special Environmental
Conditions None
Change 16 16-2.1/(16-2.2 blank)
TM 55-1520-236-23
(9) Remove bolt (26) and washer (25) securing
clamp (23) to bottom of azimuth resolver (22) and
remove clamp (23).
To prevent injury to personnel, ensure (10) Remove remaining four bolts (26) and
that all weapon systems are unloaded washers (25) on bottom of azimuth resolver (22) and
and all armament circuit breakers are remove bottom cover (24).
OFF or out before starting any
maintenance procedures. (11) Reinstall all mounting hardware for
storage.
a. Preparation for Maintenance.
(1) Disconnect helicopter battery.
Do not rotate turret after installing allen
(2) E n s u r e t h a t n o e x t e r n a l e l e c t r i c a l o r wrench or tie wrap in resolver gear
hydraulic power is applied to helicopter. tension hole.
(3) Ensure that gun, feeder, gun drive, and
recoil attenuation system have been removed from
turret.
(12) Rotate turret by hand as necessary to
install a 3/32-inch allen wrench or plastic tie wrap in
resolver gear tension hole (27). Tape wrench or tie
wrap in place.
Do not attempt to remove the turret
(13) Using a piece of chalk, place an alignment
unless the gun, feeder, gun drive, and
recoil attenuation system have been mark (30) on the resolver gear (28) and azimuth ring
previously removed from the turret. gear (29) where the two gears mesh.
(14) Remove four bolts (21) and washers (20)
b. Removal Procedures.
and remove azimuth resolver (22). Reinstall bolts and
(1) Remove left and right panels (1, figure 16-1) washers for storage. Tape two shims (19) in place on
above turret fairings from helicopter. turret.
(2) Remove left and right fairings (2) above (15) Loosen four azimuth drive mounting bolts
turret from helicopter. (18) as required to obtain clearance for removal of
turret.
(3) Open left and right ammo bay doors (3).
(4) Disconnect and cap connector W4P2 (7)
from helicopter.
(5) Disconnect and cap connectors W1P3 (5) Before proceeding, ensure that four
and W3P1 (4) from turret. turret mounting bolts (31) are installed
and secure.
(6) Disconnect and cap connectors W1P16 (6)
and W1P15 (8).
(7) Disconnect and cap connectors W1P22 (9), (16) Remove twelve turret mounting nuts (39),
W1P7 (10) and W1P5 (11). four bolts (36), four washers (37), eight bolts (40) and
aluminum washers (38).
(8) Remove two screws (12) and washers (13)
securing stow switch/azimuth tachometer bracket (17) Place turret handling adapter (T65) in
(14) to azimuth drive (15). position under turret using lift truck (T71).
16-3
TM 55-1520-236-23
Figure 16-1.
16-4
TM 55-1520-236-23
Figure 16-1.
16-5
TM 55-1520-236-23
Figure 16-1.
16-6
TM 55-1520-236-23
Figure 16-1. Turret Installation (Sheet 4 of 4)
16-7
TM 55-1520-238-23
NOTE
Coat all common hardware on turret
The turret weighs approximately 200 with MIL-C-16173 (C43.1), and all electri-
pounds. Exercise care when perform- cal connectors with MIL-C-85054
ing following step to prevent injury to (C44.2) IAW TM 1-1500-344-23.
personnel and avoid damage to turret
and/or helicopter components. Person- (3) Install turret on turret handling adapter
nel should be positioned on all sides of
(T65).
turret to watch for any possible interfer-
ence or damage as turret Is being low-
(4) Using lift truck (T71) place turret in posi-
ered and removed from helicopter.
tion under helicopter.
(18) While supporting turret with turret
handling adapter (T65) and lift truck (T71), remove last (5) Align fore and aft locating pin holes (41) in
four mounting nuts (33), four bolts (31), aluminum turret with corresponding helicopter positioning pins
washers (32), damp assembly (34) and two aluminum and carefully rake turret into position on helicopter.
washers (35). Access to forward bolts is through
gunner cockpit, and access to aft bolts is through ac-
cess hole in forward panel of ammo box compartment.
(19) Lower and remove turret from helicopter. Failure to install mounting hardware as
specified in following steps will result
16-20. In damage to equipment.
ASSEMBLY.
(6) Install four turret mounting bolts (31), two
a. Preparation for Maintenance. aluminum washers (35), damp assembly (34) and
number of aluminum washers (32) required to obtain
(1) Disconnect helicopter battery. proper thread engagement with four nuts (33). Torque
nuts 150 TO 190 inch-pounds.
(2) Ensure that no external electrical or
hydraulic power is applied to helicopter.
(7) Move turret handling adapter (T65) and lift
NOTE truck (T71) sway from helicopter.
If installed on turret, remove azimuth (8) Install four washers (37), four bolts (36),
resolver In accordance with instruc- eight bolts (40) and number of aluminum washers (38)
tions contained In paragraph 16-16. required to obtain proper thread engagement with
twelve nuts (39). Torque nuts 150 TO 190 inch-
b. Installation Procedures. pounds.
(1) If installed, remove left and right fairings
(9) Secure azimuth drive (15) in position by
(1, figure 16-1) above turret from helicopter.
tightening four bolts (18).
(2) Open left and right ammo bay doors (3).
(10) Remove tape from two azimuth resolver
shims (19).
(11) Place azimuth resolver (22) in position on
The turret weighs approximately 200 turret with alignment marks (30) on resolver gear (28)
pounds. Exercise care when perform- and azimuth ring gear (29) aligned, and secure with
ing following step to prevent Injury to four washers (20) and bolts (21).
personnel and avoid damage to turret
and/or helicopter components. Person- (12) Remove allen wrench or plastic tie wrap
nel should be positioned on all sides of from resolver gear tension hole (27).
turret to watch for any possible interfer-
ence or damage as turret is being raised (13) Install damp (23) on bottom of azimuth
and installed in helicopter. resolver (22) with washer (25) and bolt (26).
16-8 Change 22
TM 55-1520-236-23
(14) Place stow switch/azimuth tachometer each outboard wing stores pylon. Each TOW missile
bracket (14) in position on azimuth drive (15) and launcher carries two TOW missiles.
secure with two washers (13) and screws (12).
16-23. MAINTENANCE - TOW MISSILE
(15) Connect connector W1P22 (9) to A7J23, SUBSYSTEM.
connector W1P7 (10) to A7J4 and connector W1P5
(11) to A7J2 (all on turret). Refer to TM 9-1425-473 series manuals for
additional information and maintenance procedures.
(16) Connect connectors WIP16 (6) to A7J13 Refer to paragraph 9-427 or 9-464 9-524 in
and W1P15 (8) to A7J12 (all on turret). this manual for airframe armament system circuitry
information and maintenance procedures. Refer to
(17) Connect connectors W1P3 (5) to paragraph F-6 for airframe armament electrical
helicopter J3 and W3P1 (4) to helicopter J1. equipment list, and paragraph F-9 for airframe wiring
diagrams.
(18) Connect connector W4P2 (7) to helicopter
J2. 16-24. WING STORES ROCKET
LAUNCHER SUBSYSTEM.
(19) Perform turret system checkout in
accordance with applicable TM 9-1090-206 series 16-25. DESCRIPTION - ROCKET
manual. CONTROL SUBSYSTEM.
(20) Boresight turret system in accordance The rocket control subsystem utilizes 2.75 inch
with applicable TM 9-1090-206 series manual. folding fin aerial rockets (FFAR) as a light anti-
personnel/assault weapon. The subsystem consists
(21) Install cover (24) on bottom of azimuth of a pilot rocket control panel, two intervalometers
resolver (under clamp) and secure with five washers (one for inboard rocket pods, one for outboard rocket
(25) and bolts (26). Use longest bolt to attach clamp. pods), interconnecting electrical components, and
rocket launchers (seven tube or nineteen tube).
(22) Close and secure left and right ammo bay Rocket launchers can be mounted on each of the
doors (3). inboard and outboard wing stores pylons.
16-26. MAINTENANCE - ROCKET
(23) Install left and right fairings (2) above CONTROL SUBSYSTEM.
turret on helicopter.
Refer to TM 9-1055-460-14 for additional
(24) Install left and right panels (1) above turret information and maintenance procedures. Refer to
fairings. paragraph 9-439 in this manual for airframe
armament system circuitry information and airframe
(25) Connect helicopter battery. electrical component maintenance procedures. Refer
to paragraph F-6 for airframe armament electrical
1 6 - 2 1 . T O W M I S S I L E SUBSYSTEM. equipment list, and paragraph F-9 (wing stores) for
subsystem airframe wiring diagrams,
16-22. DESCRIPTION - TOW MISSILE
SUBSYSTEM. 16-27. DESCRIPTlON - ROCKET
MANAGEMENT SUBSYSTEM M138.
The TOW Missile subsystem M65 is utilized as a
heavy anti-tank/assault weapon. The system utilizes The rocket management subsystem (RMS) utilizes
an optical means of tracking a target and guiding a 2.75 inch folding fin aerial rockets (FFAR) as a light
TOW missile to the target. The system consists of a anti-personnel/assault weapon. The subsystem
sight hand control (SHC), telescopic sight unit (TSU), consists of a pilot control and display unit, four
pilot steering indicator (PSl), Head Up operations units (one at each wing stores station),
Display (HUD), TOW control panel (TCP), electronic interconnecting electrical components, and rocket
components, and TOW missile launchers. Electrical launchers (M158A1, M158A1RC, or LWL-7 seven
harnesses connect the electronic units together. One tube, and M200A1, M227, or LWL-19 nineteen tube).
or two TOW missile launchers can be mounted on The RMS provides the capability to select fire zone for
16-9
TM 55-1620-236-23
firing. The zone containing the desired warhead may clear of the helicopter. Each ejector rack contains two
be selected and programmed for the rate, mode and cartridges that can be fired electrically by the jettison
quantity of rockets to be fired, and the range for switches. Electrical firing of one cartridge
airburst of M439 type fuse or penetration of forest automatically detonates the other cartridge.
canopy for M433 type fuse. Rocket launchers can be
mounted on each of the inboard or outboard wing
stores pylons.
16-28. MAINTENANCE - ROCKET To prevent injury to personnel, ensure
MANAGEMENT SUBSYSTEM M138. that all weapon systems are unloaded
and all armament circuit breakers are
Refer to TM 9-1270-207-13 and-TM 9-1270-207- OFF or out before starting any
13P for additional information and maintenance maintenance procedures or tests.
procedures. Refer to paragraph 9-477 or 9-
539 in this manual for airframe armament system
circuitry information and maintenance procedures.
Refer to paragraph F-6 for airframe armament
electrical equipment list, and paragraph F-9 (wing Remove impulse cartridges from ejector
stores) for subsystem airframe wiring diagrams. rack breech prior to placing helicopter in
a hangar, to prevent injury to personnel
16-29. 7.62 MM GUN POD (M-18, and damage to equipment.
M18E1). Exception: Removal is not necessary
when helicopter is to be stored in hangar
16-30. DESCRIPTION - 7.62MM GUN f o r s h o r t - t e r m , providing all three
POD. jettison circuit breakers ( one on
AC/ARMT circuit breaker panel and two
The wing stores 7.62mm gun pod is a self-contained
in aft electrical compartment, or all
unit housing a 7.62mm machine gun, its own
three on AC/ARMT circuit breaker panel
electrical system, a battery recharging system, and a are open (OFF)). ground safety pins
maximum of 1500 rounds of ammunition. The gun is installed, jettison switches are OFF, and
capable of firing six second bursts at 2000 or 4000 warning signs indicate that helicopter
rounds per minute. The 7.62mm gun pod can be
has an armed jettison system.
mounted on each inboard wing stores pylon.
16-31. MAINTENANCE - 7.62MM GUN
POD. 16-34. REMOVAL - IMPULSE
CARTRIDGES.
Refer to TM 9-1005-257-12 manual for additional
information and maintenance procedures. Refer to
paragraphs 9-438 9-488 9-548 for airframe
armament system circuitry information and
maintenance procedures. Refer to paragraph F-6 for
airframe armament electrical equipment list, and
paragraph F-9 (wing stores) for subsystem airframe
wiring diagrams. Static electricity may cause inadver-
tent firing of ejector cartridges.
16-32. IMPULSE CARTRIDGES. Maintenance personnel should
statically discharge themselves on a
suitable ground prior to installation o r
16-33. DESCRIPTION - IMPULSE
removal of ejector cartridges.
CARTRIDGES.
Impulse cartridges are used as a power source to
force the rack suspension hooks open and actuate a
downward force on the ejector foot to eject stores
16-10 Change 9
TM 55-1520-236-23
a. Outboard Ejector Rack Impulse Cartridges.
Refer to paragraph 16-41 for removal
procedures. (Accomplish 16-41 a. through 16-41 b.
(4).)
b. Inboard Ejector Rack Impulse Cartridges.
Refer to paragraph 16-49 for removal
procedures. (Accomplish 16-49 a through 16-49 b.
16-35. INSPECTION - IMPULSE
CARTRIDGES.
a. Inspect cartridges for damage and corrosion.
Change 9 16-10.1/(16-10.2 blank)
TM 55-1520-236-23
b. Inspect cartridges for service life require- Premaintenance Requirements for
ments (see NOTE below). Installation of Impulse Cartridges
Conditions Requirements
NOTE
Support Equipment None
A cartridge Is considered unserviceable
after ten insertions and removals from Mininmun Personnel One
ejector rack. Each time a cartridge is Required
removed, place a radial mark on the
base of the cartridge with indelible ink Consumable Materials None
Monitor the service life by a record of
inked markings and expiration date on Special Environmental None
cartridge case. Conditions
c. Inspect cartridges for shelf life (storage life) a. Using multimeter (T77), set for testing volt-
requirements. See NOTE below. age, attach one Iead to breech assembly and attach
other lead to first one cartridge cavity firing contact,
then the other. If no voltage is measured, proceed to
NOTE step b. if voltage is measured, trace jettison circuitry
The maximum shelf life for a cartridge is
nine years from date of manufacture wiring diagram) to locate and correct problem before
stamped on the cartridge. Cartridge proceeding.
ARD 63-1 and P7911-2 must be used
within 15 months; cartridge CCU-44B
must be used within 24 months from
date of opening hermetically sealed Ensure that no external electrical power
shipping container. When opening a is applies to helicopter and that battery
container, the service life expiration is disconnected before installing im-
date (month and year) shall be marked pluse cartridges
on the side of the cartridge with
indelible ink b. Visually inspect ejector rack and perform
ground check, as required, to determine rack condi-
16-36. INSTALLATION IMPULSE tion.
CARTRIDGES.
c. Install ground safety pin (1, figure 16-2).
d. Pull ejector piston out of housing to extend as
far as possible.
Ensure that no external electrical power
is applies to helicopter and that battery Place a cartridge into each of two cartridge
is disconnected before installing im- retainers(18, figure 16-3), or (9, figure 16-6) and screw
pluse cartridges. into breech assembly. Torque retainers 75 TO 100 inch
pounds and Iockwire (C137) cartridge retainers
together.
Premaintenance Requirements for
installation of Impulse Cartridges
Conditions Requirements
Overtorque of retainers causes damage
Model AH-1E, F&P to both cartridge and electronic firing
contact.
Part No. or Serial No. All
f. Push ejector piston back into housing and
Special Tools T66 seat.
Test Equipment T77
16-37. EJECTOR RACKS.
Change 22 16-11
TM 55-1520-236-29
16-38. DESCRIPTION EJECTOR RELEASE end turned according to arrow markings. A
RACKS. special ground safety pin (1, figure 16-2) must be
inserted into the GROUND SAFETY PIN HOLE of each
Each rack has a pair of hooks for attachment of an rack when the helicopter is on the ground, The rack
armament pod or other stores, and incorporates a hooks, will not open with the ground safety pins
cartridge-fired ejector device for emergency jettison installed if the jettison mechanism is fired; however,
of stores. The outboard ejector rack is adjustable in the attached stores may be damaged by the ejector
elevation by means of a hydraulic actuator. Each piston.
ejector rack contains two cartridges which can be
fired electrically by pilot or gunner jettison switches.
The ejector, when activated, automatically opens the 16-39, FUNCTIONAL TEST EJECTOR
hooks and forcibly ejects the pylon stores clear of the RACKS.
helicopter. During operations, stores are loaded or
unloaded on the racks with a special wrench (T66) (2,
figure 16-2) inserted into the HOOK MANUAL and perform wing stores jettison circuitry test.
Figure 16-2, Special Tools For Ejector Racks
16-12 Change 16
TM 55-1520-236-23
16-40. TROUBLESHOOTING - EJECTOR
RACKS.
Refer to table 16-1 or table 6-2.
NOTE
Before using tables, ensure all normal
operational checks have been
performed. if a malfunction is found
which is not listed in tables notify the
next higher level of maintenance.
Table 16-1 Troubleshooting Ejector Racks
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. With WING STORES JTSN circuit breaker closed, the appropriate wing stores are not jettisoned when
JETTISON SELECT switch is positioned to either INBD or OUTBD and pilot JETTISON switch is pressed.
STEP 1. Check for defective wiring.
Repair wiring (figure F-28).
STEP 2. Check for defective WING STORES JTSN circuit breaker.
Replace circuit breaker (paragraphs 9-27 and 9-29).
STEP 3. Check for defective pilot JETTISON switch.
Replace switch (paragraphs 9-20 and 9-22).
STEP 4. Check for defective JETTISON SELECT switch.
Replace switch (paragraphs 9-20 and 9-22).
STEP 5. Check for defective diode between terminals 3 and 4 or 5 and 6 on terminal board (ITB13).
Replace diode (paragraphs 9-20 and 9-22).
STEP 6. Check for defective inboard or outboard jettison select relay (21K3).
Replace relay (paragraphs 9-20 and 9-22).
2. The appropriate wing stores are jettisoned on one side, but not the other when JETTISON SELECT switch is
positioned to either INBD or OUTBD, and pilots JETTISON switch is pressed.
STEP 1. Check for defective or improperly installed ejector rack cartridge.
Replace cartridges and tighten retainers to specified torque (paragraph 16-41).
16-13
TM 55-1520-236-23
Table 16-1. Troubleshooting Ejector Racks (Cont)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
STEP 2. Check for defective wiring.
Repair wiring (figure F-28).
STEP 3. Check for defective wing disconnect connectors.
(21J1-21P1, 21J3-21P3) or (21J2-21P2, 21J4-21P4) on the side which does not jettison.
Replace connector (paragraphs 9-20 and 9-22).
STEP 4. Check for defective pilot jettison switch relay (21K3).
Replace relay (paragraphs 9-20 and 9-22).
STEP 5. Check for defective JETTISON or JETTISON SELECT switch.
Replace switch (paragraphs 9-20 and 9-22).
3. With WING STORES JTSN circuit breaker closed, wing stores are not jettisoned when gunner WING
STORES JETTlSON switch is positioned to up position.
STEP 1. Check for defective wiring.
Repair wiring (figure F-28). .
STEP 2. Check for defective WING STORES JTSN circuit breaker.
Replace circuit breaker (paragraphs 9-27 and 9-29).
STEP 3. Check for defective gunner WING STORES JETTISON switch.
Replace switch (paragraphs 9-20 and 9-22).
STEP 4. Check for continuity between pins B2 and B3 of jettison control relay (21K2) when WING STORES
JETTISON switch is positioned to up position. Next check for required continuity between pins 62 and B1 of
relay.
Replace relay if it fails check (paragraphs 9-20 and 9-22).
STEP 5. Check for defective jettison control relay (21K2) (inboard only).
Replace relay (paragraphs 9-20 and 9-22).
STEP 6. Check for defective firing circuit in rack.
Test continuity from rack connector to firing pin using multimeter (paragraph 9-438).
Replace rack if defective (paragraphs 16-41, 16-44, 16-49, and 16-52.)
16-14
TM 55-1520-236-23
Table 16-1. Troubleshooting Ejector Racks (Cont)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
4. Outboard ejector rack pylon fails to activate in elevation or depression.
STEP 1. Check that LCHR BORESIGHT SWITCH (in ammo compartment) is in proper position.
Position switch to OFF.
STEP 2. Defective hydraulic actuator.
Replace hydraulic actuator (paragraph 16-43).
STEP 3. Defective resolver.
Replace resolver (paragraphs 16-41 a. through 16-41 b. (5) and 16-44 f. and h.
STEP 4. Check for defective wiring between TSU and ejector rack pylon.
Repair wiring (figure F-28.)
5. Excessive torque required for manual release.
STEP 1. Dirty linkage in the release system.
Clean the rack (paragraph 16-47 or 16-53).
STEP 2. The hook pivot bolt may be damaged.
Replace the rack (paragraphs 16-41 and 16-44 or paragraphs 16-49 and 16-52).
STEP 3. The rack side plates may be distorted.
Replace the rack (paragraphs 16-41 and 16-44 or paragraphs 16-49 and 16-52).
Adjustment of sway brace bolts may affect boresighting. Sway brace bolts
must be adjusted by armament personnel.
STEP 4. Sway brace bolts not unloaded.
Back off sway brace bolts.
16-15
TM 55-1520-236-23
Table 16-2. Troubleshooting Ejector Racks
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
1. With WING STORE PLT JETT circuit breaker closed (up), the appropriate wing stores are not jettisoned when
JETTlSON SELECT switch is positioned to either INBD or OUTBD and pilot JETTISON switch is pressed.
STEP 1. Check for defective wiring.
Repair wiring, Figure F.64, F-111.
STEP 2. Check for defective WING STORE PLT JETT circuit breaker.
Replace circuit breaker (paragraphs 9-27 and 9-29).
STEP 3. Check for defective pilot JETTISON switch.
Replace switch (paragraphs 9-20 and 9-22).
STEP 4. Check for defective JETTISON SELECT switch.
Replace switch (paragraphs 9-20 and 9-22).
STEP 5. Check for defective pilot jettison switch relay (21K3).
Replace relay (paragraphs 9-20 and 9-22),
2. The appropriate wing stores are jettisoned on one side, but not the other when JETTISON SELECT switch is
positioned to either INBD or OUTBD and pilot JETTISON switch is pressed.
STEP 1. Check for defective or improperly installed ejector rack cartridge.
Replace cartridges and tighten retainers to specified torque (paragraph 16-41).
STEP 2. Check for defective wiring.
Repair wiring Figure F-64, F-111.
STEP 3. Check for defective wing disconnect connectors (21J1-21P1) or (21J2-21P2) on the side which
does not jettison.
Replace connector (paragraphs 9-20 and 9-22).
STEP 4. Check for defective pilot jettison switch relay (21K3).
Replace relay (paragraphs 9-20 and 9-22).
STEP 5. Check for defective JETTISON or JETTISON SELECT switch.
Replace switch (paragraphs 9-20 and 9-22).
16-16
TM 55-1520-236-23
Table 16-2 Troubleshooting Ejector Racks (Cont)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
3. With WING STORES GNR JETT circuit breaker closed (up), wing stores are not jettisoned when JTSN SEL
switch is positioned to either INBD or OUTBD and gunner WING STORES JETTISON switch is positioned to
up position.
STEP 1. Check for defective wiring.
Repair wiring Figure F-64, F-111.
STEP 2. Check for defective WING STORE GNR JETT circuit breaker.
Replace circuit breaker (paragraphs 9-27 and 9-29).
STEP 3. Check for defective gunner WING STORES JETTISON switch.
Replace switch (paragraphs 9-20 and 9-22).
STEP 4. Check for defective JTSN SEL switch.
Replace switch (paragraphs 9-20 and 9-22).
STEP 5. Check for defective jettison control relay (21K2) (inboard only).
Replace relay (paragraphs 9-20 and 9-22).
STEP 6. Check for defective firing circuit in rack.
Test continuity from rack connector to firing pin using multimeter (paragraph 9-492). Replace
rack if defective (paragraphs 16-41, 16-44, 16-49, and 16-52).
4. Outboard ejector rack pylon fails to activate in elevation or depression.
STEP 1. Check that LCHR BORESIGHT SWITCH (in ammo compartment) is in proper position.
Position switch to OFF.
STEP 2. Defective hydraulic actuator.
Replace hydraulic actuator (paragraph 16-43 d.)
STEP 3. Defective resolver.
Replace resolver (paragraphs 16 41 b(5) and 16-44 f and h.
STEP 4. Check for defective wiring between TSU and ejector rack pylon.
Repair wiring Figure F-64, F-111.
16-17
TM 55-1520-236-23
Table 16-2 Troubleshooting Ejector Racks (Cont)
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
5. Excessive torque required for manual release.
STEP 1. Dirty linkage in the release system.
Clean the rack (paragraph 16-47 or 1 6 - 5 3 ) .
STEP 2. The hook pivot bolt is damaged.
Replace the rack (paragraphs 16-41 and 16-44 or paragraphs 16-49 and 16-52).
STEP 3. The rack side plate is distorted.
Replace the rack (paragraphs 16-41 and 16-44 or paragraphs 16-49 and 16-52).
Adjustment of sway brace bolts may affect boresighting. Sway brace bolts
must be adjusted by armament personnel.
STEP 4. Sway brace bolts not unloaded.
Back off sway brace bolts.
16-41. R E M O V A L - OUTBOARD Premaintenance Requirements For
EJECTOR RACKS. Maintenance of Outboard Ejector Racks (Cent)
Premaintenance Requirements For Conditions Requirements
Maintenance of Outboard Ejector Racks
Consumable C19, C37, C58, C112,
Conditions Requirements Materials C113, C137
Model AH-1S Special Environmental
Conditions None
Part No. or Serial No. All
Special Tools T13, T66, T67, T82, T83
Test Equipment T77
To prevent injury to personnel, ensure
Support Equipment S2, S12 that all weapon systems are unloaded
and all armament circuit breakers are
Minimum Personnel OFF or out before starting any
Required One maintenance procedures or tests.
16-18
TM 55-1520-236-23
(9) Remove three nuts (40), three washers (41),
three washers (42) and three bolts (43) connecting aft
Serious injury can result from accidental sway brace assembly (10) to aft end of rack (21).
ground Jettison of outboard ejector
racks.
NOTE
a. Preparation for Maintenance.
Do not remove threaded shaft (5) from
(1) Disconnect battery. bolt on fitting assembly (2).
(2) Position all armament circuit breakers and
switches to OFF. (10) Remove nut (13), washer (12) and rotter pin
(11) from bolt on fitting assembly (2) and lift rack (21)
outboard.
Ensure all stores are properly supported
before removing ground safety pin (1,
figure 16-2). Take care not to damage threaded l haft
(5) during removal and subsequent
(3) Loosen four sway brace bolts. handling of fitting assembly (2).
(4) Remove stores from rack using special rack
release wrench (T66) (2, figure 16-2) for manual (11) Remove fitting (2) from wing pylon.
release.
(a) Disconnect hydraulic line from actuator (1).
b. Removal Procedures.
(b) Remove two bolts (4) and two washers (3).
(1) Remove wing tip fakings from rack and
outboard leading edge of wing. (c) Remove bolt (7) and washer (6), bolt (9),
washer (8), bolt (19) and washer (20) and lift fitting (2)
(2) Disconnect electrical connectors from from wing pylon.
components on rack.
16-42. INSPECTION OUTBOARD EJECTOR
(3) Cut and remove Iockwire from retainers (18, RACKS.
figure 16-3).
a. Visually inspect hydraulic actuator (1, figure
(4) Remove cartridge retainers (18) and 16-3) for leakage or damage.
cartridges from breech of ejector rack.
b. Inspect electrical cables for fraying or damaged
(5) Remove resolver and bracket (14) from electrical connectors.
outboard side of rack (21).
c. Visually inspect accelerometer (17) and resolver
(6) Disconnect and remove accelerometer (17). (14) for evidence of mechanical damage, binding, or
misalignment.
(7) Remove bolt (37), washers (36 and 35) nut
(34), and cotter pin (33) connecting actuator (1) to sway d. Inspect for cracks, external corrosion, and
brace assembly (22). cleanliness. If rack has been used to jettison stores,
perform cleaning and inspection of ejector parts. (Refer
(8) Remove three nuts (39), three washers (38), to paragraphs 16-46 and 16-47).
three washers (31) and three bolts (32) connecting
forward sway brace assembly (22) to forward end of e. Inspect forward and aft sway brace assemblies.
rack (21 ).
Change 18 16-19
TM 55-1520-236-23
(1) The clearance between the groove on the (10) Remove caps (if installed) from inlet and
fitting assembly (2) and the tongue of the sway braces outlet pods of actuator (1).
(10 or 22) must not exceed 0.020 inch. Remove fair-
ings and disconnect servo actuator from fitting (2), and (11) Install hydraulic fittings in inlet and outlet
then move fitting (2) full up or full down. The clearances ports of actuator (1).
can be obtained by using a feeler gauge with all the
components installed on the aircraft or by measuring (12) Position actuator (1) on fitting assembly
the differences between the tongues and the grooves. (2) and forward sway brace assembly (22).
(2) If there is a high level of vibration trans-
(13) In upper end of actuator (l), install bolt
mitted into the aircraft due to excessive clearance, the
(23), washer (24), and nut (25). Torque nut (25) to 5
sway braces will be replaced.
inch-pounds and install cotter pin (26).
16-43. REPAIR O U T B O A R D E J E C T O R
RACKS.
screw (30) on bracket (28) and actuator (1) as shown
a. Replace any cracked, damaged or unservice- in view A.
able hydraulic fittings or flexible lines.
(15) Install bolt (37), washers (36 and 35), nut
b. Replace fakings if unserviceable.
(34), and cotter pin (33) in Iower end of actuator(1).
c. Remove external superficial corrosion from
rack by using crocus cloth (C37) or phosphoric solution (16) Install hydraulic lines on fittings of actua-
(C19). tor (1).
d. Replace rack hydraulic actuator (1, figure (17) Connect electrical connectors to actuator.
16-3), if unserviceable.
(1) Dined electrical connectors to (18) Bleed hydraulic system.
actuator (1).
paragraph 7-3
(2) Remove hydraulic Iines from actuator (1).
paragraph 7-143
(3) Cap open hydraulic lines.
(4) Remove hydraulic fittings from inlet and (19) Perform alignment test (paragraph
outlet ports of actuator (1). Retain fittings for reinstalla- 16-45).
tion.
(5) Cap inlet and outlet ports of actuator (1). 16-44. INSTALLATION OUTBOARD EJEC-
TOR RACKS.
(6) Remove cotter pin (33), nut (34), washers
(35 and 36), and bolt (37), securing lower end of NOTE
actuator (1) to forward sway brace assembly (22).
Coat all common hardware on outboard
ejector rack with MIL-C-16173 (C43.1)
and spacer (27) from bracket (38) and actuator (1).
and all electrical connectors with
(6) Remove cotter pin (26), nut (25), washer MIL-C-85054 (C44.3) IAW TM
(24), and bolt (23), securing upper end of actuator (1) 1-1500-344-23.
to fitting assembly (2).
a. Install fitting (2, figure 16-3) on end of wing.
(9) Remove actuator (1) from helicopter.
(1) Position fitting (2) on wing pylon and
NOTE
connect hydraulic lines to actuator (12).
Rack hydraulic actuator is factory
adjusted for proper length. Adjustment (2) Install two bolts (4) and two washers (3).
of actuator will be accomplished during Install washers with countersink toward head of bolt.
final adjustment and boresighting of Torque bolts 300 TO 333 inch-pounds. Lockwire
system. (C137) bolts.
16-20 Change 22
TM 55-1520-236-23
(3) Install bolt (19) and washer (20). Install washer b. Install rack (21) on bolt of fitting (2), and install
with countersink toward head of bolt. Torque bolt 120 washer (12) and nut (13). Torque nut 5 TO 50 inch-
TO 160 inch-pounds. Lockwire (C137) bolt. pounds and install cotter pin (11).
(4) Install bolt (7) and washer (6). Install washer
with countersink toward head of bolt. Torque bolt 75
c. Install sway forward brace assembly (22) on end
TO 95 inch-pounds. Lockwire (C137) bolt.
of rack (21) with three bolts (32), three washers (31),
(5) Install bolt (9) and washer (8). Install washer three washers (38) and three nuts (39). Install washers
with countersink toward head of bolt. Torque bolt with countersink side toward bolt head. Torque nuts
468-516 inch-pounds. Lockwire (C137) bolt. 120 TO 160 inch-pounds.
Change 8 16-20.1/(16-20.2 blank)
TM 55-1520-236-23
Figure 16-3. Outboard Ejector Rack Installation (Sheet 1 of 2)
16-21
TM 55-1520-236-23
Figure 16-3. Outboard Ejector Rack Installation (Sheet 2 of 2)
16-22
TM 55-1520-236-23
d. Install aft sway brace assembly (10) on end of (4) Position hydraulic actuator (1) so that ejector
rack (21) in same manner. Install washers with rack assembly (6) can be manually rotated without
countersink side toward bolt head. Torque nuts 120 TO interference with actuator.
160 inch-pounds.
(5) Place gunner quadrant (T13) on TSU
e. Connect actuator (1) to forward sway brace (22) boresight device, level the bubble, and record the angle.
with bolt (37) washers (36 and 35) and nut (34). Torque (Note the nose-up or nose-down attitude.)
nut (34) to 5 inch-pounds and install cotter pin (33),
(6) Transfer gunner quadrant to ejector rack
f. Install resolver and bracker (14) with four screws alignment fixture.
(15).
(7) Manually rotate ejector rack assembly (6)
g. Install accelerometer (17) with two screws (16). toward a nose-up attitude. Adjust forward mechanical
stop (3) until the maximum pitch-up attitude of ejector
h. Connect ail electrical connectors. rack assembly is 124.4 TO 128.8 mils (7 degrees to 7
degrees, 15 minutes) greater than the angle recorded
on TSU boresight device (step (5) and figure 16-4).
Tighten forward locknut (2).
(8) Manually rotate ejector rack assembly (6)
Do not install ejector cartridges in the toward a nose-down attitude Adjust aft mechanical stop
ejector reck prior to alignment. (5) until the mxaimum pitch-down attitude of ejector rack
assembly is 88.9 to 93.3 mils (5 degrees to 5 degrees,
15 minutes) less than the angle recorded on TSU
boresight device (step (5) and figure 16-4). Tighten aft
i. Perform alignment test (paragraph 16-45). locknut (4).
16-45. ALIGNMENT TEST - OUTBOARD (9) Manually rotate ejector rack assembly toward
EJECTOR RACKS. a nose-up attitude. Adjust hydraulic actuator rod end
until the nose-up attitude of the ejector rack is 71.1 (
The alignment test consists of adjusting the mechanical 8.9) mils (4 (0.5) degrees) greater than the angle
stops, pylon actuator and pylon resolvers. recorded on TSU boresight device (step (5) and figure
16-4).
a. Test Preparations.
NOTE
Remove TSU nose fairing and outboard portions of
One complete turn of hydraulic actuator
outboard pylon fairings.
rod end equals approximately 4 mils (0.25
degrees) elevation of the ejector rack.
b. Elastomeric Stop Adjustment.
The following procedure is used to set the mechanical (10) Reconnect hydraulic actuator (1) to sway
stops to allow a total of 12 degrees of ejector rack travel: brace assembly (7).
(1) Install TSU boresight device (T83) on pitch (11) Transfer ejector rack alignment fixture (T82)
and roll pads of TSU. to the opposite pylon and repeat steps (2) hrough (10).
(2) Loosen sway brace pads and install ejector c. Control Switch Positions.
rack alignment fixture (T82) on ejector rack hooks.
Finger tighten sway brace pads. Position following switches as indicated:
(3) Disconnect hydraulic actuator (1, figure (1) Pilot Armament Control Panel:
16-4) from sway brace assembly (7) by removing bolt
(8) from rod end of actuator. MASTER ARM OFF
WPN COUNT GUNNER
Change 18 16-23
TM 55-1520-236-23
Figure 16-4. Ejector Rack Alignment
(b)
(2) Electrical Power.
AC/ARMT
Check that helicopter battery is connected, then apply DC CB PANEL
CB PANEL
28 Vdc power from electrical auxiliary power unit
(S12).
WPN CONTR
WPN FIRE CAUT LT
(3) Circuit Breakers. PLT INST LT
TURRET CONTR
ARMT CONTR
Engage the following circuit breakers: DC VM
REF XFMR
TMS PWR INV
(a) EMER HYD PUMP
28 VAC XFMR
AC/ARMT SECU PWR
CB PANEL DC CB PANEL
(c)
WPN CONT
WPN FIRE CAUT LT AFT ELEC CMPT
TURRET CONT PLT INSTR LT AC CB PANEL
REF XFMR DC VM
TOW PWR lNV MAIN TOW PWR
TSGMS PWR
AC/ARMT BATT RLV
CB PANEL DC CB PANEL ESNTL BUS
28 VAC XFMR INV STBY
SECU EM HD PWR
16-24 Change 7
TM 55-1520-236-23
(4) Power Switch Positions. (7) Place gunner quadrant (T13) on TSU
boresight device, level the bubble, and record pitch
Position the following switches as shown: angle. (Note the nose-up or nose-down attitude.)
(a) (8) Transfer gunner quadrant to ejector rack
alignment fixture, maintaining same fore and aft
INV MAIN orientation as measured on TSU boresight device.
BAT OFF
NON-ESNTL BUS MANUAL (9) Adjust fine adjustment screw on resolver
ELECT PWR/EMER OFF ELEC PWR mount assembly until the angle of ejector rack
alignment fixture is 17.8 mils 1.78 mils (1 0.1)
(b) degrees greater than the angle recorded on TSU
boresight device.
BATTERY RUN
NOTE
NON-ESNTL BUS MANUAL
ELEC PWR/EMER OFF ELEC PWR I f p r o p e r a d j u s t m e n t is achieved,
MASTER ARM STBY proceed to step (12). If proper
adjustment cannot be achieved, return
(5) Hydraulic Power. fine adjustment screw to the mid
position and proceed to steps (10) and
Place pilot (or gunner) EMER HYDR PUMP switch to (11).
BORESIGHT position. (This applies limited hydraulic
power to turret and outboard pylon.) (10) Loosen resolver coarse adjustment screw
and rotate body of resolver until approximate desired
d. Alignment Procedures. angle is achieved.
NOTE
(1) Turn MODE SELECT switch on the TCP to
ARMED MAN. If pylon will not stop at approximate
desired angle, resolver may be out-of-
(2) Position Hi/LO MAG switch on left hand. phase. Rotate resolver 180 degrees and
grip (LHG) to HI and verify that ACQ/TRK/STOW repeat step (10).
switch on sight hand control (SHC) is in the STOW
position. (11) Tighten resolver coarse adjustment screw
and repeat step (9).
(3) Install ejector rack alignment fixture (T82)
on ejector rack hooks. (12) Tighten four setscrews on resolver mount
assembly.
(4) Activate left or right launcher with LCHR
BORESIGHT switch, located in left ammo bay on the (13) Check that the 17.8 mil difference did not
aft wall. change after tightening setscrews.
(14) Deactivate and activate the LCHR bore-
sight switch several times to ensure rack will stow
and lock.
Before turning pilot MASTER ARM NOTE
switch to ARM position. keep hands
clear of articulating outboard ejector If rack will not lock in the stow position,
rack assembly. Racks may move rapidly determine which direction to adjust the
up or down. hydraulic actuator rod end to ensure
proper locking. (e.g., If downward pres-
(5) Position MASTER ARM switch to ARM. sure on aft end of rack alignment fixture
will cause actuator to lock; the actuator
(6) Loosen four setscrews on ejector rack rod end should be extended until the
resolver mount assembly. stowing mode will lock the rack.)
Change 5 16-25
TM 55-1520-236-23
(15) Transfer ejector rack alignment fixture to CAUTION
opposite ejector rack hooks and repeat steps (4)
through (13).
When sideplate is removed from
remainder of ejector rack, shackies and
linkage will fall out if remaining assembly
is inverted. During disassembly, remove
Do not install cartridges in ejector racks required screws from right (bottom)
prior to continuity test. sideplate first so that rotation will not be
required after left sideplate is loosened.
e. Using multimeter (T77), perform electrical
continuity test of wing stores jettison circuits (paragraph
9-438, 9-492 or 9-552).
c. Remove three screws (33) from right sideplate
(13) (two from aft closeout and one in cylinder cap).
NOTE
d. Cut Iockwire and remove retainer (26) with piston
Adjust ejector foot pad (18, figure 16-5) to (21) and spring (19) from breech.
snugly fit the specific armament weapon
installed. e. Pull piston (21) out of retainer (26), then remove
and discard packings (20, 28 and 29).
f. Install cartridges in breech assembly (paragraph f. Remove ejection cylinder (7), ejection piston (5),
16-36). foot (18) and packing (17) from breech as an assembly.
16-46. DISASSEMBLY FOR CLEANING AFTER g. Unscrew foot (18) from ejection piston (5) and
JETTISON - OUTBOARD EJECTOR RACKS. push ejection piston (5) up out of ejection cylinder (7).
Remove and discard packing (17) from inside lower end
As soon as possible after ejector rack has been used to of ejection cylinder (7).
jettison stores, perform cleaning prcedure as follows:
h. Remove nut (31), two washers (30 and 2) and
a. Remove outboard ejector rack (paragraph bolt (1); then place ejector rack on a clean workbench
16-41). with the left sideplate (24) up for remainder of
disassembly.
i. Remove nut (23), washer (22) and screw (25)
from forward end of breech and left sideplate (24).
To prevent injury to personnel, ensure j. Remove four screws (27) securing left sideplate
that all weapon systems are unloaded (24) to four spacers (14).
and all armament circuit breakers are
OFF or out before starting any k. Remove four screws (32) securing left sideplate
maintenance procedures. (24) to mounting column.
To prevent injury to personnel, make l. Remove four screws (34) securing left sideplate
certain no live cartridges are installed in (24) to two bumper pads and forward closeout, then
the breech prior to disassembly. remove remaining screw (23) from cylinder cap (8).
m. Carefully lift sideplate (24) off remainder of
b. Remove two cartridge retainers (16, figure 16-5)
assembly, tapping sideplate at openings where
to ensure no live cartridges are installed. Remove and
linkage, shackles, and spring retainers fit into
discard any fired cartridges. Dispose of live cartridges
bushings. Ensure that left sideplate (24) separates
in accordance with prescribed ordnance procedures,
16-26 Change 18
TM 55-1520-236-23
from shackles and linkage trunnions that must o. Pull gas tube (4) out of breech; then remove and
remain seated in right sideplate (13). discard two packings (3).
n. Move cylinder cap (8) out slightly away from p. Clamp cylinder cap (8) in a vise that has padded
right sideplate (13) to clear pin from bushing and lift jaws. Cut Iockwire and remove orifice holder (9) from
cylinder cap (8) off gas tube (4). Remove and discard cylinder cap (8). Remove and discard packings (10 and
packing (6) from inside cylinder cap (8). 11) and backup ring (12)
Change 5 16-26.1/(16-26.2 blank)
TM 55-1520-236-23
Figure 16-5 Outboard Ejector Rack Assembly (Sheet 1 of 2)
Change 22 16-27
TM 55-1520-236-23
Figure 16-5. Outboard Rack Assembly (Sheet 2 of 2)
16-47. CLEANING/INSPECTION -
OUTBOARD EJECTOR RACKS.
To prevent injury to eyes, wear eye
NOTE protection when using compressed air.
After removal from the ejector reck, the c. Dry all parts, particularly passages in breech
ballistic components and the breech end and retainers, using a clean, lint-free cloth and
ejection cylinder in the partially filtered, low pressure air.
assembled ejector rack are cleaned to
remove residue from the fired cartridges d. Ensure all loose matter is removed after
and then visually inspected for evidence cleaning and drying.
of damage. The opening in the orifice is
critical and must be checked for size as
well as carefully cleaned. When visual
inspection indicates evidence of wear or
damage, send ejector rack to next higher The sues of openings in orifice holder (9,
maintenance Ievel. figure 16-5) are critical, and sharp
objects such as drill bits shall not be used
a. Clean components of the ballistic system using for cleaning out these openings. An
a warm solution of warm water and detergent (C113), increase in the 0.0370 0.005 inch
and a soft bristle brush to loosen any caked residue. diameter of center orifice will increase
thrust applied to the ejector piston. An
increase of 0.002 inch above maximum
can increase the thrust as much as 20
percent.
Cleaning solvent is flammable and toxic.
Provide adequate ventilation. Avoid NOTE
prolonged breathing of solvent vapors
and contact with skin or eyes. When necessary, use the shank of a drill
bit 0.0370 inch in diameter to open
b. Rinse parts using dry cleaning solvent (C112) center orifice (and the shank of a drill bit
to remove moisture, 0.060 inch in diameter for side orifices).
16-28
TM 55-1520-236-23
e. Use a soft wire (copper or brass) approximately b. Install assembled orifice holder (9) in cylinder
0.0370 inch in diameter to clean orifice in orifice cap (8). Clamp cylinder cap in a vise to permit
holder (9). Ensure center and side openings are clear tightening and torque orifice holder (9) 95 TO 115
(approximately 0.060 inch diameter). inch pounds. Lockwire (C137) cylinder cap (8) to
orifice holder (9).
f. Inspect parts as follows:
c. Install lubricated packing (6) inside groove in
cylinder cap (8) to seal ejection cylinder (7).
(1) Visually examine all parts for cleanliness,
evidence of corrosion, cracks and damaged threads.
d. Install lubricated packing (3) on each end of gas
tube (4) and insert gas tube in opening in cylinder cap
(2) Visually examine openings in orifice holder (8). Ensure packing (3) remains seated in groove.
(9) for obstruction and obvious distortion such as
dents or cuts in area around openings. If damage is
suspected, send ejector rack to next higher level of e. Position cylinder cap (8) and gas tube (4) in
maintenance. partially assembled ejector rack, inserting end of gas
tube in breech and trunnion of cylinder cap in bushing
of right sideplate (13).
(3) Roll spring (19) across a flat su rface to check
for distortion.
f. Install lubricated packing (17) in groove inside
(4) I f d i m e n s i o n a l o r t h r e a d damage is lower end of ejection cylinder (7), and insert ejection
suspected, send ejector rack to next higher level of piston (5) inside ejection cylinder, extending end of
maintenance. piston out through end of cylinder. Do not bottom out
piston in cylinder.
16-48. A S S E M B L Y - OUTBOARD
EJECTOR RACKS. g. Holding ejection piston (5) at wrenching flats
on end of piston, thread foot (18) into end of ejection
NOTE piston (5). Do not bottom out foot to piston.
Exercise care in handling partially h. Install lubricated packings (28 and 29) in
disassembled ejector rack during grooves in retainer (26).
assembly to prevent accidental
disassembly of shackles, linkage, and i. Install lubricated packing (20) in groove in
spring retainer spacers from bushings in piston (21) and insert base of piston into opening in
right sideplate. Parts are spring loaded retainer (26).
and if loosened from bushings, will fall
out of partially assembled ejector rack
j. Place spring (19) over piston (21) and install
causing additional assembly.
spring, piston and retainer (26) into breech. Do not
tighten at this time.
NOTE
k. Apply a light coating of grease (C58) to the
exposed trunnions of the two shackles, the two
Apply a light coating of silicone grease
shackle locking Iink-trunnions, and the hexagon
(C59) to all packings and back-up rings
release wrench trunnion. Ensure all six end spacers
prior to installation.
(14) are in bushings in right sideplate.
a. Apply a light coating of silicone grease (C59) to l. P o s i t i o n l e f t s i d e p l a t e ( 2 4 ) o v e r p a r t i a l l y
packings (10 and 11, figure 16-5) and back-up ring assembled ejector rack, and, using a punch or other
(12) and install on orifice holder (9) in sequence blunt object, align shackle, linkage trunnions and
shown in figure 16-5. spring retainer spacer to bushing of left sideplate.
16-29
TM 55-1520-236-23
Install four screws (27) in sideplate and four bushings Premaintenance Requirements For
to retain sideplate while aligning the trunnions and Maintenance of Inboard Ejector Racks (Cont)
spacers to bushings.
NOTE Conditions Requirements
The spring retainer spacers can be
aligned by inserting a blunt screwdriver Special Tools T13, T66
in opening at bottom of ejector rack to
carefully move spacers. Test Equipment T77
m. After two shackle trunnions, three linkage Support Equipment None
trunnions and two spring retainer spacers are into
bushings in right and left sideplates, check springs to Minimum Personnel
ensure coils are not between shoulder of trunnions Required Two
and sideplate, and tighten the four screws (27).
Consumable Materials C19, C37, C60, C78,
n. Install and tighten screw (35), four screws (34) C112
and four screws (32).
Special Environmental
o. Install bolt (1), two washers (30 and 2) and nut Conditions None
(31), placing one washer under head of bolt and one
under nut. Torque nut (31) 95 TO 115 inch-pounds.
p. Install screw (24), washer (22) and nut (23).
Torque nut on screw through both sideplates 50 TO
70 inch-pounds.
To prevent injury to personnel, ensure
q. Install assembled ejection cylinder (7), ejection that all weapon systems are unloaded
piston (5), packing (17) and foot (18) into breech, and all armament circuit breakers are
inserting end of cylinder into cylinder cap (8). OFF or out before starting any
maintenance procedures or tests.
r. Torque retainer (26) in breech 95 TO 115 inch-
pounds. Serious injury can result from accidental
ground jettison of inboard ejector racks.
s. Torque ejection cylinder (7) in breech 290 TO
310 i n c h - p o u n d s a n d I o c k w i r e ( C 1 3 7 ) e j e c t i o n a. Preparation for Maintenance.
cylinder (7) to retainer (26).
(1) Disconnect battery.
t. Install two cartridge retainers (16) in breech.
Tighten the two cartridge retainers finger tight. Do (2) Position all armament circuit breakers and
not install Iockwire at this time. switches to OFF
16-49. REMOVAL - INBOARD EJECTOR
RACKS.
Premaintenance Requirements For
Maintenance of Inboard Ejector Racks
Ensure all stores are properly supported
before removing ground safety pin (1,
Conditions Requirements
figure 16-2).
Model AH-1S (3) Remove stores from rack using special rack
release wrench (T66) (2, figure 16-2) for manual
Part No. or Serial No. All release.
16-30
TM 55-1520-236-23
b. Removal Procedures. f. Using depth gage, check protrusion of contact
(4, figure 16-6.1). Contact protusion inside both
(1) Remove fakings (1, figure 16-6) from rack cartridge bore breeches (5) shall be shown in figure
(12) and inboard leading edge of wing.
(2) Disconnect rack electrical cable (15) from NOTE
connector in wing.
Contact is integral to wire harness (fig-
(3) Cut and remove Iockwire from two ure 16-6.2). If one-half turn or less of
cartridge retainers (9). retainer (1, figure 16-6.1) does not bring
contact protrusion within Iimits, refer to
(4) Remove two cartridge retainers (9) and higher level of maintenance.
cartridges from breech assembly.
g. Inspect rack for cleanliness. If rack has been
used to jettison stores, perform cleaning and inspec-
(5) Remove bolt (14), nut end washers to
tion of ejector parts (paragraph 16-53).
detach fork (13) of elevation adjustment fitting from
front of rack. Do not change length of fitting. 16-51. REPAIR INBOARD EJECTOR
RACKS.
(6) Remove two bolts (3), two nuts and
washers to detach two tumbuckles (16) from fittings a. Replace any cracked, damaged, or unservice-
(2) on wing. Do not change length of turnbuckles. able fittings.
(7) Remove Iockwire and eight bolts, with b. Replace fairing (1) if unserviceable.
washers and shims, to detach rack fittings (4) end
remove rack assembly from wing. Observe locations c. Remove corrosion from rack by using crocus
of any shims for reinstallation. cloth (C37) or phosphoric solution (C19).
NOTE 16-52. INSTALLATION INBOARD EJEC-
TOR RACKS.
If rack IS being removed to dean ejector,
steps (6) and (9) are not required NOTE
(8) Remove bolts (5, 6 end 10) to detach Coat all common hardware on Inboard
fittings from rack Keep any shims found on bolts (5 ejector rack with MIL-C-85054 (C44.3)
and 10) for reinstallation. MIL-C-85054 (C44.3) IAW TM
1-1500-344-23.
(9) When necessary, remove attaching nuts
and screws to separate inboard fittings and brace. a. Assemble fittings (4, figure 16-6) if removed,
on ejector rack (12) with bolts (5, 6, and 10). Ensure
16-50. INSPECTION INBOARD EJECTOR that original shims are in place between fittingson bolts
(5 and 10). Use thin steel washers under bolt beds
RACKS.
and nuts (do not fully tighten bolts at this time).
a. Visually inspect all fittings for crack, damage, NOTE
and serviceable condition.
Shims on bolts (5 and 10) provide 1.375
b. Inspect sway brace pads (11, figure 16-6), for to 1.380 Inches between inside bosses
security and ensure that locknut is securely in place. of fittings at hole for bolt (6). If shims l re
lost or mixed, assemble fittings without
c. Inspect fairing (1 ) for damage and serviceable rack and prepare shims for correct
condition. dimension, then proceed with step b.
d inspect ejector reck for corrosion, distortion of b. Lift rack and fitting assemblies in position.
any parts, and evidence of damage. Align fittings (4) to mounting holes and install fourpairs
of bolts with washers, using shims between wing and
e. Inspect electrical cable (15) for fraying or dam- fittings at locations noted during removal of rack
aged connector. Torque bolts 100 TO 140 inch-pounds.
Change 22 16-31
TM 55-1520-236-23
Figure 16-6. Inboard Ejector Rack Installation
16-32 Change 19
TM 55-1520-236-23
Figure 16-6.1. Contact Protrusion Inside Breech.
Change 16 16-32.1
TM 55-1520-236-23
Figure 16-6.2. Wiring Harness Assembly.
c. Align fork (13) to forward hook pivot of rack, and d. Using gunner quadrant (T11), check rack for
install bolt (14) with thin steel washers under bolt head and nose-up elevation of 71.1 (+8.9) mils (4 (+0.5)
nut. Align two turnbuckles (16) to fittings (2) and install two degrees) with respect to fore and aft attitude of heli-
bolts (3) with thin washers under bolt heads and nuts. copter. If necessary to adjust rack, remove bolt (14)
Adjust rod ends of turnbuckles (16) as required to provide and adjust length of fork (13). Reinstall fork (13) to
ease of installation of bolts (3). If bolts do not fit freely,
change or add shims between wing and fittings (4) to
obtain alignment. Use no more than one shim per bolt.
16-32.2 Change 19
TM 55-1520-236-23
(14), washers and nuts, and check for required angle c. Remove gas tube retainer (4) and gas tube
Repeat as necessary to achieve required angle. assembly (3).
e. When alignment of rack is satisfactory, d. Remove piston retainer (18) and piston (21).
Iockwire (C137) bolts attaching fittings to wing in
pairs. Torque bolts (6, 10 and 14) 80 TO 100 inch-
pounds. Tighten bolt (5).
NOTE
Cleaning solvent is flammable and toxic.
Adjust ejector foot pad (16, figure 16-7) Provide adequate ventilation. Avoid
to snugly fit the specific armament prlonged breathing of solvent vapors and
weapon installed. contact with skin or eyes.
f. Check manual release (8) operation of rack, e. Clean all internal surfaces of piston block and
piston housing (1) with solvent (C112), using bore
brushes to clean gas passages. Clean all removed
parts with same solvent.
Do not install cartridges in rack prior to
continuity test.
To avoid excessive wear, clean firing
g. Connect rack electrical cable (15) to connector contacts with a cloth and solvent only.
in leading edge of wing. Using multimeter (T77), Ensure that no dirt or portions of old
perform electrical continuity test of wing stores cartridges remain in cartridge cavity.
jettison circuits (paragraph 9-438, 9-492 or
9-552). f. Coat all cleaned surfaces and parts with a very
light coating of oil (C78). Parts should be almost dry.
h. Install impulse cartridges (9) and cartridge Cartridge cavity shall be left dry.
retainers (10) (paragraph 16-36).
g. Coat all packings with grease (C60).
i. Install fairings (1) on wing leading edge and
ejector rack (12). h. Replace any unserviceable parts.
16-53. CLEANING AFTER JETTISON - NOTE
INBOARD EJECTOR RACKS.
Gas tube retainer (4) should be alternated
Perform cleaning procedure as soon as possible after between right and left inboard racks after
ejector rack has been used to jettison stores. each firing to minimize concentration of
gas erosion on beveled surface at bottom
NOTE of retainer. Retainer shall be replaced if
erosion of beveled surface reaches
Inboard ejector rack must be removed center hole.
from wing, but fittings can remain
attached to rack (paragraph 16-49). i. Reassemble rack.
a. Remove slave piston (12, figure 16-7) and (1) Position packing (19) on piston (21) and
compression spring (11) by removing retaining plug insert piston into piston housing (1).
(15) and packings (14, 5 and 13).
(2) Install packing (19) on piston retainer (18).
NOTE Install piston retainer.
Pins (8) are not used in this rack (3) Install packing (2) on gas tube assembly (3).
installation, Cartridge retainers (10) and Install packings (5) and gas tube retainer (4).
cartridges (9) will have been removed
during removal of rack. (4) Install packing (23) on breech plug (22) and
b. Remove plug (6) and breech plug (22). install plug.
Change 5 16-33
TM 55-1520-236-23
1. Piston housing 9. Cartridge 17. Retaining ring
2. Packing 10. Cartridge retainer 18. Piston retainer
3. Gas tube assembly 11. Compression spring 19. Packing
4. Gas tube retainer 12. Slave piston 20. Packing
5. Packing 13. Packing 21. Piston
6. Plug 14. Packing 22. Breech plug
7. Packing 15. Retaining plug 23. Packing
8. Pin 16. Ejector foot pad
209071-365A
Figure 16-7. Inboard Ejector Rack Assembly
16-34
TM 55-1520-236-23
(5) Install packing (7) on plug (6) and Install 16-56. REMOVAL - EJECTOR RACK
plug. FAIRINGS.
(6) Install packings (5 and 14) on retaining plug Remove inboard and outboard fairings (figure 16-8)
(15). from rack and leading edge of wing by removing
screws and releasing the fasteners.
(7) Install packing (13) on slave piston (12).
(8) Install compression spring (11), slave piston 16-57. REPAIR - EJECTOR RACK
(12), and retaining plug (15). FAIRINGS.
j . Reinstall rack assembly on pylon (paragraph Replace any fairings that are damaged severely
16-52.) enough to prohibit proper functioning of ejector rack.
Repair inboard and outboard fairings per TM 55-
16-54. EJECTOR RACK FAIR N G S . 1500-204-25/1.
16-55. INSPECTION - E J E C T O R RACK 16-58. INSTALLATION - E J E C T O R RACK
FAIRINGS. FAIRINGS.
Inspect inboard and outboard fairings (figure 16-8) for Install inboard and outboard fairings (figure 16-8) to
cracks, damage and serviceable condition the wing by locking fasteners and adding screws.
Figure 16-8. Wing stores pylon and fairings
Change 12 16-35
TM 55-1520-236-23
16-59. CHAFF DISPENSER SUBSYSTEM. gunsight subsystem circuitry information. Refer to
paragraph F-6 for airframe armament electrical
16-60. DESCRIPTION OF DISPENSER, equipment list, and paragraph F-9 for subsystem
GENERAL PURPOSE, M-130. airframe wiring diagrams.
The dispenser, general purpose, aircraft: M130 16-65. CLEANING - AIM-1/EXL LASER
(NSN 1095-01-036-6886) consists of a single GUNSIGHT SUBSYSTEM.
system (dispenser assembly, payload module
assembly, electronics module and dispenser control a. Clean body of aiming light with a wet cloth.
panel) designed to dispense chaff M-1. The system
provides effective survival countermeasures against b. Clean front window with blower or soft brush.
radar guided weapon systems threats. The Wipe with optical paper.
dispenser system M130 has the capability of
dispensing up to 30 chaff cartidges. 16-66. INSPECTION - AIM-1/EXL LASER
GUNSIGHT SUBSYSTEM.
NOTE
a. Inspect electrical cable for fraying or damaged.
The flare dispenser function is
not employed in the AH-1P, AH- b. Inspect aiming light for bending, cracks,
1E, AH-1F helicopter. fractions and loose parts.
16-61. MAINTENANCE - CHAFF DISPENSER c. I n s p e c t a i m i n g l i g h t f r o n t w i n d o w f o r
SUBSYSTEM. scratches, cracks and humidity markings.
Refer to TM 9-1095-206-13 & P for additional 16-67. REMOVAL - AIM-1/EXL LASER
information and maintenance procedures. Refer to GUNSIGHT SUBSYSTEM.
FO-143.
Premaintenance Requirements for
16-62. AIM-1/EXL LASER GUNSIGHT Maintenance of AIM-1/EXL Laser Assembly
SUBSYSTEM.
16-63. DESCRIPTION - AIM-1/EXLLASER
Conditions Requirements
GUNSIGHT SUBSYSTEM.
The AIM-1/EXL aiming light is mounted on the gun
Model AH-1F
saddle of the universal turret. It enables low-
light/night target acquisition for the turret gun by
Part No. or Serial No. All
using a boresighted infrared laser beam that can
only be viewed with night vision goggles (NVGs).
Special Tools None
The AIM-1/EXL subsystem can be used in conjunc-
tion with the Helmet Sight Subsystem (HSS) when Test Equipment None
NVGs are worn. The AIM-1/EXL aiming light can
operate in continuous mode or activated when None
Support Equipment
ACTION switch on pilot cyclic control is pressed.
Subsystem operations are controlled by the switch/ Minimum Personnel
relay assembly located on the outboard side of
Required One
pilots ash receiver.
Consumable Materials, C-137
16-64. MAINTENANCE - AIM-1/EXL
LASER GUNSIGHT SUBSYSTEM. Special Environmental
Conditions None
Removal and installation instructions for the AIM-
1/EXL laser gunsight are given below. Refer to
paragraph 9-573 in this manual for AIM-1/EXL laser
16-36 Change 19
TM 55-1520-236-23
a. Install adapter (5, figure 16-9) on right side of
gun turret with two flat washers (7) and two bolts
(6). Secure bolts with Iockwire (C-137).
b. Install aiming light (1) on adapter (5) with flat
The AIM-1/EXL laser is very dangerous. washer (4), Iockwasher (3) and bolt (2).
Ensure that the laser protective cover is
kept over the emitter and AIM switch is off c. Connect electrical connector to aiming light (1).
at all times.
16-70. FUNCTIONAL TEST - AIM-1/EXL
a. Preparation for Maintenance. LASER GUNSIGHT SUBSYSTEM.
(1) Disconnect battery. Refer to paragraph 9-575 and perform AIM-1/EXL
laser gunsight subsystem circuitry test.
(2) Position all armament circuit breakers and
switches to OFF. 16-71. TROUBLESHOOTING - AIM-1/EXL
LASER GUNSIGHT SUBSYSTEM.
b. Removal Procedures.
(1) Disconnect electrical connector from aiming
light (1, figure 16-9).
The AIM-1/EXL laser beam is dangerous
(2) Remove bolt (2), Iockwasher (3), flat washer and can cause blindness if it enters the
(4) and aiming light (1) from adapter (5). eye either directly or reflected from a
shiny surface. Ensure that the laser
(3) Cut lockwire securing two bolts (6). Remove protective cover is kept over the emitter
two bolts (6), flat washers (7) and adapter (5). and that the AIM power switch is off at
all times when the laser is not in use.
16-68. REPAIR - AIM-1/EXL LASER The laser shall be used only in controlled
GUNSIGHT SUBSYSTEM. areas by qualified personnel. Night
goggles are required during operation.
a. Repair or replace connector and wiring if they
fail to meet minimum serviceability standards. NOTE
b. Replace aiming light if damaged or defective. Before using table, ensure all normal
Evacuate removed aiming light to higher echelon for operational checks have been performed.
disposition. If a malfunction is found which is not
listed in table notify the next higher level
1 6 - 6 9 . R E I N S T A L L A T I O N - AIM-1/EXL of maintenance.
LASER GUNSIGHT SUBSYSTEM.
The AIM-1/EXL Laser is very dangerous.
Ensure that the laser protective cover is
kept over the emitter and AIM switch is off
at ail times.
Change 19 16-37
TM 55-1520-236-23
Figure 16-9. AIM-1/EXL Laser Installation
16-38 Change 19
TM 55-1520-236-23
TABLE 16-3. Troubleshooting AIM-1/EXL Laser Gunsight Subsystem
CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION
Night goggles are required during operation of AIM-1/EXL
aiming light.
1. With TURRET DRIVE MOTOR circuit breaker closed, no laser beam is seen when AIM switch is positioned in NORM
or CONT when ACTION switch is depressed..
STEP 1. Laser window is covered.
Remove protective cover from aiming light.
STEP 2. Check for defective AIM switch.
Replace switch (paragraphs 9-20 and 9-22).
STEP 3. Check for defective wiring.
Repair wiring (FO-118.1).
STEP 4. Check for defective TURRET DRIVE MOTOR circuit breaker.
Replace circuit breaker (paragraphs 9-27 and 9-29).
STEP 5. Check aiming light for continuity.
If continuity is not present notify the next higher level of maintenance.
2. Aiming light is weak.
Clean front window.
3. Aiming light is blurred (diffused).
STEP 1. Check aiming front window.
Clean front window.
STEP 2. Check night vision goggles.
Focus night vision goggles.
Change 19 16-39/(16-40 blank)
TM 55-1520-236-23
CHAPTER 17
EMERGENCY EQUIPMENT
17-1. CANOPY REMOVAL SYSTEM. Premaintenance Requirements
For Window Cutting Assembly
17-2. DESCRIPTION - CANOPY
REMOVAL SYSTEM.
Conditions Requirements
The canopy removal system (CRS) consists of two
window cutting assemblies (WCAs), two hinge
cutting assemblies, two thrusters, two pin pullers,
two arming/firing mechanisms (A/F), twelve Model AH-1P/E/F
interconnecting lines, and two inert manifolds (figure
17-1). Manual operation of any one of the two A/F Part No. or Serial No. All
mechanisms will cause explosive energy to be
generated and routed by the shielded mild detonating Special Tools None
cords (SMDCs) through the manifold to all other CRS
components. The system then functions such that the Test Equipment None
two WCAs sever the gunner right and pilot left fixed
window acrylic material around each windows Support Equipment None
periphery. Two linear shaped charge assemblies
(LSCAs) sever both door hinges, the thrusters release Minimum Personnel
both door match mechanisms and the pin pullers Required Two
release both door counterpoise struts. The result is
complete jettisoning of both doors and both fixed Consumable Materials (C74), (C75),
window transparencies. (C105), (C137)
Special Environmental
Conditions None
Ensure that both the pilot and gunner
arming/firing mechanism handles are
secured with safety pins (37 and 38,
figure 17-1) prior to entry into the
cockpit area.
NOTE
All unserviceable explosive items used Ensure that both the pilot and gunner
in the CRS e.g; arm fire initiator, arming/firing mechanism handles are
detonating cord, junction manifold secured with safety pins (37 and 38,
interconnect line shall be tagged with Figure 17-1) prior to entry into the
NSN , nomenclature, lot number, instal- cockpit area.
lation date, removal date, reason for
removal, helicopter type/model, serial
number and returned to supporting
ammunition supply activity in the con-
tainer used to transport the replace- Activation of the canopy removal sys-
ment item. tem when combustible fuel/vapors are
present can result in an explosion/fire.
17-3. WINDOW CUTTING ASSEMBLY. Crew members survival knife may be
used as an alternate means of egress.
17-4. DESCRIPTION - W I N D O W
CUTTING ASSEMBLY. 17-5. INSPECTION - WINDOW CUTTING
ASSEMBLY.
The window cutting assemblies (1 and 20, figure 17-
1) are mounted to the pilot and gunner window Inspect window cutting assemblies (1 and 20, figure
frames as shown in figure 17-1. 17-1) for cracks.
Change 16 17-1
TM 55-1520-236-23
Figure 17-1. Canopy Removal System (Sheet 1 of 2)
17-2
TM 55-1520-236-23
Figure 17-1. Canopy Removal System (Sheet 2 of 2)
17-6. REMOVAL - WINDOW CUTTING d. Use a putty knife or other suitable tool to loosen
ASSEMBLY (AVIM). sealant. Clean sealant from window transparency with
naphtha (C75), and from frame with MEK (C74).
a. Disconnect interconnect lines (3 and 6, or 24
and 28, figure 17-1) from adapter on window cutting
assembly (1 or 20). Cap lines. 17-7. REPAIR OR REPLACEMENT - CRACKED
WINDOW CUTTING ASSEMBLY.
b. Disconnect and remove air data subsystem
wiring at aft upper corner of window cutting assembly Replace window cutting assembly if cracked or
(1). damaged.
c. Remove screws securing window transparency
and window cutting assembly to window frame and 17-8. INSTALLATION - WINDOW CUTTING
remove cutting assembly. ASSEMBLY (AVIM).
a. Position window cutting assembly (1 or 20, figure
17-1) in place between window transparency and door
frame.
Cleaning solvent is flammable and toxic. b. Use holes in window frame as a guide and drill
Provide adequate ventilation. Avoid holes through window cutting assembly and window
prolonged breathing of solvent vapors glass using a hole finder. Use fasteners as holes are
and contact with skin or eyes. drilled to maintain alignment.
c. After all holes are drilled, remove glass and
window cutting assembly from frame and clean all
CAUTION cuttings from parts.
Do not allow any ketone-type solvents to d. Apply sealant (C105) to faying surfaces of
contact window transparencies. These window cutting assembly.
solvents will damage the transparencies
by attacking the plastic materials. e. Place window cutting assembly (1 or 20) and
glass on window frame and install mounting screws.
Change 18 17-3
TM 55-1520-236-23
f. Route and connect air data subsystem
wiring at aft upper corner of window cutting assembly
(1).
g. Connect interconnect line end fitting (3 and 6
or 24 and 28) to window cutting assembly. Torque nut
30 TO 45 inch-pounds.
17-9. LINEAR SHAPED CHARGE
ASSEMBLY.
17-10. DESCRIPTION - LINEAR SHAPED
CHARGE ASSEMBLY.
The linear shaped charge assemblies (7 and 10,
figure 17-1) are mounted to the canopy frame inboard
of the top of the pilot and gunner doors. In case of an
emergency the charge assembly will sever the door
hinge.
Figure 17-2. Damage Limits - Linear
Ensure that both the pilot and gunner
Shaped Charge Assembly
arming/firing mechanism handles are
secured with safety pins (37 and 38,
figure 17-1) prior to entry into the
cockpit area.
c. R e m o v e r i v e t s (9) securing linear shaped
charge assembly to door frame and disengage
17-11. INSPECTION - LINEAR SHAPED assembly from frame.
CHARGE ASSEMBLY.
Inspect linear shaped charge assembly (7 or 10,
figure 17-1) and plastic covering for the following: 1 7 - 1 3 . I N S T A L L A T I O N - LINEAR
SHAPED CHARGE ASSEMBLY. (AVIM).
a. Security.
a. Position linear shaped charge assembly in place
b. Nicks, dents, scratches, and corrosion in on canopy frame.
accordance with figure 17-2.
b. Using a hole finder drill holes in linear shaped
c. Inspect linear explosive for damage or cracks. charge assembly (7 or 10, figure 17-1) to match holes
in door frame and install rivets (9).
17-12. REMOVAL - LINEAR SHAPED
CHARGE ASSEMBLY (AVIM). c. Connect interconnect lines (8 and 11 or 12) at
each end of charge assembly. Torque nut 30 TO 46
a. Remove door from helicopter (paragraph 2- inch-pounds.
131).
d. If charge assembly has been fired, install new
b. Disconnect interconnect lines (8 and 11 or 12, hinge on door.
figure 17-1) from each end of linear shaped charge
assembly (7 or 10). Cap lines. e. Install door (paragraph 2-137).
17-4
TM 55-1520-236-23
17-14. SIGNAL TRANSMISSION b. Arming/Firing Mechanism.
SUBSYSTEM.
(1) Cut Iockwire and disconnect interconnect
17-15. DESCRIPTION - SIGNAL line (23 or 34) from arming/firing mechanism (22 or
TRANSMISSION SUBSYSTEM. 35).
The signal transmission subsystem consists of (2) Install protective cap and plug,
interconnecting lines of detonating cord with
threaded connections for attachment to window (3) Remove four screws (21 or 36) to detach
cutting assembly and linear shaped charge assembly mechanism from bracket.
adapters, junction manifolds, and an arming/firing
mechanism. The arming/firing mechanism is c. Junction Manifold.
activated when the handle is rotated 90 degrees
counterclockwise to arm, then pulled to fire primer (1) Cut Iockwire and disconnect interconnect
charge. The junction manifolds are used to connect lines (3, 23, 24, and 34) from junction manifold (26).
the systems together.
(2) Install protective caps and plugs.
17-16. INSPECTION - SIGNAL
TRANSMISSION SUBSYSTEM. (3) Remove two screws (25) to detach manifold
from bracket.
d. Pin Puller.
(1) Cut Iockwire and disconnect interconnect
Ensure that both the pilot and gunner lines (2 and 6 or 12 and 27) from pinpuller (5 or 19).
arming/firing mechanism handles are
secured with safety pins (37 and 38, (2) Install protective caps and plugs.
figure 17-1) prior to entry into the
cockpit area. (3) Remove two screws (4 or 18) to detach pin
puller (5 or 19) from canopy frame.
a. Inspect all interconnect lines (figure 17-1) for
nicks, dents, scratches, and for secure installation. e. Thruster.
b. Inspect arming/firing mechanism (22 and 35) (1) Cut Iockwire and disconnect interconnect
for nicks, dents, scratches, and for secure lines (2 and 11 or 27 and 28) from thruster (16 or 31).
installation.
(2) Install protective caps and plugs.
c. Inspect pinpullers (5 and 19), if the piston is in
the release position or if the piston can be pushed in (3) Remove two screws (13 or 33) and two nuts
with minimal effort replace the pinpuller.
(17 or 32) securing thruster (16 or 31) to structure.
17-17. R E M O V A L - SIGNAL (4) Remove jamnut (14 or 30) and shims (15 or
TRANSMISSION SUBSYSTEM. (AVIM) 29) from thruster (16 or 31) and detach thruster from
bracket.
a. Interconnecting Lines.
17-18. INSTALLATION - SIGNAL
(1) Remove clamps as necessary to detach line TRANSMISSION SUBSYSTEM. (AVIM)
from structure.
a. Interconnecting Lines.
(2) Cut Iockwire and disconnect each end of
line from junction manifold (26, figure 17-1), in line (1) Remove protective caps and plugs.
connector (39), window cutting assembly (1 or 20),
arming/firing mechanism (22 or 35), linear shaped (2) Connect each end of line to junction
charge assembly (7 or 10), thruster (16 or 31) or pin manifold (26, figure 17-1), in-line connector (39),
puller (5 or 19). window cutting assembly (1 or 20), arming/firing
(3) Install protective caps and plugs.
Change 16 17-5
TM 66-1620-236-23
mechanism (22 or 35), linear shaped charge (3) Remove protective caps and plugs.
assembly (7 or 10), thruster (16 or 31), or pin puller (5
or 19). Torque nuts 30 TO 45 inch-pounds. (4) Connect interconnect lines (2 and 11 or 27
and 28) to thruster (16 or 31). Torque nuts 30 TO 46
(3) Lockwire (C137) nuts. inch-pounds.
(4) Secure lines in place on structure with (5) Lockwire (C137) nuts.
applicable clamps.
b. Arming/Firing Mechanism. 17-19. FIRST AID KIT.
(1) Secure mechanism (22 or 35) to bracket
with four screws (21 or 36). 17-20. DESCRIPTION - FIRST AID KIT.
(2) Remove protective cap and plug. The first aid kit is fastened with snap fasteners behind
the pilot seat.
(3) Connect interconnect line (23 or 34) to
mechanism (22 or 35), Torque nut 30 TO 45 inch-
pounds. 17-21. REMOVAL - FIRST AID KIT.
(4) Lockwire (C137) nut. Pull outward on kit to release fasteners.
c. Junction Manifold.
17-22. INSPECTION - FIRST AID KIT.
(1) Secure manifold (26) to bracket with two
Refer to TM 55-1500-328-25.
screws (25).
(2) Remove protective caps and plugs. 17-23. INSTALLATION - FIRST AID KIT.
(3) Connect interconnect lines (3, 23, 24 and Position kit on fasteners and push to engage
34) to manifold (26). Torque nuts 30 TO 46 inch- fasteners.
pounds.
1 7 - 2 4 . F I R E EXTINGUISHER.
(4) Lockwire (C137) nuts.
d. Pin Puller. 17-25. DESCRIPTION - FIRE
EXTINGUISHER.
(1) Secure pin puller (5 or 19) to canopy frame
with two screws (4) or 18). The fire extinguisher is installed on the floor of a
bracket in front of gunner seat.
(2) Remove protective caps and plugs.
(3) Connect interconnect lines (2 and 6 or 12
and 27) to pin puller (5 or 19). Torque nuts 30 TO 45
inch-pounds.
When helicopter is to be parked where
(4) Lockwire (C137) nuts. ambient temperature equals or exceeds
90 degrees F (32 degrees C), the fire
e. Thruster. extinguisher shall be removed until the
next mission.
(1) Place thruster (16 or 31) through hole in
bracket and attach with shims (15 or 29) and jamnut Should an extinguisher inadvertently be
(14 or 30). left in the helicopter during a high
temperature period, the extinguisher
(2) Secure thruster (16 or 31) to structure with shall be weight checked prior to the next
two screws (13 or 33) and two nuts (17 or 32). mission.
17-6
TM 55-1520-236-23
d. Weigh fire extinguisher every six months (as
recorded on inspection label) and ensure that it
weighs no less than four ounces below fully charged
gross weight stamped on nameplate.
Exposure to high concentrations of e. inspect fire extinguisher mounting bracket for
monobromotrifluoromethane (CF3br) damage and security.
extinguishing agent or decomposition
products should be avoided. The liquid
17-28. REPAIR - FIRE EXTINGUISHER.
should not be allowed to come into
contact with the skin, as it may cause
a. Replace fire extinguisher that is damaged or
frostbite, low-temperature burns, or
does not meet fully charged weight requirements.
severe irritation of eyes and nose.
b. Repair or replace damaged mounting bracket
17-26. REMOVAL - FIRE EXTINGUISHER. as applicable.
a. Unlatch holding strap and lift extinguisher from
17-29. INSTALLATION - FIRE
bracket.
EXTINGUISHER.
b. Remove retaining screws and washers and a. Attach bracket to floor panel with screws and
remove bracket from floor panel. washers.
17-27. INSPECTION - FIRE
b. Place extinguisher in bracket and latch in place
EXTINGUISHER.
with holding strap.
a. Inspect fire extinguisher for obvious physical
damage.
17-30. S U R V I V A L KIT.
b. Inspect handle for security. 17-31. DESCRIPTION - SURVIVAL KIT.
c. Check that handle safety pin is installed and Provisions for the customer furnished survival kit are
secure. installed on the bulkhead aft of the pilot.
17-7/(17-8 blank)
TM 55-1520-236-23
APPENDIX A
REFERENCE
The following references of the issue in effect, are required for use by aviation unit and intermediate maintenance per-
sonnel in performance of their duties.
NUMBER TITLE
AR 95-1 Army Aviation General Provisions and Flight Regulations
AR 95-3 Weight and Balance, Army Aircraft
AR 95-5 Aircraft Accident Prevention and Investigation
AR 310-50 Authorized Abbreviations and Brevity Codes
AR 750-50 Aircraft Cannibalization
AR 755-15 Disposal of Unwanted Radioactive Material
DA PAM 738-751 The Army Maintenance Management System (TAMMS)
FM 10-68 Aircraft Refueling
FM 10-69 Petroleum Handling and Operation
FM 55-413 Aerial Recovery of Aircraft
MIL-L-6866 Penetrant Method of Inspection
MIL-L-6868 Magnetic Particle Inspection Process
TB MED 501 Noise and Conservation of Hearing
TB 1-1615-351-23 Rotor Blade Erosion Protection
TB 43-0106 Army Oil Analysis Program
TB 750-25 Maintenance of Supplies and Equipment Army Metrology and Calibration System
TB 55-1500-334-25 Conversion to Fire Resistant Hydraulic Fluid
TB 55-1560-276-24/1 Polish Kit, Glass, Part Number: RS-69, NSN: 1560-00-450-3622
TB 55-9150-200-24 Engine and Transmission Oils, Fuels, and Additives for Army Aircraft
TM 1-7R1-3-1-1 Cleaning, Testing, and Corrosion Treatment of Air Cooled Aluminum, Brass and Copper
Type Oil Coolers
TM 1-1520-250-23-1 General Tie-Down and Mooring Technical Manual Aviation Unit and Intermediate Main-
tenance All Series Army Models AH-64, UH-60, CH-47, UH-1, AH-1, OH-58 Helicopters
TM 9-1095-206-13 & P Operation Aviation Unit Maintenance and Aviation Intermediate Maintenance Manual
(Including Repair Parts and Special Tool Lists) for Dispenser, General Purpose Aircraft
XM130
TM 10-1101 Petroleum Handling and Operation (superseded by FM 10-69)
Change 19 A-1
TM 55-1520-236-23
NUMBER TITLE
TM 1-1500-328-25 Aeronautical Equipment Maintenance Management Policies and Procedures
TM 11-1520-236-20 Organizational Maintenance Manual: Electronic Equipment Configurations
(AH-1S)
TM 11-1520-236-34 Direct and General Support Maintenance Manual: Electronic Equipment
Configurations (AH-1S)
TM 11-6125-220-12 Organizational Maintenance Manual: Motor-Generator PU-543/A (Modified),
PU-543 A/A (modified), PU-543 B/A, PU-543 C/A, and PU-543 D/A.
TM 11-6130-385-34 Direct Support and General Support Maintenance Manual: Inverter, Static Power
PP-7274/A
TM 11-6140-203-14-2 Operators, Organizational, Direct Support, General Support, and Depot
Maintenance Manual for Aircraft Nickel-Cadmium Batteries
TM 3-220 Chemical, Biological and Radiological (CBR) Decontamination
TM 43-0105 Corrosion Control for Army Aircraft
TM 55-1500-204-25/1 General Aircraft Maintenance Manual
TM 55-1500-220-PM Phased Maintenance Checklist
TM 55-1500-220-PMD Preventive Maintenance Daily Checklist
TM 55-1500-322-24 Organizational, Direct, and General Support Maintenance Manual: Cleaning
Procedure for Army Aircraft
TM 55-1500-326-24 General Aircraft Maintenance Manual: Standards of Serviceability for Transfer of
Aircraft.
TM 55-1500-333-24 Organizational, Direct Support, and General Support Maintenance Manual:
Cleaning Procedure for Army Aircraft
TM 55-1500-335-23 Non-Destructive Inspection Methods
TM 55-1500-342-23 Army Aviation Maintenance Engineering Manual: Weight and Balance
TM 55-1500-345-23 Painting and Marking of Army Aircraft.
TM 55-1520-236-MTF Aircraft Maintenance Test Flight Manual for AH-lP/E/F Aircraft
TM 55-1520-236-T Aviation Unit and Intermediate Maintenance Level Troubleshooting Instructions;
Integrated Armament and Fire Control Systems; AH-1S (MC).
TM 55-1520-236-10 Operators Manual: Army Model (AH-1P/E/F)
TM 55-1520-236-23P Aviation Unit and Intermediate Maintenance Repair Parts and Special Tools List
(Including Depot Maintenance Repair Parts and Special Tools); Helicopter, Attack,
AH-1P/E/F
TM 55-2620-200-24 Inspection, Maintenance Instructions, Storage and Disposition of Aicraft Tires and
Inner Tubes
A-2 Change 16
TM 55-1520-236-23
NUMBER TITLE
TM 55-2840-229-24 Organizational, Direct Support, and General Support Maintenance Manual:
Engine, Shaft Turbine
TM 55-4920-201-14 Operators, Organizational, Direct Support, and General Support Maintenance
Manual: Including Repair Parts and Special Tools List: Balancing and Adapter Kits
TM 55-4920-244-14 Operators, Organizational, Direct Support, and General Support Maintenance
Manual (Including Repair Parts and Special Tools List) for Tester, Exhaust Gas
Temperature, Model: BH 112JA-36.
TM 55-4920-401-13&P Operators, Organizational and Direct Support Maintenance Manual (Including Repair
Parts and Special Tools List) for Exhaust Gas Temperature Tester, BH112JB-53
TM 740-90-1 Administrative Storage of Equipment
TM 9-1055-460-14 Operator, Organizational, Direct Support, and General Support Maintenance
Manual (Including Repair Parts and Special Tool Lists with Depot Maintenance
Allowance): 2.75 Inch Aircraft Rocket Launchers M158A1, M200 and M200A1
TM 9-1090-203-12 Operator and Organizational Maintenance Manual for Armament Subsystem,
Helicopter 7.62 Millimeter, 40mm Gernade Launcher: M28A1
TM 9-1270-212-14 Operator, Organizational, Direct Support, and General Support Maintenance
Manual for Ml 28 and Ml 36 Helmet-Sight Subsystem (HSS)
TM 9-1270-217-13&P Operators, Aviation Unit and Intermediate Maintenance Manual with Repair Parts
and Special Tools List (Including Depot Maintenance Repair Parts and Special
Tools) for Rocket Management Subsystem, Inventory-Deployment, XM138
TM 9-1270-218-13 Aviation Unit and Aviation Intermediate Maintenance Manual for Fire Control
Computer Subsystem XM22.
TM 9-1270-219-13 Operator Aviation Unit and Aviation Intermediate Maintenance Instructions
TM 9-1270-220-13 Aviation Unit and Aviation Intermediate Maintenance Manual for Head-Up Display,
Subsystem XM76
TM 9-1425-473-20 Organizational Maintenance Manual for Armament Subsystem, Helicopter, TOW
Guided Missile XM65
TM 9-1425-473-34 Direct and General Support Maintenance Manual, Armament Subsystem,
Helicopter, TOW Guided Missile XM65
Change 19 A3/(A-4 blank)
TM 55-1520-236-23
APPENDIX B
MAINTENANCE ALLOCATION CHART
SECTION I. INTRODUCTION
B-1 . MAINTENANCE ALLOCATION preflight, daily, intermediate, periodic, and special
CHART inspections as authorized by the MAC or higher
headquarters. Identify the cause of
equipment/system malfunctions using applicable
a. T h i s M a i n t e n a n c e A l l o c a t i o n C h a r t ( M A C ) technical manual troubleshooting instructions, built-
assigns maintenance functions in accordance with in-test equipment (BITE), installed aircraft
the Three Levels of Maintenance concept for army instruments, or easy to use/interpret
aircraft. These maintenance levels, Aviation Unit diagnostic/fault isolation devices (TMDE). Replace
Maintenance (AVUM); Aviation Intermediate worn or damaged modules/components which do
Maintenance (AVIM) and Depot Maintenance are not require complex adjustments or system
depicted on the MAC as: alignment and which can be removed/installed with
available skills, tools and equipment. Perform
AVUM which corresponds to the O Code in the operational and continuity checks and make minor
RPSTL repairs to the electrical system. Inspect, service, and
AVIM which corresponds to an F Code in the RPSTL make operational, capacity, and pressure checks to
DEPOT which corresponds to a D Code in the hydraulic systems. Perform servicing, functional
RPSTL adjustments, and minor repair/replacement to the
flight control, propulsion, power train, and fuel
systems. Accomplish air frame repair which does not
b. The maintenance to be performed below depot
require extensive disassembly, jigging, or alignment.
and in the field is described as follows:
The manufacture of air frame parts will be limited to
those items which can be fabricated with tools and
(1) A v i a t i o n U n i t Maintenance (AVUM)
equipment found in current air mobile tool and shop
activities will be staffed and equipped to perform high
sets. Evacuate unserviceable modules/components
frequency On-Aircraft maintenance tasks required
and end items beyond the repair capability of AVUM
to retain or return aircraft to a serviceable condition.
to the supporting AVIM.
The maintenance capability of the AVUM will be
governed by the Maintenance Allocation Chart (MAC)
and limited by the amount and complexity of ground (b) Less than Company Size Aviation Units:
support equipment (GSE), facilities required, and Aviation elements organic to brigade, group, battalion
number of spaces and critical skills available. The headquarters, a n d d e t a c h m e n t s i z e u n i t s a r e
range a n d q u a n t i t y o f authorized spare normally small and have less than ten aircraft
modules/components will be consistent with the assigned. Maintenance tasks performed by these
mobility requirements dictated by the air mobility units will be those which can be accomplished by the
concept. (Assignments of maintenance tasks to aircraft crew chief or assigned aircraft repairman and
divisional company size aviation units will consider will normally be limited to preventive maintenance,
the overall maintenance capability of the division, the inspections, servicing, spot painting, stop drilling,
requirement to conserve personnel and equipment application of nonstress patches, minor adjustments,
resources and air mobility requirements.) module/component fault diagnosis, and replacement
of selected modules/components. Repair functions
will normally be accomplished by the supporting
(a) Company Size Aviation Units: Perform
AVIM unit.
those tasks which consist primarily of preventive
maintenance and maintenance repair and
replacement functions associated with sustaining a
high level of aircraft operational readiness. Perform (2) Aviation Intermediate Maintenance (AVIM)
maintenance inspections and servicing to include provides mobile, responsive One Stop
B-1
TM 55-1520-236-23
maintenance support. (Maintenance functions which (2) Time required.
are not conducive to sustaining air mobility will be
assigned to depot maintenance). Performs all (3) Tools and test equipment required and/or
maintenance functions authorized to be done at available.
AVUM. Repair of equipment for return to user will
emphasize support or operational readiness b. The assigned levels of maintenance authorized
requirements. Authorized maintenance includes to perform a maintenance function is indicated.
replacement and repair of modules/components and
end items which can be accomplished efficiently with c. A maintenance function assigned to a lower
available skills, tools, and equipment, Established the maintenance level will automatically be authorized to
Direct Exchange (DX) program for AVUM units by be performed at any higher maintenance level.
repairing selected items for return to stock when such
repairs cannot be accomplished at the AVUM level.
Inspects, troubleshoots, test diagnoses, repairs, d. A m a i n t e n a n c e f u n c t i o n t h a t c a n n o t b e
adjusts, calibrates, and aligns aircraft system performed at the assigned level of maintenance for any
modules/components. AVIM units will have capability reason may be evacuated to the next higher
to determine the serviceability of specified maintenance organization. Higher maintenance levels
modules/components removed prior to the expiration will perform the maintenance functions of lower
of the Time Between Overhaul (TBO) or finite life. maintenance levels when required or directed by the
Module/component disassembly and repair will sup- appropriate commander.
port the DX program and will normally be limited to
tasks requiring cleaning and the replacement of seals, e. The assignment of a maintenance function will
fittings, and items of common hardware. Airframe not be construed as authorization to carry the
repair and fabrication of parts will be limited to those associated repair parts in stock. Information to
maintenance tasks which can be performed with requisition or otherwise secure the necessary repair
available tools and test equipment. Unserviceable parts will be as specified in the Repair Parts, Special
reparable modules/components and end items which Tools List.
are beyond the capability of AVIM to repair will be
evacuated to Depot Maintenance. This level will f. Normally there will be no deviation from the
perform aircraft weight and balance inspections and assigned level of maintenance. In cases of operational
other special inspections which exceed AVUM necessity, maintenance functions assigned to a higher
capability. Provides quick response maintenance maintenance level may, on a one-time basis and at the
support, including aircraft recovery and air evacuation, request of the lower maintenance level, be specifically
on-the-job training, and technical assistance through authorized by the maintenance officer of the higher
the use of mobile maintenance contact teams. level of maintenance to which the function is assigned.
Maintains authorized operational readiness float The special tools, equipment, etc. required by the
aircraft. Provides collection and classification services lower level of maintenance to perform this function will
for serviceable/unserviceable material. Operates a be furnished by the maintenance level to which the
cannibalization activity in accordance with AR 750-50. function is assigned. This transfer of a maintenance
(The aircraft maintenance company within the function to a lower maintenance level does not relieve
maintenance battalion of a division will perform AVIM the higher maintenance level of the responsibility of the
functions consistent with air mobility requirements and function. The higher level of maintenance has the
conservation of personnel and equipment resources. authority to determine:
Additional intermediate maintenance support will be
provided by the supporting nondivisional AVIM unit). (1) If the lower level is capable of performing the
work.
(2) If the lower level will require assistance or
B-2. USE OF THE MAINTENANCE technical supervision and on-site inspection.
ALLOCATION CHART.
(3) If the authorization will be granted.
a. The Maintenance Allocation Chart assigns
maintenance functions based on past experience and g. Maintenance of the US Army Communications
the following consideration: and Electronics Materiel Readiness Command
equipment will be performed by designated US Army
(1) Skills available. CERCOM personnel.
B-2 Change 8
TM 55-1520-236-23
h. Changes to the Maintenance Allocation Chart h. Replace. The act of substituting a serviceable
will be based on continuing evaluation and analysis like type part, subassembly, or module, (component or
by responsible technical personnel and on reports assembly) for an unserviceable counterpart.
received from field activities.
i. Repair. T h e a p p l i c a t i o n o f m a i n t e n a n c e
services or other maintenance actions to restore
B-3. DEFINITIONS. serviceability to an item by correcting specific
damage, fault, malfunctions or failure in a part,
Maintenance functions. Maintenance functions will subassembly, module (component or assembly), end
be limited to and defined as follows: item, or system.
a. Inspect, To determine the serviceability of an
item by comparing its physical, mechanical and/or j . Overhaul. That maintenance effort
electrical characteristics with established standards (service/action) necessary to restore an item to a
through examination. completely serviceable/operational condition as
prescribed by maintenance standards (i.e. DMWR) in
appropriate technical publications. Overhaul is
b. Test. T o v e r i f y s e r v i c e a b i l i t y a n d d e t e c t normally the highest degree of maintenance
incipient failure by measuring the mechanical or performed by the Army. Overhaul does not normally
electrical characteristics of an item and comparing return an item to like new condition.
those characteristics with prescribed standards.
k. Rebuild. Consists of those service actions
c. Service. Operations required periodically to necessary for the restoration of unserviceable
keep an item in proper operating condition, i.e. to equipment to a like new condition in accordance with
clean (decontaminate), to preserve, to drain, to paint, original manufacturing standards. Rebuild in the
or to replenish fuel, lubricants, hydraulic fluids, or highest degree of materiel maintenance applied to
compressed air supplies. Army equipment. The rebuild operation includes the
act of returning to zero those age measurements
(hours/miles, etc.) considered in classifying Army
d. Adjust. To maintain, with prescribed limits, by equipments/components.
bringing into proper or exact position, or by setting the
operating characteristics to specified parameters.
B-4. STANDARD GROUPS.
e. Align. To adjust specified variable elements of
The standard groupings shown below are used, as
an item to bring about optimum or desired
applicable, t h r o u g h o u t t h i s M A C M a i n t e n a n c e
performance.
manuals and RPSTLS reflect these standard
groupings as individual chapters with sections in
f. Calibrate. To determine and cause corrections each chapter relative to the individual complete
to be made or to be adjusted on instruments or test systems, subsystems, modules, components,
measuring and diagnostic equipment used in assemblies, or specific parts noted.
precision measurement. Consists of comparisons of
two instruments, one of which is a certified standard
of known accuracy, to detect and adjust any
B-5. SYMBOLS.
discrepancy in the accuracy of the instrument being
compared.
The letters AVUM, AVIM and DEPOT as placed on
the Maintenance Allocation Chart indicate the level
g. Install. The act of emplacing, seating, or fixing of maintenance responsible for performing the
into position an item, part, or module (component or particular maintenance function based upon
assembly) in a manner to allow the proper functioning assigned skills, tools, and test equipment and time
of an equipment or system. required to accomplish maintenance.
B-3
TM 55-1520-236-23
AIRFRAME ITEMS
GROUP GROUP
NUMBER DESCRIPTION NUMBER DESCRIPTION
00 Aircraft System 06 Drive Train Systems
01 Aircraft General Transmission, gearboxes, clutches,
shafting, oil systems, bearings,
Servicing, handling, inspection require- hangers, oil tanks, and freewheeling
ments, lubrication requirements, over- units.
haul and retirement requirements,
cleaning, mooring, towing, jacking, 07 Hydraulic and Pneumatic Systems
hoisting, preservation requirements,
weight and balance requirements, spot Pumps, filters, reservoirs, cylinders,
painting, complete painting, and subas- valves, servos, motors, starters, and
sembly painting requirements. accumulators.
02 Airframe 08 Instrument Systems
Fuselage, empennage, pylons, wings Flight instruments, navigation instru-
mounts (engine and transmission), ments, engine instruments, miscel-
armor, seats, ramps, decks, and laneous instruments (i.e. clocks)
tiedowns. sending units, panels, and flow meters.
03 Alighting Gear 09 Electrical Systems
Landing gear, skids, floats, skis, struts, Motors, actuators, regulators, gener-
wheel brakes, and mechanical ators, starters, batteries, lighting, cau-
mechanisms. tion and warning lights, inverters, fault
isolation systems, rotor brakes, and
04 Power Plant Installation avionics provisions.
Removal, installation, cooling systems, 10 Fuel Systems
air induction, exhaust, oil systems,
components, ignition systems, power Tanks, cells, filters, pumps, valves,
control, harnesses, carburetors, fuel auxiliary fuel systems, and refueling
controls, pumps (engine driven), systems.
filters/particle separators, and Quick
Change Assemblies (QCA). (See 11 Flight Controls System
Power Plant Items, figure 2, for more
detailed functions.) Control sticks, pedals, cables, pulleys,
push-pull rods, torque tubes, quadrants,
05 Propellors/Rotors Systems force gradients, control surfaces
bellcranks, and trim actuators
Propellers, governors, rotors (main and (mechanical).
tail), hubs, blades, dampeners, stabi-
lizer bars, and swashplates. 12 Utility Systems
Fire detecting/extinguishing systems,
oxygen systems, windshield wiper sys-
tems, mirrors, de-ice/anti-ice systems,
and LOW G warning system.
B-4 Change 16
TM 55-1520-236-23
GROUP GROUP
NUMBER DESCRIPTION NUMBER DESCRIPTION
13 Environmental Control Systems 16 Mission Equipment
(ECS)
Spraying equipment, stores, racks,
Heaters, air conditioners, defrosters, armament, reconnaissance,
control mixing valves, and ducts. photography pods, and litters.
17 Emergency Equipment
14 Hoists and Winches
Ejection seats, canopies, jettison
Cargo/rescue hoists, winches, hooks system, portable fire extinguishers,
slings, loading systems, and axes, and first aid kits.
emergency release systems.
18 Installed Avionics Components
15 Auxiliary Power Plants (APP)
Communications and Navigational
Fuel, exhaust, and ducting. Black Boxes
B-6. WORK TIME. maintenance function on the helicopter may not
necessarily be the same. As the -23 Maintenance
In the Maintenance Category column by the listing of manual is addressed to AVUM & AVIM maintenance
a work time figure in the appropriate subcolumn(s), levels the DEPOT column may be disregarded.
levels of maintenance authorized to perform the
function are specified. This figure represents the B-7. TOOLS AND TEST EQUIPMENT
active time (Man-hours) required to perform the (SECTION Ill)
specified function. The number of man-hours
specified represents the average time required to Special tools, test, and support equipment required to
restore an item (assembly, subassembly, component, do maintenance functions are listed with a reference
module, end item or system) to a serviceable number to permit cross-referencing to column 5 in
condition under typical field operating conditions. the MAC. In addition, the maintenance category
This time includes preparation time, troubleshooting authorized to use the device is listed along with the
time and quality assurance/quality control time in item National Stock Number and if applicable, the
addition to the time required to perform the specific number to aid in identifying the tool/device.
tasks identified for the maintenance functions
authorized. B-8. REMARKS (SECTION IV)
NOTE: The times indicated in the Maintenance Column 6 of the MAC contains alphabetic reference
category columns were arrived at by simulated time codes which are explained in Section IV of this
study. Actual time required to perform the specified appendix.
SECTION Il. MAINTENANCE ALLOCATION CHART
B-5
TM 55-1520-236-23
MAINTENANCE ALLOCATION CHART
NOMENCLATURE OF END ITEMS
HELICOPTER, ATTACK, AH-1
(1) (2) (3) (4) (5) (6)
MAINTENANCE CATEGORY
GROUP COMPONENT/ASSEMSLY MAINTENANCE TOOLS
REMARKS
NUMSER FUNCTION AND
AVUM AVIM DEPOT EQUIPMENT
NOTE
The extent of maintenance to be performed by AVUM as indicated in this MAC is
governed by the size of the unit and the tools authorized (Refer to paragraph
B-1 b(1) a. and b). Specific notes are given to further identify or describe the
extent or limit of maintenance to be performed.
0100 Aircraft System (End
Article Vehicle System)
0100 Aircraft General
0101 Clean 2.0 100,102
0102 Moor 1.0 100,102
0103 Tow 1.0 100,102
0104 Jack 1.0 100,102
0105 Hoist 1.0 100,102
0106 Preservation 1.0 100,102
0107 Weight and Balance 1.0 102,118
0108 Spot Paint 1.0 100,102
0109 Complete Painting 24.0
0110 Sub-assembly Painting 4.0 102,118
0111 Service 2.0 100,102
0200 Airframe Overhaul 100.0
0201 Tail boom Assy Inspect 2.0
Replace 2.0 100,102 A
Repair 4.0 100,102,
103
8.0 102,117
Overhaul 60.0
B-6
TM 55-1520-236-23
MAINTENANCE ALLOCATION CHART
NOMENCLATURE OF END ITEMS
HELlCOPTER, ATTACK AH-1
(1) (2) (3) (4) (5) (6)
MAINTENANcE CATEGORY
GROUP COMPONENT/ASSEMBLY MAINTENANcE TOOLS
REMARKS
NUMBER FUNCTION AND
AVUM AVIM DEPOT EQUIPMENT
0202 Fuselage Inspect 4.0
Repair 4.0 100,102, A
103
8.0 103,107
0202 Sheet Metal for Structural Inspect 1.0
01 Members and Honeycomb Replace 2.0 100,102, A
Panels not requiring Jigs 103
and Fixtures 4.0 102,103
Repair 2.0 100,102, A
103
4.0 103,117
0202 Sheet Metal for Structural Inspect 1.0
02 Members and Honeycomb Replace 4.0
Panels that require Jigs and Repair 8.0
Fixtures
0202 Honeycomb Panels Inspect 1.0
03 Replace 2.0 100,102
Repair 2.0 100,102, A
103
4.0 103,117 c
0202 Wings Inspect 1.0
04 Replace 4.0 100,102
Repair 2.0 100,102,
103
0202 Transmission Mounts Inspect 1.0
05 Align 1,0 100,36,
32
Replace 2.0 100,102
Repair 100,102
0202 Transmission Inspect 1.0
05 Mount Dampers Replace 2.0 100,102 D
Repair 2.0 102,103
0202 Windshield Inspect 1.0
06 Replace 8.0 101,102 S
(02) Repair 1.0 101,102 D
4.0 102,103
B-7
TM 55-1520-236-23
MAINTENANCE ALLOCATION CHART
NOMENCLATURE OF ENO ITEMS
HELlCOPTER, ATTACK, AH-1
(1) (2) (3) (4) (5) (6)
MAINTENANCE CATEGORY
GROUP COMPONENT/ASSEMSLY MAINTENANcE TOOLS
REMARKS
NUMSER FUNCTION AND
AVUM AVIM DEPOT EQUIPMENT
0202 Doors Inspect 1.0
07 Adjust 1.0 100,102
Replace 3.0 100,102
Repair 2.0 100,102,
103
0202 Window Assembly Inspect 1.0
07 Replace 12.0 101,102, S
103
Repair 1.0 101,102
4.0 102,103
0202 Striker Assembly Inspect 1.0
07 Replace 2.0 100,102
(02) Repair 2.0 100,102
0202 Handle Assembly Inspect 1.0
07 Replace 1.0 100,102
(03) Repair 1.0 100,402
0202 Seat Installation, Pilot Inspect 1.0
08 and Gunner Repair 2.0 100,102
0202 Seat Belts and Inspect 1.0
08 Shoulder Harness Replace 2.0 100,102
(01)
0202 Shoulder Harness Reel Inspect 1.0
08 Replace 2.0 100,102
(03) Repair 1.0 100,102
0202 Seat Assembly Inspect 1.0
08 Replace 6.0 100,102
(03) Repair 4.0 100,102
0202 Armor Inspect 1.0
08 Replace 2.0 100,102
(03)
(01) Repair 1.0 100,102
0202 Blanket Assembly, Inspect 1.0
09 Soundproofing Replace 3.0 100,102
Repair 1.0 100,102
B-8
TM 55-1520-236-23
MAINTENANCE ALLOCATION CHART
NOMENCLATURE OF END ITEMS
HELlCOPTER, ATTACK, AH-1
(1) (2) (3) (5) (6)
MAINTENANCE CATEGORY
GROUP COMPONENT/ASSEMBLY MAINTENANcE TOOLS
REMARKS
NUMBER FUNCTION AND
AVUM AVIM DEPOT EQUIPMENT
0202 Dock Assembly, Engine Inspect 1.0
10 Align 2.0 102
Replace 4.0 102
Repair 4.0 117
0202 Mount Assembly Inspect 1.0
11 Align 1.0 100
Replace 4.0 100,102
Repair 2.0 100,102 A
4.0 102
0202 Cowl Assmeblies Inspect 1.0
12 Replace 4.0 100,102
Repair 4.0 100,102,
103
0202 Firewall Assembly Inspect 1.0
13 Replace 4.0 100,102,
103
Repair 2.0 101,102,
103
0202 Heatshield Assembly Inspect 1.0
14 Replace 4.0 101,102,
103
Repair 2.0 101,102,
103
0202 Mount Installation, Engine
15
0202 Support Arms Inspect 1.0
15 (Brace Rods, Tripod, Replace 3.0 101,102
(01) and Bipod) Repair 2.0 101,102
0202 Pillow Block Assembly Inspect 1.0
15 Replace 1.0 102
(02) Repair 1.0 100,102
0202 Map and Data Case Inspect 1.0
17 Replace 1.0 100,102
0300 Alighting Gear Assembly
0301 Cross Tubes Inspect 1.0 100,102
B-9
TM 55-1520-236-23
MAINTENANCE ALLOCATION CHART
NOMENCLATURE OF END ITEMS
HELlCOPTER, ATTACK, AH-1
(1) (2) (3) (4) (5) (6)
MAINTENANCE CATEGORY
GROUP COMPONENT/AS5EMBLY MAINTENANCE TOOLS
REMARKS
NUMBER FUNCTION AND
AvUM AvIM DEPOT EQuIPMENT
0301 Cross Tubes (Cont) Replace 4.0 100,102
(Cont) Repair 2.0 100,102, A
103
4.0 102
0302 Skid Tubes Inspect 1.0
Rep lace 4.0 100,102
Repair 2.0 100,102 A
4.0 102
0303 Skid Shoes Inspect 1.0
Replace 2.0 100,102
Repair 2.0 100,102 A
2.0 102,120
0304 Skid Saddles Inspect 1.0
Replace 2.0 100,102
0305 Ground Handling Wheels Inspect 1.0
Repair 4.0 100,102
4.0 102
Service 1.0 100,102
0305 Pump Assembly Inspect 1.0
Test 1.0 100,102
Replace 1.0 100,102
Repair 4.0 102,104,
111
0305 Cylinder Assembly Inspect 1.0
02 Replace 1.0 100,102
Repair 1.0 102,111
0305 Wheel Assembly Inspect 1.0
03 Replace 1.0 100,102
Repair 2.0 100,102
Service 1.0 100,102
0306 Skid Installation Tail Inspect 1.0
Replace 2.0 100,102
Repair 2.0 100,102
0400 Power Plant Installation
0401 Engine (Complete Assembly) Inspect 2.0
B-10
TM 55-1520-236-23
MAINTENANCE ALLOCATION CHART
NDMENCIATURE OF END ITEMS
HELlCOPTER, ATTACK AH-1
(1) (2) (3) (4) (5) (6)
MAINTENANCE CATEGORY
GROUP COMPONENWASSEMBLY MAINTENANCE TOOL
NUMBER FUNCTION AND REMARKS
AVUM AVIM DEPOT EQUIPMENT
0401 Engine (Complete Assembly) Test 4.0 100,102
(Cont) (Cent) 4.0 102,108, H
118,119
Service 2.0 100,102
Replace 30.0 100,102,
108,21,
40
Repair 8.0 100,102, G
108
16.0 112,118, G
119
Overhaul ; 50.0
0401 Tail Pipe Inspect 1.0
01 Replace 2.0 100,102
Repair 1.0 100,102 A
4.0 102,120
0401 Oil Strainers Inspect 1.0
02 Replace 1.0 100,102
0401 Droop Compensator Inspect 1.0
03 Adjust 1.0 100,102
Replace 2.0 100,102
Repair 1.0 100,102
0401 Actuator, Linear Inspect 1.0
04 Adjust 1.0 100,102
Replace 2.0 100,102
0401 Hoses, Fittings, Couplings, Inspect 1.0
05 and Tubing Replace 1.0 100,102
0402 Particle Separator Inspect 1.0
01 Replace 2.0 100,102
Repair 1.0 100,102
4.0 102,103,
112,117,
120
Change 20 B-11
TM 55-1520-236-23
MAINTENANCE ALLOCATION CHART
NOMENCLATURE OF ENO ITEMS
HELICOPTER, ATTACK, AH-1
(1) (2) {31 (4) {5) (6)
MAINTENANCE CATEGORV
GROUP C0MP0NEN7/AssEM6LV MAINTENANCE TOOLS
REMARKS
NUMBER FUNCTION ANO
AVUM AVIM DEPOT EQuIPMENT
0402 Centrisep Perticle Separator Inspect 1.0
02 Replace 4.0 100, 102
Repair 1.0 100, 102
4.0 102, 103
112,117
120
0403 Controls, Power Lever Inspect 1.0
Adjust 1.0 100,102
Replace 2.0 100,102
B-12 Change 16
TM 55-1520-236-23
MAINTENANCE ALLOCATION CHART
NOMENCLATURE OF END ITEMS
HELlCOPTER, AlTACK, AH-1
(1) (2) (3) (4) (5) (6)
MAINTENANCE MAINTENANCE CATEGORY TOOLS
GROUP COMPONENT/ASSEMBLY FUNCTION AND REMARKS
NUMBER AVUM AVIM DEPOT EQUIPMENT
0403 Controls, Power Lever Repair 4.0 100,102
(Cont) (Cont)
0404 Oil Tank, Engine Inspect 1.0 100,102
Test 1.0 100,102
Se fvice
1.0 100,102
Replace
Repair 2.0 100,102
2.0 100,102
4.0 120
0405 Hoses, Fittings, and Inspect 1.0
Tubing Replace 1.0 100,102
0406 Oil Cooler, Engine Inspect 1.0
Test 4.0 102
Replace
2.0 100,102
Repair
4.0 100,102
0407 Oil Cooler Shut-Off Valve Inspect 1.0
Replace 1.0 100,102
0408 Oil Cooler Blower, Turbine Inspect 1.0
Replace 1.0 100,102
Repair
2.0 102,112
118,119
120
0409 Chip Detector, Engine Inspect 0.5
Test 1.5 100,102
Replace 100,102
1.0
0410 Valves, Breakaway Inspect 1.0
Replace 2.0 100,102
0411 External Filter inspect 100,102
107
Replace
Repair
0412 Oil Separator (Lubnclone) Inspect 101,102
107
Replace
Repair
Change 20 B-12.1
TM 55-1520-236-23
MAINTENANCE ALLOCATION CHART
NOMENCLATURE OF END ITEMS
HELICOPTER, AlTACK, AH-1
(1) (4) (5) (6)
MAINTENANCE CATEGORY TOOLS
GROUP AND REMARKS
NUMBER AVUM AVIM DEPOT EQUIPMENT
0500 Rotor Systems
0501 Pylon Assembly, Inspect 1.0
External Components Replace 2.0 100,102
Repair
2.0 100,102
103
0502 Hub and Blade Assy, Inspect 1.0
Main Rotor Adjust 2.0 101,102
44,51
B-12.2 Change 20
TM 55-1520-236-23
MAINTENANCE ALLOCATION CHART
NOMENCtiTURE OF END ITEMS
HELlCOPTER, ATTACK, AH-1
(1) (2) (3) (4) (5) (6)
MAINTENANCE CATEGORY
GROUP COMPONENT/ASSEMSLY MAINTENANCE TOOLS
REMARKS
NUMBER FUNCTION ANO
AVUM AVIM DEPOT EQuIPMENT
0502 Hub and Blade Assy, Align 3.0 101,102,
(Cont) Main Rotor (Cent) 26,30,31,
34,41,59
Replace 4.0 101,102,
13,14,
21,59
0502 Hub Assembly Inspect 1.0
01 Align 2.0 101,102, J
14,21,59
Replace 4.0 101,102,
109,13,
14,21,59
Repair 2.0 101,102
4.0 102,105,
109,113,
114,45,
47
Overhaul 40.0
0502 Drag Brace Assembly Inspect 1.0
01 Replace 1.0 101,102,
(01) 109
Repair 2.0 101,102,
109
0502 Grip Assembly Inspect 1.0
01 Replace 3,0 102,118
(02) Repair 2.0 102,109,
112,113,
118
3502 Housing Assembly Inspect 1,0
01 Replace 2,0 102,109
(03) Repair 2.0 102,109,
112,113,
118
0502 Defector, Sand Inspect 0.5
01 Replace 1.0 100,102,
(04) 109
0502 Pitch Horn Assembly Inspect 1.0 1,0
01 Replace 2.0 101,102
(05) Repair 1.0 101,102 D
Change 16 B-13
TM 55-1520-236-23
MAINTENANCE ALLOCATION CHART
NOMENCLATURE OF END ITEMS
HELlCOPTER, AlTACK, AH-1
(1) (2) (3) (4) (5) (6)
MAINTENANCE CATEGORY TOOLS
GROUP COMPONENVABSEMBLY MAINTENANCE AND REMARKS
NUMBER FUNCTION AVUM AVIM DEPOT EWIPMENT
0502 Pitch Horn Assembly (Cent) 2.0 102,109,
01 112, 113,
(05) 118
(Cont)
0502 Extension Assembly Inspect 1.0
01 Replace 4.0 102, 109
(06) Repair 1.0 101, 102
4.0 102, 109,
112,113,
118
0502 Strap Assembly Tension Inspect 1.0
01 Replace 4.0 102, 112,
(07) 113, 118
0502 Bolt Assembly, Blade Inspect 1.0
01 Retention Replace 1.0 101, 102,
(08) 109
Repair 1.0 101, 102,
109
0502 Yoke Assembly Inspect 1.0
01 Replace 4.0
(09) Repair 1.0 101, 102 D
2.0 102, 109,
112, 113
0502 Trunnion Assembly Inspect 1.0 1.0
01 Replace 3.0
(10) Repair 1.0 101, 102 D
2.0 102, 109,
112, 113,
118
0502 Housing Assembly Inspect 1.0 1.0
01 Trunnion Replace 3.0 102, 109
(11) Repair 1.0 101, 102, D
109
2.0 102, 104
B-14 Change 16
TM 55-1520-236-23
MAINTENANCE ALLOCATION CHART
NOMENCLATURE OF END ITEMS
HELlCOPTER, AlTACK, AH-1
(1) (2) (3) (4) (5) (6)
MAINTENANCE CATEGORY TOOLS
GROUP COMPONENWASSEMBLY MAINTENANCE AND REMARKS
NUMBER FUNCTION AVUM AVIM DEPOT EQUIPMENT
0502 Strap, Hub Moment Inspect 1.0 1.0
01 Replace 1.0 1.0 102
(12) Repair
0502 Plate, Hub Moment Inspect 1.0 1.0
01 Replace 1.0 1.0 102
(13) Repair
0502 Blade Assembly, Main Rotor Inspect 1.0 101,41,51
02 Adjust 1.0 101, 102
Replace 3.0 109
Change 16 B-14.1/(B-14.2 blank)
TM 55-1520-236-23
MAINTENANCE ALLOCATION CHART
NOMENCLATURE OF END ITEMS
HELlCOPTER, ATTACK, AH-1
(1) (2) (3) (4) /5/ (6)
MAINTENANcE CATEGORY
GROW COMPONENT/ASSEMBLY MAINTENANCE TOOLS
REMARKS
NUMBER FuNCTION AND
AVUM AVIM DEPOT EQUIPMENT
0502 Blade Assembly, Main Rotor Repair 1.0 101,102,
02 (Cent) 109
(Cont) 12.0 121
Overhaul 60.0
0503 Scissors and Sleeve Assembly Inspect 1.0
Replace 4.0 101,102,
109
Repair 4 .() 101,102
102,109,
112,118,
10,110,27(
28,35,87,
88
Overhaul 35.2
0503 Link Assembly, Scissors Inspect 1.0 1.0
01 Replace 1.0 101,102,
109
Repair 101,102 D
2.0 102,109,
112
0503 Scissors Assembly Inspect 1.0 1.0
02 Replace 2.0 101,102,
109
Repair 4.0 101,102 D
102,109,
112
0503 Hub Assembly Inspect 1,0 1.0
03 Replace 4.0
Repair 2.0 101,102 D
102,109,
113
0503 Sleeve, Collective Inspect 1.0 1.0
04 Replace 4.0
Repair 2.0 101,109 !)
0504 Swashplate and Support Inspect 1.0
Assembly Replace 4.0 101,102,
109
Repair 2.0 101,102 D
4,0 102,109
Overhaul 40.0
Change 11 B-15
TM 55-1520-236-23
MAINTENANCE ALLOCATION CHART
NOMENCLATURE OF END ITEMS
HELlCOPTER, ATTACK, AH-1
(1) {2) (3) (4) 15) /6)
MAINTENANCE CATEGORY
GROUP COMPONENT/AS8EMSLY MAINTENAIuCE TOOLS
REMARK!
NUMBER FUNCTION ANO
AVUM AVIM DEPOT EQUIPMENT
0505 Rotor Installation, Tail Inspect 1.0
Replace 4.0 101,102,
109
Repair 2.0 100,102,
109
0505
Link Assembly Inspect 1.0
01 Replace 1.0 100,102,
109
Repair 1.0 100,102,
109
0505 Crosshead Inspect
02 Replace ::: 100,102,
109
Repair 2,0 100,102,
109
0505 Hub and Blade Assembly Inspect 1.0
03 Adjust 1.0 100,102 I
Align 1.0 100,102, J
109,82
Replace 4.0 100,102
109,90
Repair 2.0 100,102,
109
4.0 102,109,
90
0505 Blade Assembly Inspect 1.0
03 Replace 2.0 100,102
(01) Repair 1.0 100,102
4.0 102,109
0505 Hub Assembly Inspect 1.0
03 Setvice 1.0 100,102
(02) Adjust 2.0 100,102
Replace 4.0 100,102,
109
Repair 1.0 100,102,
109
4.0 102,109
*US. GOVERNMENT PRINI; N(; OFFICE: 19S9 65d-030/00054
B-16 PIN: 03~4f5(3_oll
TM 55-1520-236-23
MAINTENANCE ALLOCATION CHART
NOMENCLATURE OF END ITEMS
HE LlCOPTER, ATTACK, AH-1
(1) (2) (3) (4) (5) (6)
MAINTENANCE CATEGORY
GROUP COMPONENT/ASSEMBLY MAINTENANCE TOOLS
REMARKS
NUMBER FUNCTION ANO
AVUM AVIM DEPOT EQUIPMENT
0600
Drive Train System
0601 Intermediate and Tail Rotor Inspect 1.0
Drive Gearboxes Sewice 1.0 100,102
Replace 4.5 100,102
Repair 1.5 100,102
Overhaul 22,5
0601 Intermediate and Tail Rotor Inspect 1.5
Drive Gearbox Quills Service 1.5 100,102
Replace 2.0 101,102, T
23,25,24,
38,39,58
Repair 1.5 23,24,25,
38,39,58
Overhaul 5.0
0602 Tail Rotor Drive Shaft Inspect 1.0
Replace 3.4 100,102
Repair 1.5 100,102 T
2.0 102,109
0603 Tail Rotor Drive Shaft Inspect
Hanger Assemblies Service 1.0 102
Align 4.5 100,102
Replace 2.5 100,102
Repair 1.5 100,102, M
109
3.0 113
0604 Main Transmission Inspect 1.0
Service 2.0 102
Replace 6.5 101,105,
17
Repair 1.2 101,105,
17
2.5 102,105,
109,17
Overhaul 82.5
0604 Drive Quill Assemblies Inspect 1.5
Service 2.5 100,102
Replace 4.5 101,109,
24
Change 5 B-17
TM 55-1520-236-23
MAINTENANCE ALLOCATION CHART
NOMENCLATURE OF END ITEMS
HELICOPTER, ATTACK, AH-1
(1) (2) (3) (4) (5) (6)
MAINTENANCE CATEGORY
GROUP COMPONENT/ASSEMSLY MAINTENANCE TOOLS
REMARKS
NUMBER FUNCTION ANO
AVUM AVIM DEPOT EQUIPMENT
0604 Drive Quill Assemblies (Cent) Repair 2.5 101,109, M
(Cont) 24,46
Overhaul 5.5
0605 Main Drive Shaft (Engine Inspect 1.0
to Transmission) Service 1.5 100,102
Align 1.0 100,109,
32,36
Replace 4.5 100,102,
109
Repair 1.5 100,22,33
Overhaul 6.5
0606 Lines, Manifolds and Inspect 1.0
Fittings Replace 2.0 100,102
Repair 1.0 100,102
0607 Sight Gages Inspect 0.5
Replace 0.5 100,102
Repair 0.5 100,102
0608 Oil Jets Inspect 1.0
Replace 1.5 100,102
Repair 1.0 100,102
0609 Filters, Filter Housings Inspect 1.0
and Screens Replace 2.5 100,102
Repair 1.5 100,102
0610 Transmission Oil Cooler Inspect 1.0
Assembly Replace 1,0 100,102
Repair 1.0 100,102
0611 Bypass Valve Assembly Inspect 1.0
Replace 1.5 100,102
Repair 2.0 52,53,
54,55
0612 Oil Pump Inspect 1.0
Test 1.0 100,102
Replace 2.5 100,102
Repair 1.5 102
Overhau I 4.5
B-18 Change 16
TM 55-1520-236-23
MAINTENANCE ALLOCATION CHART
NOMENCLATURE OF END ITEMS
HELlCOPTER, ATTACK, AH-1
(1) (2) (3) (4) (5) (6)
MAINTENANCE MAINTENANCE CATEGORY TOOLS
GROUP COMPONENTIASSEMBLY E AND REMARK
NUMBER FUNCTION AVUM AVIM DEPOT EQUIPMENT s
0613 Mast Assembly Inspect 1.0
Replace 5.6 101,102,
13,14
Repair 1.0 101,103
113,12,91
Overhaul ~ 16.5
0613 Support, Hub Inspect 1.0 1.0
01 Moment Replace 1.0 1.0 102
0613 Spring, Hub Inspect 0.5
02 Moment Replace 0.5 102
0614 Friction Collect Inspect 0.5
Adjust 6.5 101,109,
89
Replace 6.5 101,109
Repair 1.0 101,109
0615 Debris Monitor Inspect 1.0 100,102
107
Test 1.0
Replace 2.0
Repair 2.0
0700 Hydraulic and Pneumatic
systems
0701 Pumps Inspect 1.0
Replace 2.5 100,102
Repair 1.5 100,102,
104
Overhaul 12.0
0702 Reservoirs Inspect 1.0
Service 1.0 100,102
Replace 2.5 100,102,
104
Repair 1.5 100,102,
104
0703 valves inspect 1.0
Replace 1.5 101,102,
104
Repair 2.0 104,111
Change 20 B-19
TM 55-1520-236-23
MAINTENANCE ALLOCATION CHART
NOMENCLATURE OF END ITEMS
HELlCOPTER, ATTACK, AH-1
1) (a m (4) (q (6)
MAINTENANCE CATEGORY
GROUP COMWNENVABSEMBLY MAINTENANCE TOOLS
NUMBER mmc-nOM AND REMARK:
AVUM AVIM DEPW EOUIPME~
0705 Solenoid Valve Inspect 1.5
Replace 1.5 101,102,
104
Repair 1.0 102,104,
111
0706 Hose, Tubing, and Fittings Inspect 1.0
Replace 1.5 102,104
0707 Hydraulic Module Inspect 1.5
Replace 2.4 101,102,
104
Repair 1.5 102,104,
111
Overhaul 4.6 v
0708 Hydraulic Servo Cylinders Inspect 1.5
Replace 2.0 100,104,
23
Repair 1.5 102,104,
111
0709 Hydraulic Accumulator Inspect 1.0
Test 0.5 104,111
Service 0.5 100,104
Replace 2.1 100,104
Repair 1.0 104,111
0710 Accumulator Air Press Gage Inspect 1.0 100,104
Replace 1.0
0711 SCAS Servo Actuators Inspect 1.5
Test 2.1 104,111
Replace 2.5 100,104
Repair 3.5 104,111
Overhaul 9.5
B-20 Change 18
TM 55-1520-236-23
MAINTENANCE ALLOCATION CHART
NOMENCLATURE OF END ITEMS
HELlCOPTER, ATTACK, AH-1
(1) (2) (3) (4) /5) (6)
MAINTENANcE CATEGORY
GROUP COMPONENT/ASSEMBLY MAINTENANcE TOOLS
REMARKS
NUMBER FUNCTION AND
AVUM AVIM DEPOT EOUIPMENT
0800 1 nstrument Systems
0801 Instrument Panels Inspect 2.5
Replace 3.5 106
Repair 2.1 106
0801 Miscellaneous Instruments
01
0801 Clock Inspect 1.5
Rep lace 1.5 100,106
Overhau I 3.0
0801 Free Air Temperature Gage Inspect 1.0
0102 Test 1.0 101,106
Replace 1.0 101,106
0801 Volt, Load and Ammeter Inspect 1.0
0103 Adjust 1.0 100,107
Replace 1.5 100,107
0801 Fuel Quantity Indicator
02 System
0801 Fuel Quantity Indicator and Inspect 1.0
0201 Amplifier Test 2.5 101,110 u
Adjust 2.5 110
Replace 2.5 106
Overhau I 8.0
0801 Tank Sensor, Probes and Inspect 1.0
0202 Units Test 1.5 110
Replace 2.5 106
0801 Flight Instruments
03
0801 Vertical Velocity Inspect 0.5
0301 Indicator Test 1.0 100,106
Replace 1.5 100,106
Overhau I 8.0
0801 Standby Compass Inspect 045
0302 Adjust 0.5 100,106
Replace 1.0 100,106
B-21
TM 55-1520-236-23
MAINTENANCE ALLOCATION CHART
NOMENCLATURE OF END ITEMS
HE LlCOPTER, ATTACK, AH-1
(1) (2) (3) (4) (5) (6)
MAINTENANCE CATEGORY
GROUP COMPONENT/ASSEMBLY MAINTENANCE TOOLS
REMARKS
NUMBER FUNCTION AND
AVUM AVIM DEPOT EQUIPMENT
0801 Airspeed Indicator Inspect 1.0
0303 Test 1.0 100,106
Replace 2.0 100,106
Overhaul 7.5
0801 Altimeter Inspect 1.0
0304 Test 1.0 100,106
Replace 2.0 100,106
Overhaul 9.5
0801 Attitude Indicator Inspect 0.5
0305 Replace 0.5 100,106
Overhau I 8.5
0801 Turn and Slip Indicator Inspect 0.5
0306 Replace 0.5 100,106
Overhau I 8.5
0801 Pitot System Inspect 0.5
0307 Test 1.5 100,106
Calibrate 2.0 110
Repair 1.5 100,106
0801 Engine Instruments
04
0801 Engine and Rotor Tachometer Inspect 1.0
0401 Test 2.0 110
Replace 1.0 100,106
Overhaul 11.5
0801 Turbine Gas, Temperature Inspect 0.5
0402 Test 1.5 110
Cal ibrate 2.0 110
Repair 1.5 100,106
Overhau I 6.5
0801 Engine Oi I Temperature Inspect 0.5
0403 Gage Replace 1.0 100,106
Overhaul 4.0
B-22
TM 55-1520-236-23
MAINTENANCE ALLOCATION CHART
NOMENCLATURE OF ENO ITEMS
HELlCOPTER, ATTACK, AH-1
(1) (2) (3) (4) (5I (6)
MAINTENANCE CATEGORY
GROUP COMPONENT/ASSEMBLY MAINTENANCE TOOLS
REMARKS
NUMBER FUNCTION AND
AVUM AVIM DEPOT EQUIPMENT
0801 Engine Oi I Pressure Inspect 0.5
0404 Transmitter and Indicator Replace 1.5 100,106
Overhau I 3.5
0801 Fuel Pressure Indicator Inspect 0.5
0405 and Transmitter Test 1.0 110
Replace 1.0 100,106
Overhau I 2.5
0801 Torquemeter and Inspect 0.5
0406 Transmitter Replace 1.0 100,106
Overhau I 2.5
0801 Tachometer, Generators Inspect 0.5
Replace 1.0 100,106
0801 Engine Instruments
05
0801 Gas Producer Tachometer Inspect C.5
0501 Test 1.0 110
Replace 1.5 100,106
Overhau I 3.0
0801 Transmission Instruments
06
0801 Oil Temperature Gage Inspect 0.5
0601 Replace 0.5 100,106
Overhaul 3.5
0801 Oil Pressure Gage Inspect 0.5
0602 and Transmitter Replace 1.5 100,106
Overhau I 2.5
0801 Temperature Bulbs Inspect 0.5
0603 Test 0.5 110
Replace 0.5 100,106
B-23
TM 55-1520-236-23
MAINTENANCE ALLOCATION CHART
NOMENCLATURE OF ENO ITEMS
HELlCOPTER, ATTACK, AH-1
(1) (2) (3) (4) (5) (6)
MAINTENANCE CATEGORY
GROUP COMPONENT/ASSEMBLY MAINTENANCE TOOLS
REMARKS
NUMBER FUNCTION AND
AVUM AVIM DEPOT EQUIPMENT
0900 Electrical Systems
0901 Inverters Inspect 0.5
Replace 1.5 100,107 N
Repair 2.0 100,107
0902 Relays, Rheostats Switches, Inspect 0.5
Circuit Breakers, Plugs, Test 0.5 110
Leads, Connectors, Conduits, Replace 1.0 100,107
Receptacles, Shunts, and Repair 0.5 107,110
Circuit Boards
0903 Wiring Inspect 4.5 100,107
Test 8.5 100,107
Replace 1.0 100,107
Repair 10.5 100,107
0904 Regulator Inspect 0.5
Adjust 0.5 100,107
Replace 1.0 100,107
Overhau I 8.0
0905 Battery Inspect 0.5
Test o
Service o
Replace 1.0 100,102
Repair o
0906 Starter Generator Inspect 1.5
Test 2.0 107,110
Replace 2.0 100,107
Repair 2.5 107,110 P
0907 Cooling Blower Inspect 0.5
Replace 1.5 100,107
Repair 0.5 100,107
Overhaul 10.5
0908 Lights Inspect 0.5
Replace 0.5 100,107
B-24 Change 1
TM 55-1520-236-23
MAINTENANCE ALLOCATION CHART
NOMENCLATURE OF END ITEMS
HELICOPTER, ATTACK, AH-1
(1) (2) (3) (4) (5) (6)
MAINTENANCE MAINTENANCE CATEGORY TOOLS
GROUP COMPONENT/ASSEMBLY E AND REMARK
NUMBER FUNCTION AVUM AVIM DEPOT EQUIPME s
NT
0909 Alternator Inspect 0.5
Replace 2.5 100,107
Repair 1.5 100,107
Overhaul 8.0
0910 Navigation, instrument, Inspect 1.0
lnteriorCabin, Anti- Replace 1.5 100,102
Collision, and Flasher Units Repair 1.5 100,102
0910 GPS Trimpack Inspect 0.5
01 Test 0.5
Replace 0.5
Repair 3.0
0911 Search Light Assembly Inspect 0.5
Replace 0.5 100,107
Repair 1.5 100,107
Overhaul 5.5
0912 Caution Panels Inspect 0.5
Test 0.5 107,100
Replace 1.0 100,107
Repair 1.5 1.0 107,110
0913 RPM Warning Control Box Inspect 1.5
Adjust 3.5 100,106
Replace 1.5 100,106
Repair 0.5 106,110
Overhaul 9.5
0914 Chip Detector System Inspect 0.5
ODDS Power Module Replace 1.0 100,107
1000 Fuel System
1001 Main Fuel Tanks, both Inspect 1.5
crashworthy and Service 0.5 100,102
non-crashworthy Replace, 8.5 102
Repair 6.5 102,117
1002 Fuel Low Level Warning Inspect 0.5
system Test 2.0 100,102
Replace 4.5 100,102
1003 Boost Pumps Inspect 1.5
Replace 2.0 101,102
Repair 5.5
Change 20 B-25
TM 55-1520-236-23
MAINTENANCE ALLOCATION CHART
NOMENCLATURE OF END ITEMS
HELICOPTER, ATTACK, AH-1
(1) (2) (3) (4) (5) (6)
MAINTENANCE MAINTENANCE CATEGORY TOOLS
GROUP COMPONENT/ASSEMBLY E AND REMARK
NUMBER FUNCTION AVUM AVIM DEPOT EQUIPME s
NT
1004 Valves and Fittings Inspect 0.5
Replace 1.0 100,102
1005 Filter Assembly Inspect 0.5
Replace 1.5 100,102
Repair 0.5 100,102
1006 Hoses, Tubing and Filter Inspect 0.5
caps Replace 1.5 100,102
1100 Flight Control Systems
1101 Main Rotor Control Tubes Inspect 3.5
and Rod Ends Adjust 2.5 100,102
Replace 4.0 101,102
Repair 2.5 101,102
1102 Force Gradient Assembly Inspect 0.5
Adjust 3.0 100,102
Replace 1.0 101,102
Repair 2.0 102
1103 Control Stick (Collective and Inspect 1.0
Cyclic) Adjust 2.0 100,102
Replace 2.5 102,46
Repair 2.0 4.0 102,107
1104 Synchronized Elevator Inspect 2.0
Adjust 3.0 100,102
Replace 4.0 101,102
Repair 2.0 101,103
1105 Magnetic Brake Inspect 0.5
Adjust 0.5 100,102
Replace 1.0 101,102
Repair 4.0
1106 Collective and Cyclic Inspect 2.0
Linkage Adjust 5.0 100,102
Replace 2.0 101,102
Repair 1.0 101,102
1107 Tail Rotor Pedal Assy Inspect 3.0
Linkage Adjust 5.0 100,102
B-26 Change 5
TM 55-1520-236-23
MAINTENANCE ALLOCATION CHART
NOMENCLATURE OF END ITEMS
HELlCOPTER, ATTACK, AH-1
(1) (2) (3) {4) (5) (6)
MAINTENANCE CATEGORY
GROUP COMPONENT/ASSEMBLY MAINTENANCE ToOLS
REMARKS
NUMBER FUNCTION AND
AVUM AVIM DEPOT EQUIPMENT
1107 Tail Rotor Pedal Assy (Cent) Replace 8.0 101,102
(Cont) Repair 3.0 101,102
1108 Pedal Adjusting Assembly Inspect 1.5
Adjust 1.5 100,102
Replace 2.5 101,102
Repair 2.0 101,102
1109 Tail Rotor Pitch Control Inspect 1.5
Linkage Adjust 2.0 100,102
Replace 2.5 101,102
Repair 1.0 101,102
1110 Tail Rotor Pitch Control Inspect 2.0 100,102
Mechanism Adjust 3.0 101,102
Replace 2.0 101,102
Repair 2.0 101,102
1111 Tail Rotor Pitch Change Inspect 1.0
Rods and Links Adjust 1.5 100,102
Replace 2.0 101,102
Repair 1.0 101,102
1112 Stabilization Equipment
1112 Control Panel Inspect 0.5
01 Replace F
Repair F
1112 Control Box Inspect 0.2
02 Test N
Replace 0.5 100,102
Repair N
1112 Solenoid Valves, Hoses, Inspect 1.0
03 Connectors Replace 1.5 100,102
1112 Transducers Inspect 0.5
04 Replace 1.0 100,102
B-27
TM 55-1520-236-23
MAINTENANCE ALLOCATION CHART
NOMENCLATURE OF END ITEMS
HELlCOPTER, ATTACK, AH-1
(1) (2) (3) (4) (5) (6)
MAINTENANCE CATEGORY TOOLS
GROUP COMPONENT/ASSEMBLY MAINTENANCE AND REMARKS
NUMBER FUNCTION AVUM AVIM DEPOT EQUIPMENT
1200 Utility Systems
1201 Fire Detector System - Inspect 0.5
Engine Replace 1.5 100,102
1202 Anti-king, System Inspect 0.5
Replace 1.5 100,102
1203 Low G Warning Inspect 0.5
System Test 1.0
01 8A10 Assembly Test 0.5
Replace 0.5 100,102
1203 Accelerometer Inspect 0.5
02 8A11 Test 0.5
Replace 0.5 100,102
1203 Low G Warning Inspect 0.5
03 Light/switch 8DS25 Test 0.5
Replace 0.5 100,102
1203 Counter 8M1 Inspect 0.5
04 Test 0.5
Replace 0.5 100,102
1203 Relay, 8K1, 8K2 Inspect 0.5
05 Test 0.5
Replace 0.5 100, 102
1203 Wiring Inspect 0.5
06 Test 0.5
Replace 0.5 100,102
1300 Environmental Control
System (ECS)
1301 Bleed Air Heater System Inspect 0.5
Repair 2.0 100,102
1302 Control Valves Inspect 1.5
Replace 2.5 100,102
Repair 1.5 107, 110
Test 1.5 107, 110
B-28 Change 16
TM 55-1520-236-23
MAINTENANCE ALLOCATION CHART
NOMENCLATURE OF END ITEMS
HELlCOPTER, AlTACK, AH-1
(1) (2) (3) (4) (5) (6)
MAINTENANCE CATEGORY TOOLS
GROUP COMPONENWASSEMBLY MAINTENANCE AND REMARKS
NUMBER FUNCTION AVUM AVIM DEPOT EQUIPMENT
1303 Vent Blower Inspect 2.0
Replace 2.0 100, 102
Repair 2.0 100, 102
1304 Ventilating Ducts, Inlet Inspect 1.0
Door, and Control Adjust 1.0 100, 102
Replace 1.5 100, 102
Repair 1.0 100, 102,
103
1305 Environmental Control Inspect 1.0
Unit Service 1.0 100, 102
Replace 3.0 101,102
Repair 1.0 101, 102
Overhaul 45.0
1306 Heater Exchanger Inspect 0.5
Replace 2.0 100, 102
Repair 2.0 100, 102
1307 Temperature Control/ Inspect 0.5
Sensor Replace 1.0 100, 107
Repair 2.0 107, 110
Overhaul 10.0
Change 16 B-28.1/(B-28.2 blank)
TM 55-1520-236-23
MAINTENANCE ALLOCATION CHART
NOMENCLATURE OF END ITEMS
HELICOPER, ATTACK, AH-1
(1) (2) (3) (4) (5) (6)
MAINTENANCE CATEGORY
GROUP COMPONENT/AS3EM6LY MAINTENANCE TOOLS
REMARKS
NUMBER FUNCTION AND
AVUM AVIM DEPOT EQUIPMENT
1308 Temperature Control/ Inspect 0.5
Valve Replace 1.5 100,107
Repair 2.0 100,107
Overhau I 10.0
1308 Torque Motor Inspect 0.5
01 Replace 1.0 100,102
Overhau I 8.0
1308 Turbine Assembly Inspect 0.5
02 Replace 7.0 101,102
Overhaul 18.0
1308 Nozzles, Cockpit Outlet Inspect 0.5
03 Replace 1.0 100,102
1309 Pressure Regulating Inspect 0.5
and Shut-off Valve Test 1.5 110,107
Replace 2.0 100107
Overhaul 12.0
1309 Solenoid Valve Inspect 0.2
01 Replace 0.5 100,107
Overhaul 6.0
1309 Pressure Relief Valve Inspect 0.2
02 Replace 0.5 100,107
1309 Temperature Selector Inspect 0.5
03 Replace 0.5 100,102
1310 Rain Removal System Inspect 1.5
Replace 3.0 100,102
Repair 2.0 100,102
1311 Hot Air Valve Inspect 2.0
Replace 1.0 100,102
Overhau I 8.0
B-29
TM 55-1520-236-23
MAINTENANCE ALLOCATION CHART
NOMENCLATURE OF ENO ITEMS
HE LlCOPTER, ATTACH, AH-1
(1) (2) (3) (4) (5) (6)
MAINTENANCE CATEGORY
GROUP COMPONENT/ASSEM8LY MAINTENANCE TOOLS
REMARKS
NUMBER FUNCTION AND
AVUM AVIM OEPOT EQUIPMENT
1400 Hoist and Winches
(Not Applicable)
1500 Auxiliary Power Plants
(App) (Not applicable)
1600 Mission Equipment Armament
(Aircraft Components)
NOTE
Organizational maintenance of the armament system will
be performed by Aircraft Armament Sub-system Repairmen.
1601 Turret Weapons System
1601 Pilot Gun Sight Inspect 0.5
01 Replace R
1601 Pilot Gunners Control Inspect 0.5 R
02 Panels Test R
Replace R
Repair R
1602 External Stores
1601 Emergency Jettison Inspect 1.0
01 System Adjust 0.5 101,102
Replace 7.5 101,102
Repair 3.0 101,102
Test 1.5 101,102
1602 Ejector Rack Inspect 0.5
02 Adjust 5.0 100,102
Replace 2.0 100,102
Repair 1.0 100,102
Overhau I 12.0
1602 Grenade Dispenser Inspect 0.5
03 Replace 1.0 100,102
B-30
TM 55-1520-236-23
MAINTENANCE ALLOCATION CHART
uOMENC@TURE OF END ITEMS
HEL ICQPJFR. ATTACU. AH-1
(1) (2) (3) (4) (5) (6)
MAINTENANCE CATEGORY
GROUP COMPONENT/ASSEMBLY MAINTENANCE TOOLS
REMARKS
NUMBER FUNCTION AND
AVUM AVIM DEPOT EQuIPMENT
1602 Accelerometer Resolver Inspect 0.2
04 Adjust 0.5 100,102
Replace 0.5 100,102
Repair 8.0 101,102
1602 Servo-electronic Control Unit Inspect 0.5
05 Adjust 1.0 101,107
Replace 2.0 101,107
Repair 1.0 2.0 101,107
Overhaul 24.0
1602 Hydraulic Power Cylinder Inspect 0.5
06 Replace 1.0 101,102
Repair 3.0 101,104
Overhaul 16.0
1602 AIM-1 /EXL Laser Inspect 0!5
07 Replace 0.5 102
Repair 8.0
1700 Emergency Equipment
1701 Canopy Removal System Inspect 0.5
Replace 5.0 102
Repair 10.0 102
1800 Installed Avionics
Components
NOTE
TM 11-1520-221-30 contains maintenance instructions
for avionics.
Change 19 B-31
TM 55-1520-236-23
SECTION ill. TOOLS AND TEST EQUIPMENT REQUIREMENTS
TOOL OR TEST MAINTENANCE NATIONAL/NATO TOOL
EQUIPMENT CATEGORY NOMENCLATURE STOCK NUMBER NO.
5 0 Bit, Screwdriver 5120-00-863-4941 HTS-6
6 0 Socket, Adapter 5120-00-937-8481 HTS-10
10 F Stand Assy, Scissors and PD 1468
Sleeve
11 F Socket, Wrench, Face PD1469
Spanner
12 o Socket, Sptined 5120-00-619-9773 PD 2658
13 0 Socket, Mast Nut 51 20-~-61 9-9779 PD 2659
14 0 Adapter, Reaction 5120-00-619-9776 PD 2660
17 F Transmission Adapter 4920-00-676-2307 SWE1 3852-40
21 o Sling, Aircraft Maint 1730-00-099-8099 T1 00220
22 0 Wrench, Transmission 4920-00-797-3672 T1013O6
23 0 Wrench, Tail Rotor 4920-00-718-6533 T1013O7
24 0 Jack Screw Set 4920-00-710-7946 T1013O8
25 0 Jack Screw Set 4920-00-765-4410 T101338
26 0 Build Up Bench 4920-00-678-5431 T101356
27 F Support Scissors and 4920-00-786-1756 T101369
Sleeve
28 F Ram Adapter, Scissors & 4920-00-713-5555 T101382
Sleeve
30 o Scope Assy Blade 4920-00-718-6674 T1014O1
Alignment
31 0 Socket, Wrench, Face 5120-00-044-1426 T101414
Spanner
32 0 Tool Set, Alignment 5120-00-894-6540 T101419
33 0 Fixture, Holding Shaft 4920-00-876-0103 T10142O
B-32
TM 55-1520-236-23
TOOL OR TEST MAINTENANCE NATIONAL/NATO TOOL
EQUIPMENT CATEGORY NOMENCLATURE STOCK NUMBER NO.
34 0 Plate 4920-00-898-0015 T101421
35 0 Bar, Bearing Removal 4920-00-876-0102 T101424
36 0 Jack Set 4920-00-805-5123 T101 440
38 0 Socket, Wrench, Face, 5120-00-967-7699 T101449
Spanner
39 0 Plate Assy 4920-00-967-7651 T101455
40 0 Hoisting Unit, Engine 1730-00-073-9258 T101452
41 0 Support, Main Rotor 4920-00-907-7649 T101467
44 0 Bending Gage, Trim 5210-00-919-2374 T101485
45 0 Installation Tool, Seal 5120-00-925-5085 T101487
46 F Wrench, Input Quill 5120-00-932-3670 T101488
47 F Puller, Bearing 5120-00-999-5306 TI01491
50 o Fixture, Rigging, Stick 4920-00-848-4930 TI01524
Cycle
51 0 Tab Bender, Main 5120-00-844-7757 T101525
Rotor Blade
52 0 Fixture, Holding 4920-00-176-3708 T101549
53 0 Disassembly Tool, Valve 5120-00-176-3698 T10155O
54 0 Puller, plug 5120-00-400-7724 TIO1551
55 0 Tool Set, Plunger Assy 5180-00-176-3701 T101553
57 0 Staking Tool 5120-00-409-9524 T101577
58 0 Wrench, Spanner 5120-00-412-7401 T1016OO
59 0 Lock Grip, Main Rotor 5120-00-451-2956 T101864
60 F Sealing Tool, Pylon Damper 4920-00-423-5239 1570-EG-00
82 o Plate Adapter 4920-00-437-5112 7HEL074
87 F Socket Collective Sleeve PD 1470
Bearing
88 F Extension, Socket Wrench 5120-00-033-2112 PD 1471
B-33
TM 55-1520-236-23
TOOL OR TEST MAINTENANCE NATIONAL/NATO TOOL
EQUIPMENT CATEGORY NOMENCLATURE STOCK NUMBER NO.
89 0 Scale Dial Indicator 6670-00-246-0347 AAAS133
90 0 Crowfoot Attachment 5120-00-184-8413 GGGW641
91 F Socket, Splined Reaction 5120-00-619-9774 PD 2657
92 o Key Socket Head 5120-01-016-5635 GGGK275
100 0 Tool Set, Avum, Set No. 1 4920-00-159-8727
101 0 Tool Set, AVUM, Set No. 2 4920-00-567-0476
102 0 Tool Kit, Aircraft Mechanics, 5180-00-323-4692
General
103 0 Tool Kit, Airframe Repairman 5180-00-323-4876
104 0 Tool Kit, Hydraulic Repairman 5180-00-323-4891
105 0 Tool Kit, Prop and Rotor 5180-00-323-4909
Repairmans
106 0 Tool Kit, Instrument 5180-00-323-49 3
Repairman
107 0 Tool Kit, Electrical Repairman 5180-00-323-49 5
108 0 Tool Kit, Eng Repair 5180-00-323-4944
109 0 Tool Kit, Power Train 5180-00-003-5267
Repairmans
110 F Shop Set, AVIM, Electrical 4920-00-165-1453
Instrument
111 F Shop Set, AVIM, Hydraulic 4920-00-165-1454
112 F Shop Set, AVIM, Machine 4920-00-405-9279
Shop
113 F Shop Set, AVIM, Powertrain 4920-00-001-4132
116 F Shop Set, AVIM, Rotor Shop 4920-00-405-9270
117 F Shop Set, AVIM, Sheet 4920-00-166-5505
118 F Shop Set, AVIM, Tool Crib 4920-00-472-4183
119 F Shop Set, AVIM, Turbine 4920-00-224-3684
Engine
120 F Shop Set, AVIM, Welding 4920-00-163-5093
121 F KepairKih Rotor Blade 492041-036-0324 K747-401
B-34 Change 3
TM 55-1520-236-23
SECTION IV. REMARKS
REFERENCE CODE REMARKS
A Limited to airframe repairmans tool kit and portable hand tools
B Not including build up
c Epoxy
D Removal of nicks and scratches
E Limited to hand stitching only
F Refer to TM 11-1520-236-23 for removal and repair instructions
G Refer to TM 55-2840-229-24
H METS Modular Engine Test System
I Track
J Balance
K Seal and Coupling Replacement
L Scratch Blending
M Seal Replacement
N Refer to TM 11-1520-221-20
o Refer to TM 11-6140-203-14-2
P Based on distribution of generator test stand
Q Replacement of worn or elongated bushings
R Refer to TM 9-1090-203 for Maintenance Instructions
s Requires 2 people and excessive time
T Restricted to AVUM units with 10 or more aircraft. Use extreme care in removal.
u If electronic test is required, accomplish with AVIM support.
v Idinited to Non-RiwkionalA VIM only
w Deleted
Change 16 B-35/(B-36 blank)
TM 55-1520-236-23
APPENDIX C
AIRCRAFT INVENTORY MASTER GUIDE
C-1. INTRODUCTION. a. Items to be listed:
C-2. SCOPE. (1) Items essential to the execution of the
designated mission of the helicopter, such as
Appendix C lists those items of installed or loose electronic, photographic, armament, special mission
equipment required by and authorized for using instruments, and safety and comfort equipment.
organizations to accomplish their primary or alternate
mission. This list will serve to standardize present (2) L o o s e e q u i p m e n t d e l i v e r e d w i t h t h e
inventory procedures, using the inventory master helicopter and items subject to pilferage or readily
guide to determine the inventoriable items of converted to personal use.
installed and loose equipment. Insofar as possible,
items of equipment are listed in the sequence of their (3) M o d i f i c a t i o n k i t s w h i c h a r e i s s u e d o r
physical location within the helicopter area. distributed to using organizations for installation and
which are not immediately placed in work will be
C-3. CHANGES TO INVENTORY. recorded on the affected aircrafts DA Form 2408-17
(Aircraft Inventory Record) and identified as loose
Aircraft inventory is subject to change as a result of equipment until modification is completed.
authorized changes (MWOS), addition or deletions of
property for special missions requirements; (4) Equipment required for operation in special
therefore, the selection of items of inventory from the environment.
inventory master guide may or may not provide a
complete inventory list. When it is known that the b. Items to be excluded:
master guide does not provide a complete inventory
list, it will be necessary to research authorized (1) Nonaccountable items coded as expendable
changes (MWOS) and local command directives in in the applicable stock lists.
order to compile an accurate and exact inventory list.
(2) P e r s o n a l i s s u e o r f u r n i s h e d o n u n i t
C-4. INVENTORY FORMS AND allowance or other authority.
RECORDS.
(3) Items or components considered as basic or
Refer to TM 38-750 for applicable forms and records. integral parts of the helicopter or basic helicopter
such as engines, propellers, wheels, and standard
C-5. REQUIREMENTS. instruments.
C-6. SECURITY. (4) Equipment publications, check lists, and
aircraft forms.
It is desired that inventory records be unclassified.
Therefore, when equipment bearing a security
classification or the installation of unclassified C-8. PERIODS OF INVENTORY.
equipment is of a confidential or secret nature,
accomplishment of the classification will be in Inventoriable items will be checked against the
accordance with security reguIations. Aircraft Inventory Record (DA Form 2408-17) at the
following periods:
C-7. INVENTORIABLE ITEMS.
a. Upon receipt of the helicopter.
The selection of inventoriable items is without regard
to the agency, governmental or contractual, b. Prior to transfer of the helicopter to another
furnishing the items. organization.
C-1
TM 55-1520-236-23
c. Upon placing helicopter in storage and upon C-9 INVENTORY ITEMS LISTED.
removing from storage. Helicopter need not be
inventoried while in storage. Refer to figure C-1.
d. T w e l v e m o n t h s e l a p s e d t i m e s i n c e l a s t NOTE
inventory.
Only those items listed which are
e. L o o s e e q u i p m e n t s h i p p e d u n d e r s e p a r a t e installed or assigned to a particular
cover is inventoried upon transfer by the sending aircraft are to be listed on a DA Form
activity and immediately upon receipt by the receiving 2408-17 (Aircraft Inventory Record) for
activity. aircraft.
C-2
TM 55-1520-236-23
AIRCRAFT SERIES AND NUMBER
OF ITEMS NORMALLY INSTALLED
NOMENCLATURE AH-1P/E/F REMARKS
Forward Section (Pilot/Gunner Compartment)
Ignition Key 2
Canopy Key 2
Aircraft Manufacturers Data Plate (100-030-1) 1
Seat Belt and Shoulder Harness, Pilot 1
Seat Belt and Shoulder Harness, Gunner 1
Clock 1
Compass, Magnetic, Pilot Standby 1
First Aid Kit 1
Fire Extinguisher Assembly 1
Electronic Control Assembly, 7.62MM Gun ~ (11691622) 1
Electronic Control Assembly, 20MM Gun ~ TCA (11830908) 1
C-6533/ARC, Control, Intercommunication 2
Audio Threshold 1021-D001 1
Power Module E1131D 1
Indicator, lD-2103/A Horizontal Situation (209-075-660) 1
Indicator, lD-2104/Attitude Direction (209-075-661) 1
Indicator, ID-2105/A Radio Magnetic Compass (212-070-180) 1
Control C-10048/ARN-123(V) 1
Compass C-6347/ASN Control 1
Control C-1053/APX-100(V) ~ 1
AN/ARC-116 or AN/ARC-164 UHF Command Communication System 1
AN/ARC-115 Radio Set OR AN/ARC-186 Radio Set 1
AN/ARC-114A Radio Set 1
APN-209 RT-1115 Radar Altimeter 1
Control HG1001 AD01 Proximity Warning 1
Control, Navigational Select (209-077-081) 1
Computer Display Unit, CP-1252/ASN-128 ~ 1
Helmet, Sight System 2
Control C-6208/APX-72 ~ 1
Telescopic Sight Unit (M-65) 1
Sight Hand Control (M-65) 1
TOW Control Panel (M-65) 1
Pilot Steering Indicator (M-65) ~ ~ 1
Low G Warning System 1
GPS Trimpack Receiver ~ 1
Figure C-1. Inventory Item List (Sheet 1 of 2)
Change 20 C-3
TM 55-1520-23-23
AIRCRAFT SERIES AND NUMBER
OF ITEMS NORMALLY INSTALLED
NOMENCLATURE AH-1P/E/F REMARKS
Forward Section (Electronics Compartment)
AN/ARN-89B Directional Finder (ADF) 1
CN-998/ASN.43 Gyro Directional 1
AN/ARN-89B, R-1496A Receiver 1
AN/ARN-89B, C7392A Control 1
AN/ARN-89A, AM-4859A AMplifier 1
Forward Section (General)
Cover, Low Air Speed Sensor ~ 1
Cover, Pilot Tube 1
Cover, Canopy 1
Shield, Engine Inlet 2
Cover, Tail Pipe/lR Suppressor 1
Fitting, Jack 4
Armament Subsystem, M-197 = ~ 1
Ammunition Storage Box ~ ~ 1
Panel, Armor 11
Armmmament Subsystem, M28A1 ~ ~ 1
TOW Missile Launcher (M-65) 4
Computer Fire Control XM22 ~ 1
Aft Section
Main Rotor Tie-Down (130-013-3) 1
Tail Rotor Tie-Down (204-070-450-19) 1
Mount, MT-3802/ARC 1
Mount, MT-3949A/U 1
RT-859A/APX-72 Receiver Transponder ~ ~ 1
Mount, MT-3809/APX-72 ~ ~ 1
Test Set TS-1843A/APX-72 ~ ~ 1
Mount, MT-3513/APX-72 ~ ~ 1
RT 1157/APX100(V) Receiver Transponder ~ 1
MT-4811/APX-100(V) Mount ~ 1
Transmitter, Induction Compass T-611/ASN 1
Compensator, CN-405/ASN, Magnetic Flux 1
Receiver, R-2023/ARN-123(V) 1
Mount, MT-4843/ARN-123(V) 1
Receiver/Transmitter, RT-1193( )/ASN-128 ~ 1
Signal Data Converter, CV-3338 ( )/ASN-128 ~ 1
Mount, MT-4980/ARN-123(V) m 1
Electronic Power Supply (M-65) 1
Missile Command Amplifier (M-65) 1
Stabilization Control Amplifier (M-65) 1
Figure C-1. Inventory Item List (Sheet 2 of 2)
C-4 Change 12
*u.S. GOVERNMENT PRINTING OFFICE 1995- 63s-028/20009
PIN: 032466-020
TM 55-1520-236-23-2
PIN: 032466-022
This fine document...
Was brought to you by me:
Liberated Manuals -- free army and government manuals
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Chicago Machinery Movers
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