Section I INTRODUCTION - TM-1-1520-253-230022GENERAL INFORMATION - TM-1-1520-253-230023Table 1-1. Supporting Technical DocumentationTable 1-1. Supporting Technical Documentation - ContinuedInspection item CodeMETHOD OF INSPECTIONFigure 1-2. General Configuration of CH/MH-47 HelicopterFigure 1-3. Stations, Water Lines, and Butt LinesTYPE OF CONSTRUCTIONEngine GroupFigure 1-4. Access Panels, Doors, and Fairings (Sheet 1 of 2)Figure 1-4. Access Panels, Doors, and Fairings (Sheet 2 of 2)Table 1-2. Access Panels, Doors, and FairingsTable 1-2. Access Panels, Doors, and Fairings - Continued - TM-1-1520-253-230036Table 1-2. Access Panels, Doors, and Fairings - Continued - TM-1-1520-253-230037NONDESTRUCTIVE INSPECTION METHODSSelecting the NDI MethodNDI General Safety PrecautionsFigure 1-5. Bond Testing Reference Block DisplaysSafety precautions During Bond TestingTable 1-3. Penetrant Procedure (Type I, Method A)Table 1-4. Penetrant Procedure (Type I, Method B)Table 1-5. Penetrant Procedure-Portable or Field ApplicationTable 1-6. Penetrant Procedure (Type I, Method D)Safety Precautions During Fluorescent Penetrant InspectionsControlling Excess Fluorescent PenetrantMagnetic Particle Inspection EquipmentFigure 1-6. Portable Magnetic Particle Inspection EquipmentDemagnetization of Inspection PartsSafety Precautions During Radiographic InspectionsSafety Precautions During Eddy Current InspectionFigure 1-7. Signatures of EDM Notches in Test BlockSorting Metal Using Eddy CurrentSafety Precautions During Ultrasonic InspectionAcceptance/Rejection CriteriaTable 1-7. Equipment Used for NDITable 1-8. Materials Used for NDITable 1-8. Materials Used for NDI - ContinuedSection II ROTOR GROUPFigure 2-1. Rotor GroupROTARY-WING HEAD (MT)Figure 2-2. Rotary-Wing HeadHUB OIL TANK (ET) cont'dPITCH VARYING SHAFT (MT)Figure 2-3. Hub Oil tankPITCH VARYING SHAFT (MT) cont'dROTOR HUB (MT)Figure 2-5. Rotor HubVERTICAL HINGE PIN FLANGES (MT)PITCH VARYING SHAFT BORE LINER (MT)Figure 2-6. Vertical Hinge Pin FlangesFigure 2-7. Pitch Varying Shaft Bore LinerHORIZONTAL HINGE PIN (MT)Figure 2-8. Horizontal Hinge PinCENTRIFUGAL DROOP STOP LUGS (ET)CENTRIFUGAL DROOP STOP LUGS (ET) cont'dFigure 2-9. Centrifugal Droop Stop LugsCENTRIFUGAL DROOP STOP BOLTS (MT)Figure 2-10. Centrifugal Droop Stop Bolts Primary Method. Bond TestingInspection Procedure - TM-1-1520-253-230084Figure 2-11. Rotary-Wing BladeBackup Method - TM-1-1520-253-230086 Inspection ProcedurePrimary Method - TM-1-1520-253-230088Figure 2-13. Ball Spherical BearingPrimary Method - TM-1-1520-253-230090Figure 2-14. Weather Protective CoverROTOR HUB LIGHTENING HOLES (ET)Reference StandardFigure 2.15C Lift off variation due to nonconductive coatingCRT Display InterpretationSection III TRANSMISSION/DRIVETRAIN GROUPFigure 3-1. Transmission / Drivetrain GroupDRIVESHAFT ADAPTERS (ALUMINUM) (ET)DRIVESHAFT ADAPTERS (STEEL) (MT)Figure 3-2. Driveshaft Adapters (Aluminum)FORWARD DRIVESHAFTING TUBES (ET)Figure 3-3. Driveshaft Adapters (Steel)Preparation of Part - TM-1-1520-253-230103Figure 3-4. Forward Driveshafting TubesPreparation of Helicopter - TM-1-1520-253-230105Figure 3-5. Aft Driveshafting TubesPrimary Method - TM-1-1520-253-230107Figure 3-6. Engine Driveshaft (Two Piece)NDI Equipment and Materials - TM-1-1520-253-230109Figure 3-7. Engine Driveshaft (One Piece)DRIVESHAFT ADAPTER PLATE (PT)ENGINE TRANSMISSION ADAPTER (MT)Figure 3-9. Engine Transmission AdapteNDI Equipment and Materials - TM-1-1520-253-230114FORWARD TRANSMISSION SLIDER SHAFT (MT)Preparation of Helicopter - TM-1-1520-253-230116FORWARD TRANSMISSION OUTSIDE SURFACE (ET)NDI Equipment Settings - TM-1-1520-253-230118Figure 3-12. Forward Transmission Outside SurfaceFigure 3-13. Aft Slider ShaftAFT ROTOR SHAFT (MT)Figure 3-14. Aft Rotor ShaftAFT ROTOR SHAFT SUPPORT (ET)NDI Equipment Settings - TM-1-1520-253-230124Figure 3-15. Aft Rotor Shaft SupportCOMBINING TRANSMISSION OUTSIDE SURFACE (ET)AFT TRANSMISSION OUTSIDE SURFACE (ET)Figure 3-16. Combining Transmission Outside SurfacePrimary Method - TM-1-1520-253-230129Figure 3-17. Aft Transmission Outside SurfaceENGINE TRANSMISSION QUILL SHAFT (MT)ENGINE TRANSMISSION OUTSIDE SURFACE (ET)Preparation of Helicopter - TM-1-1520-253-230133Figure 3-19. Engine Transmission Outside SurfacePreparation of Helicopter - TM-1-1520-253-230135Figure 3-20. Transmission Oil Cooler AssembliesSection IV AIRFRAME AND LANDING GEAR GROUPFigure 4-1. Airframe and Landing Gear GroupHONEYCOMB CORES AND PANELS (VOIDS) (BT) - TM-1-1520-253-230139HONEYCOMB CORES AND PANELS (VOIDS) (BT) - TM-1-1520-253-230140Figure 4-2. Honeycomb Cores and Panels (Voids)AIRFRAME STRUCTURES (ET)NDI Equipment Settings - TM-1-1520-253-230143Figure 4-3. Airframe StructuresFORWARD TRANSMISSION SUPPORT STRUCTURES (ET)Figure 4-4. Forward Transmission Support StructuresDYNAMIC ABSORBER SUPPORT STRUCTURE (ET)NDI Equipment Settings - TM-1-1520-253-230148Figure 4-5. Dynamic Absorber Support StructurePreparation of Helicopter - TM-1-1520-253-230150Figure 4-6. Cabin Equipment Support StructureBackup Method - TM-1-1520-253-230152AccessFigure 4-7. PodsSystem SecuringFigure 4-8. PodsRESCUE HATCH LOWER DOOR GEARBOX ASSEMBLY (MT).Figure 4-9. Rescue Hatch Lower Door Gearbox AssemblyRESCUE HATCH LOWER DOOR GEARBOX HOUSING AND COVER (ET)ND1 Equipment SettingsFigure 4-10. Rescue Hatch Lower Door Gearbox Housing and CoverCARGO RAMP (BT)Inspection Procedure - TM-1-1520-253-230163Figure 4-11. Cargo RampCOMBINING TRANSMISSION SUPPORT FITTINGS AND LONGITUDINAL BEAMS (ET)NDI Equipment Settings - TM-1-1520-253-230166Figure 4-12. Combining Transmission Support Fittings and Longitudinal BeamsCOMPOSITE PYLON HINGED FAIRINGS (WORK PLATFORM) (BT)NDI Equipment Settings - TM-1-1520-253-230169Figure 4-13. Composite Pylon Hinged Fairings (Work Platform)FORWARD LANDING GEAR SUPPORT STRUCTURE (ET)Preparation of Helicopter - TM-1-1520-253-230172LANDING GEAR WHEEL (ET)Preparation of Part - TM-1-1520-253-230174Figure 4-15. Landing Gear WheelLANDING GEAR AXLE (MT)Figure 4-16. Landing Gear AxleAFT LANDING GEAR STRUCTURE (ET)Figure 4-17. Forward Landing Gear Strut Piston TubeNDI Equipment Settings - TM-1-1520-253-230180Figure 4-18. Aft Landing Gear StructureFORWARD LANDING GEAR TORQUE ARM (ET)LOWER DRAG LINK ASSEMBLY HARDWARE (MT)NDI Equipment and Materials - TM-1-1520-253-230184Figure 4-20. Lower Drag Link Assembly HardwareLOWER DRAG LINK (ET)Figure 4-21. Lower Drag LinkCENTER CARGO HOOK (MT)Figure 4-22. Center Cargo HookPreparation of Helicopter - TM-1-1520-253-230190Figure 4-23. Aft Pylon Equipment Support StructureSection V ENGINE GROUPFigure 5-1. Engine GroupENGINE OIL PUMP, FUEL CONTROL, AND ACCESSORY GEARBOX FLANGES (ET) ENGINE MOUNT CAPS (ET)Figure 5-2. Engine Oil Pump, Fuel control, and Accessory Gearbox FlangesNDI Equipment and Materials - TM-1-1520-253-230197Figure 5-3. Engine Mount CapsENGINE MOUNT ADAPTER (ET)Figure 5-4. Engine Mount AdapterFORWARD ENGINE MOUNT STRUCTURE (ET)Figure 5-5. Forward Engine Mount StructureAFT ENGINE MOUNT LINK (MT)Figure 5-6. Aft Engine Mount Link NDI Equipment and MaterialsInspection Procedure - TM-1-1520-253-230206AFT ENGINE MOUNT ADAPTER (ET)Figure 5-8. Aft Engine Mount AdapterEXHAUST CONE AND STIFFENER (PT).Figure 5-9. Exhaust Cone and StiffenerFUEL DRAIN VALVE (PT)Figure 5-10. Fuel Drain ValveCOMBUSTION CHAMBER HOUSING (PT)Figure 5-11. Combustion Chamber HousingFIRESHIELD SECTION (PT)Figure 5-12. Fireshield SectionSection VI FLIGHT CONTROL GROUPFigure 6-1. Flight Control GroupALUMINUM FLIGHT CONTROL SYSTEM CONNECTING LINKS (ET).STEEL FLIGHT CONTROL SYSTEM CONNECTING LINKS (MT)Figure 6-2. Aluminum flight Control System Connecting LinksSTAINLESS STEEL FLIGHT CONTROL SYSTEM CONNECTING LINKS (PT).Figure 6-3. Steel Flight Control System Connecting LinksFigure 6-4. Stainless Steel Flight Control System Connecting LinksTHRUST CONTROL BELLCRANK AND SUPPORT (ET)Figure 6-5. Thrust Control Bellcrank and SupportFIRST STAGE CONTROL BELLCRANKS AND SUPPORTS (ET) SECOND STAGE CONTROL BELLCRANKS AND SUPPORTS (ET)Figure 6-6. First Stage Control Bellcranks and SupportsPreparation of Helicopter - TM-1-1520-253-230230Figure 6-7. Second Stage Control Bellcranks and SupportsINTERMEDIATE CONNECTING LINKS (ET)Figure 6-8. Intermediate Connecting LinksBELLCRANKS AND SUPPORTS, YOKES, AND CONNECTING LINKS (ET)Figure 6-9. Bellcranks and Supports, Yokes, and Connecting LinksFLIGHT CONTROL RESERVOIRS/COOLERS AND RELATED EQUIPMENT (PT)Figure 6-10. Flight Control Reservoirs/Coolers and Related EquipmentAppendix A MAINTENANCE ALLOCATION CHART NONDESTRUCTIVE INSPECTION - TM-1-1520-253-230238NOMENCLATURE OF END ITEMS - TM-1-1520-253-230239NOMENCLATURE OF END ITEMS - TM-1-1520-253-230240NOMENCLATURE OF END ITEMS - TM-1-1520-253-230241NOMENCLATURE OF END ITEMS - TM-1-1520-253-230242Appendix B EQUIPMENT LISTING - TM-1-1520-253-230244EQUIPMENT LISTINGEQUIPMENT LISTING cont'd - TM-1-1520-253-230246EQUIPMENT LISTING cont'd - TM-1-1520-253-230247Appendix C ILLUSTRATED FIELD MANUFACTURE ITEMS LIST - TM-1-1520-253-230248Figure C-1. Composite Test BlocksTM-1-1520-253-23 CH/MH-47 Helicopters Series Manual